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Chevrolet 1979 Light Duty Truck, Руководство по ремонту

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6A3-2  4.3  LITER  V

-6

CONTENTS

SUBJECT 

PAGE

Assem bly  of  Engine  (Continued)

Front  Cover  In stallatio n .............................................................................................................................................................6 A 3 -1 8
Torsional  Dam per  In stallatio n ....................... .........................................................................................................................6 A 3 -1 8
Piston  and  Connecting  Rod  In s ta lla tio n ............................................................................................................................ 6 A 3 -2 0
Oil  Pump  In s ta lla tio n ................................................................................................................................................................. 6 A 3-21
Oil  Pan  Installation...................................................................................................................................................................... 6 A 3-21
Cylinder  Head  In s ta lla tio n ........................................................................................................................................................ 6 A 3-21
Valve  Train  Com ponent  In s ta lla tio n ..................................................................................................................................... 6 A 3 -2 3
Valve  A d justm en t........................................................................................................................................................................ 6 A 3 -2 3

Intake  Manifold  In s ta lla tio n ......................................................................................................................................................6 A 3 -2 3
Rocker  Arm  Cover  In s ta lla tio n ...............................................................................................................................................6 A 3 -2 3
Exhaust  Manifold  In s ta lla tio n ................................................................................................................................................. 6 A 3 -2 3
EGR  Valve  In s ta lla tio n ............................................................................................................................................................... 6 A 3 -2 4

Flywheel  In s ta lla tio n ................................................................................................................................................................. 6 A 3 -2 4
Engine  Accessory  In s ta lla tio n ...............................................................................................................................................6 A 3 -2 4
Engine  Set-Up  and  T e s tin g ......................................................................................................................................................6 A 3 -2 5

S p e c ific a tio n s ..................................................................................................................................................................................6 A 3 -2 7
Special  T o o ls ....................................................................................................................................................................................6 A 3 -3 0

DESCRIPTION

GM  4.3L  engines  are  90-degree  V6  type,  overhead 

valve,  water  cooled,  with  cast  iron  block  and  heads.

The  crankshaft  is  supported  by  four  precision  insert 

main  bearings,  with  crankshaft thrust taken  at the  num ber 

four  (rear)  bearing.

The  cam shaft  is  supported  by  four  plain  type  bearings 

and  is  chain  driven.  Motion  from  the  cam shaft  is  transm it­

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  bearings.  The  piston  pins  are  a  press fit 
in  the  connecting  rods.

The  pistons  are  cast  alum inum   alloy.  The  piston  pins 

are  a  floating  fit  in  the  piston.

For  identification,  refer  to  GENERAL  INFORMATION 

(SEC.  OB).

ENGINE  LUBRICATION

Lubrication  schem atics  are  shown  in  figures  1  and  2. 

The  gear  type  oil  pum p  is  driven  from  the  d istributor 

shaft,  w hich  is  gear driven from  the cam shaft.  Oil  is drawn 

into  the  oil  pump  through  a  pickup  screen  and  pipe.

Pressurized  oil  is  routed  to  the  oil  filter.  In  case  of 

excessive  oil  pressure,  a  bypass  valve  is  pro vid e d . 

Filtered  oil  flows  into  the  main  gallery  and  then  to  the 
cam shaft  and  crankshaft  bearings.  The  valve  lifter  oil 
gallery  supplies  oil  to  the  valve  lifters.  Oil  flows  from  the 
hydraulic  lifters through  the  hollow  pushrods  to  the  rocker 
arms.  Oil  from  the  overhead  drains  back  to the  crankcase 
through  oil  drain  holes.

The  tim ing  chain  is  drip  fed  from  the  front  cam shaft 

bearing.  The  pistons  and  piston  pins  are  lubricated  by  oil 
splash.

Содержание 1979 Light Duty Truck

Страница 1: ......

Страница 2: ... ...

Страница 3: ...ir Conditioning Compressor 1B3 R 4 Air Conditioning Compressor 1B4 DA V5 Air Conditioning Compressor 1B5 HR 6 Air Conditioning Compressor 3 STEERING 3B2 Manual Steering Gear 3B3 Power Steering 4 AXLES 4B Rear Axle 4B1 71 2 and 75 s lnch Ring Gear 4B2 81 2 lnch Ring Gear 4B3 91 2 lnch Ring Gear 4B4 101 2 lnch Ring Gear 4B5 Dana Rear Axles 4B6 12 Inch Ring Gear Rockwell 4B7 Locking Differentials 4C ...

Страница 4: ...iv ...

Страница 5: ...e factory ALWAYS REFER TO THIS INFORMATION WHEN ORDERING PARTS VEHICLE IDENTIFICATION NUMBER The VIN is the legal identifier of the vehicle On all models except Forward Control it is located on a plate which is attached to the left top of the instrument panel and can be seen through the windshield from the outside of the vehicle figure 2 On Forward Control models the plate is on the dash and toe p...

Страница 6: ...hicle The 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 Rating The ve h icle may also have a GCW R G ross C o m b in a tio n W eight R a tin g The GCW G ross Combination Weight is the total weight of the loaded tow vehicle including passengers and a...

Страница 7: ...e 6 shows the different strength markings When replacing metric fasteners be careful to use bolts and nuts of the same strength or greater than the original fasteners the same number marking or higher It is likewise important to select replacement fasteners of the correct size Correct replacement bolts metric fasteners available in the aftermarket parts channels were designed to metric standards o...

Страница 8: ... any doubt replace with a new prevailing torque fastener or equal or greater strength c Assemble the parts and hand start the nut or bolt d O bserve that before fa ste n e r seats it develops torque per the chart in figure 13 if there is any doubt replace with a new prevailing torque fastener of equal or greater strength e Tighten the fastener to the torque specified in the appropriate section of ...

Страница 9: ...GENERAL INFORMATION OA 5 Chassis Cab Bonus Crew Cab Pickup Bonus Crew Cab Suburban U tility Vehicle Jim m y Blazer F 02281 Chassis Cab Regular Cab Pickup Regular Cab RV MODELS Figure 8 RV Models ...

Страница 10: ...TION G VAN MODELS RALLY SPORTVAN VAN DURA CHEVY VAN P MODELS VALUE VAN STEP VAN ALUMINUM MOTOR HOME CHASSIS MAGNAVAN HI CUBE VAN VALUE VAN STEP VAN STEEL FORWARD CONTROL CHASSIS B 09178 CUTAWAY VAN Figure 9 G and P Models ...

Страница 11: ...GENERAL INFORMATION OA 7 CK Pickup Sportside CK Chassis Cab CK Pickup Extended Cab CK Chassis Extended Cab F 04481 Figure 10 CK Models Figure 11 ST Models ...

Страница 12: ...r M illim eter 25 4 Threads Per Inch F 00705 Figure 12 M Models Figure 14 Thread Notation 1 Grade 2 GM 200 M 2 Grade 5 GM 280 M 3 Grade 7 GM 290 M 4 Grade 8 GM 300 M 5 M anufacturer s Identification 6 Nut Strength Identification 7 Identification Marks Posidriv Screw Head F 00695 Figure 13 Bolt and Nut Identification Figure 15 Six Lobed Socket Head Fasteners ...

Страница 13: ...izes 1 Top Lock Type 6 Nylon Strip Or Patch B Inch Sizes 2 Center Lock 7 Nylon Washer Insert 3 Dry Adhesive Coating 8 Nylon Patch 4 Out Of Round Thread 9 Nylon Insert 5 Deformed Thread Profile B 02406 Figure 16 Torque Nuts and Bolt Chart ...

Страница 14: ...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 cm 1 liters 1 liters meters3 m3 BTU Foot pound Kilowatt hour 1 055 joules J 1 355 8 joules 3 600 000 joules J one W or 3 6 x 106 LIGHT 1 076 4 lum ens m eter2 lm m2 FUEL PERFORMANCE Pound Ton 0 453 6 907 18 kilograms kg k...

Страница 15: ...937 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 32 0 78125 19 84375 19 64 0 296875 7 54062 51 64 0 796875 20 24062 5 16 0 3125 7 93750 13 16 0 8125 20 63750 21 64 0 328125 8 33437 53 64 0 828125 21 03437 11 32 0 34375 8 73125 27 32 0 84375 21 431...

Страница 16: ......

Страница 17: ...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 Stoddard solvent kerosene or equiva lent Dry with air Use a non lint producing type cloth to clean each part Although certain service operations can be performed without removing the compressor from the vehicl...

Страница 18: ...ate Front Reed Suction Valve Front Pin Bearing Drain Screw Gasket Sleeve Seal Tube Race Bearing Cylinder Front Sleeve Seal Piston Ring Piston Ball Seal Ball Key Ring Piston Pin Shaft Race Bearing C ylinder Rear Seal Tube Pin Plate Bearing Discharge Valve Plate Rear Reed Suction Valve Rear Inner Gear 51 Outer Gear 52 Seal Rear 53 Nut 54 Rear Head 55 Seal 56 Pressure Relief Valve 57 Seal 58 Screen F...

Страница 19: ... the vehicle for servicing drain and measure the amount of oil remaining in the compressor After servicing add new 525 viscosity refrigerant oil to the compressor CLUTCH PLATE AND HUB ASSEMBLY REPLACEMENT Remove or Disconnect Figures 1 2 and 3 Tools Required J 9396 Compressor Holding Fixture J 9399 Compressor Shaft Nut Socket J 9401 A Hub Drive Plate Remover J 25030 Clutch Hub Holding Tool Clamp J...

Страница 20: ...ressing 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 contact surfaces of the clutch plate and hub assembly 2 and the pulley 6 should be 0 56 1 34 mm 0 022 0 057 inch Remove J 9480 B Inspect Position of the shaft 39 even with or slightly above the clutch hub 3 Shaft nut 1 Use J 93...

Страница 21: ... 9395 for the multi groove pulley Turn the screw on J 8433 to remove the pulley 6 Im portant When using J 24092 the puller arms must extend around to the rear side of the pulley Do not attempt to pull the pulley off by engaging the puller arms in a multi groove pulley Bearing 5 from the pulley 6 figure 8 Remove the retaining ring 3 Pulley 6 to J 21352 figure 9 Drive the bearing 95 from the pulley ...

Страница 22: ... 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 necessary hand im pact a blow to the screwdriver handle or pry bar to break the adhesive bond of the clutch coil to the front head Clean Adhesive from the coil by scraping with a putty knife Remove any adhesive around the three locator hole ar...

Страница 23: ...er to the chart in this section SHAFT SEAL REPLACEMENT 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 22974 A C o m p re sso r S h aft O il Seal Protector J 23128 A C om p re ssor S haft Seal Seat Remover and Installer 1 Clutch plate and hub assembly 2 Clean The inside of the compressor around the ...

Страница 24: ...ring G O Not Go F 01583 Figure 15 Removing Installing the Shaft Seal and Seal 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 14 with clean 525 viscosity refrigerant oil Mount the seal 14 to J 9392 01 by engaging the tabs of the seal w ith the ta ngs of J 9392 01 Place J 22974 over the end ...

Страница 25: ...937 mm 0 03125 inch from the face of the compressor neck figure 16 9 Clutch plate and hub assembly 2 Refer to Clutch Plate and Hub Assembly Replacement Im portant Using improper procedures pounding or collisions can damage 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 axial plate...

Страница 26: ...emoving 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 reed seats 7 Rear suction reed plate 48 figure 20 Do not pry up on the horse shoe shaped reed valves 8 Oil pick up tube 37 with J 5239 figure 21 9 Seal 36 10 Compressor to J 21352 Figure 18 Removi...

Страница 27: ... cover 16 Cylinder halves 29 and 42 Number the piston and the piston bores with the same numbers so the pistons can be in stalled in their bores figure 23 Separate the cylinders 29 and 42 with a block of wood and a mallet figure 24 Do not let the discharge cross over tube 26 touch the axial plate 39 Do not strike the shaft at either end to sepa rate the upper and lower cylinder halves be cause the...

Страница 28: ...ch at the Front of the Piston GAGING OPERATION Install or Connect Figures 27 through 31 23 Discharge crossover tube 26 from the cylinder half 29 with locking jaw pliers This is necessary on original factory equip ment because the tube ends are swedged into the cylinder halves If previously serviced the discharge cross over tubes 26 will have a seal and bushing at the end of the tube Remove these t...

Страница 29: ...d zero thrust race 27 to the front end of the shaft 38 figure 28 Lubricate the races 27 and the bearing 28 with petroleum jelly 5 Threaded end of the shaft 39 through the needle bearing 21 in the front cylinder half 29 and allow the thrust race 27 and bearing 28 to rest on the hub of the cylinder 6 Insert a thrust race on the rear end of the shaft 38 so that it rests on the hub of the axial plate ...

Страница 30: ... GAGING PROCEDURE Tools Required J 8001 Dial Indicator Set J 9397 Compressing Fixture J 9402 Piston Assembly Tray J 9661 01 Feeler Tension Gage Set Two gaging procedures provide the running tolerances The first procedure determines the size shoe discs to p ro vid e at each pisto n a 0 041 0 061 mm 0 0016 0 0024 inch total preload between the seats and the axial plate at the tightest place through ...

Страница 31: ... 180 18 0180 185 I 8V2 0185 190 19 0190 195 191 2 0195 200 20 0200 205 20 h 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 0000 050 5 0050 055 51 2 0055 060 6 0060 065 6V2 0065 070 7 0070 075 71 2 0075 080 8 0080 085 8V2 0085 090 9 0090 095 91 2 0095 100 10 0100 105 101 2 0105 110 11 0110 115 1 1 1 2 0115 120 12 0...

Страница 32: ...sizes The thrust race number corresponds to the last three digits of the part number Refer to figure 33 Remove the nuts from the top plate of the J 9397 Remove the top plate 10 Separate the cylinder halves while the unit is in the fixture If necessary use a wood block and a mallet 11 Remove the rear cylinder half remove one piston at a time from the axial plate and front cylinder half Do not lose ...

Страница 33: ...n 32 Remove the guide from 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 segments tight enough to the J 24608 2 guide when installing the piston ring 33 to the piston 32 4 Piston 32 to J 24608 6 figure 38 Lubricate the piston ring 33 area with 525 viscosity refrigerant ...

Страница 34: ...0 through 51 Support the front half of the cylinder 29 on J 9397 1 Shaft and axial plate 38 Place the shaft threaded end down with the front bearing race pack race and bearing into the cylinder if this was not done at the end of the Gaging Procedure 2 Balls 32 and shoe discs 33 to the pistons 30 Apply a coat of petroleum jelly to the num bered shoe discs 3 Piston assembly 30 into the front cylinde...

Страница 35: ...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 with the dowel pins 20 and the openings in the front suction reed plate 18 The front discharge plate 18 has a large hole in the center 13 Front head 16 figure 46 Coat the sealing surfaces on the webs of the compressor front head casting with clean 5...

Страница 36: ...t the inside of the shell 9 with clean 525 viscosity 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 the shell 9 Slide the shell 9 down Line up the oil sump with the oil intake tube hole 16 New dowel pins 20 to the rear cylinder half Remove J 21352 Ins...

Страница 37: ...dentification 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 the outer gear 51 so that it meshes with the inner gear 50 at the 9 o clock position The cavity between the gear teeth will be at the 3 o clock position 24 Seal 52 to the discharge valve plate 49 Lubricate the seal 52 shell 9 discharge plate 49 and ...

Страница 38: ...ing into 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 at the pressure relief valve compressor shell to cylinder compressor front head seal rear head seal oil charge port and the compressor shaft seal After checking shut off the low pressure contr...

Страница 39: ... and repair 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 drain the oil sump 19 Allow the compressor to drain for 10 minutes then charge with the proper amount of oil The new oil may be poured into the suction port Torque the charge screw to 20 N m 1...

Страница 40: ...6083 J 6271 01 J 9392 01 J 9393 A J 9396 J 9397 J 9398 A J 9399 SPECIAL TOOLS 14 15 12 0 J 9401 A 1 3 c ric a Z a 1 A t i 23 J 9402 24 25 17 r 18 19 20 21 22 T D J 9432 J 9459 16 c O J 9480 B J 9553 01 J 9564 01 J 9625 J 21352 J 22974 A J 23128 A J 23500 01 J 23600 B J 23640 F 04589 ...

Страница 41: ...C lutch Drive Plate A ssem bly Rem over 13 Piston Tray 14 N eedle Bearing Installe r 15 90 Elbow A dapter 16 Hub and Drive Plate Installer 17 O ring Remover 18 Feeler Gage Set 19 C om pressor Test Set 20 C om pressor S upport B lock 21 Oil Seal P rotector 22 C om pressor S haft Seal In staller and Rem over Portable C harging S tation Belt Tension Gage Pocket T herm om eter Pulley Hub P uller Set O...

Страница 42: ...1B1 26 A 6 AIR CONDITIONING COMPRESSOR ...

Страница 43: ...ial plate or cylinder repair is needed replace the internal cylinder as sembly All clutch parts valve mechanisms and head as semblies are serviced plus seals and gaskets Refrigerant oil dispersed in the refrigerant vapor lubri cates the system The front head is shown with three integral mounting flange ears figure 2 These ears have 19 mm flats cast to provide for a wrench to be used as a prying me...

Страница 44: ...act 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 Install J 33013 B with bearing figure 7 Back off J 33013 B body enough to allow the center screw to be threaded against the end of the compressor shaft Hold the center screw with a wrench and tighten the hex portion of J 33013 B body while pre...

Страница 45: ...Head 12 Head Gasket 13 Valve Plate Discharge 14 Suction Reed Plate 15 Cylinder Seal 16 Front Cylinder 17 Discharge Crossover Seal 18 Shaft Bearing 2 20 Axial Plate Shaft Assembly 21 Shaft Key 22 Cylinder Seal 23 Rear Cylinder 24 Cylinder Seal 25 Suction Reed Plate 26 Valve Plate Discharge 27 Head Gasket 28 Rear Head 29 Switch Seal 30 System Control Switch 31 Retainer Ring Switch 32 High Pressure R...

Страница 46: ... new bearing 5 in the pulley bore Install or Connect Figures 3 12 13 14 and 15 Tools Required J 21352 A Compressor Support Block J 9481 A Pulley Bearing Installer J 33019 Bearing Staking Tool with staking pin and retaining band J 33017 Pulley and Bearing Assembly Installer J 33023 A Puller Pilot J 8433 1 Puller Bar J 33026 Compressor Holding Fixture J 6083 Snap Ring Pliers 1 Pulley 5 on J 21352 A ...

Страница 47: ...alling the Puller Pilot and Pulley Rotor Slot Location 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 14 3 Pulley 5 on the front head Position J 33017 and J 33023 A over the inner race of the bearing figure 15 Position J 8433 1 on J 33023 A and assemble the through bolts and washers thro...

Страница 48: ...08433 3 Puller Screw J 33023 A Puller Pilot J 33025 Clutch Coil Puller Legs 1 Clutch plate and hub assembly 2 2 Pulley 5 Mark or scribe the location of the clutch coil 6 to terminal on the compressor front head 11 3 Clutch coil assembly 6 Install J 33023 A on the head 11 of the compressor Install J 8433 1 with J 33025 figure 16 J 33019 J 21352 A B 06544 A Staking Pin B Rubber Band Figure 12 Instal...

Страница 49: ...g a in st J 33025 A Inspect Clutch coil assembly 6 Replace as necessary Install or Connect Figures 3 17 18 and 19 Tools Required J 8433 1 Puller Bar J 33024 Clutch Coil Installer Adapter 6 C lutch C oil A ssem bly A D rift Punch 3 mm V a inch B Stake in Front Head 3 Places F 04523 Figure 16 Removing the Clutch Coil Assembly Figure 18 Staking the Clutch Coil Assembly to the Coil Head ...

Страница 50: ...ring the compressor always add the proper amount of new 525 viscosity refrigerant oil Refer to Specifications Keep the workbench and work area clean when servic ing the compressor and use proper clean service tools NOTICE Any attem pt to use m akeshift or inade quate service tools or equipm ent may result in damage and or im proper com pressor operation All parts used for servicing the compressor ...

Страница 51: ...emove J 33011 2 Shaft lip seal using J 23128 A figure 22 Dip the shaft lip seal in clean 525 viscosity refrigerant oil and install shaft lip seal on J 23128 A Bottom the shaft lip seal into the compressor neck area using J 23128 A Release and remove J 23128 A 3 Shaft seal retainer ring using J 5403 figure 21 Install flat side of shaft seal retainer ring against the lip seal Remove J 34614 Im porta...

Страница 52: ...COMPRESSOR DISASSEMBLY INTERNAL CYLINDER AND SHAFT Remove or Disconnect Figures 3 26 27 28 and 29 Mark the front head 11 alignment with cylinders 16 23 and rear head 28 alignment 1 Clutch plate and hub assembly 2 2 Pulley 5 3 Clutch coil assembly 6 4 Shaft seal parts 8 Note the compressor alignment marks and use them as a reference for compressor assembly figure 26 5 Through bolts 7 and gaskets fi...

Страница 53: ... Cavity D Discharge Pressure Inner Cavity E Opening to Rear Discharge Port F High Pressure Relief Valve G Drilled Opening into High Pressure Relief Valve Area 28 Rear Head B 06726 Figure 30 Positioning the J 33016 Guide Pins Place J 21352 A on the workbench or suitable flat work surface 1 Rear head 28 onto J 21352 A Install J 33016 guide pins small diameter ends into the through bolt holes figure ...

Страница 54: ...ands press the cylinder and shaft assembly down into the rear head 28 Important Center cylinder seal 22 is not serviceable 7 Cylinder seal 15 21352 A A Suction Crossover Openings B Through Bolt Hole 6 C Suction Port 3 in Valve Plate D Discharge Crossover Port E Discharge Ports In Valve Plate B 06731 Figure 32 Installing the Rear Valve Plate ...

Страница 55: ... Front head 11 Line up mark on front head 11 with the alignment marks on the compressor cylinders and assemble head over J 33016 guide pins figure 26 10 11 Im portant Front head 11 is now assembled in the standa rd position and may differ 120 degrees either direction Assemble front head 11 according to location marked before removal Using both hands press down on front head 11 for installation ove...

Страница 56: ...to the compressor Open the low pressure control high pressure con trol and the refrigerant control on the charging sta tion to allow refrigerant vapor to flow into the compressor Important Check for leaks at pressure relief valve 32 compressor front and rear head seals 15 24 center cylinder seal 22 through bolt head gaskets and compressor shaft seal After leak check shut off the low pressure contr...

Страница 57: ...a good pum ping com pressor should be 690 kPa 100 psi or above A pres sure reading of less than 620 kPa 90 psi would indicate one or more suction and or dis charge valves leaking an internal leak or an inoperative valve Disassemble the compres sor 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 remov...

Страница 58: ...ller Hub and Drive Plate Remover and Installer Cylinder Alignm ent Rods Pulley and Bearing Assem bly Installer Bearing Staking Tool Pulley Puller Shaft Seal Protector 6 Point 13 mm Socket Puller Pilot 21 Clutch Coil Installer Adapter 22 Clutch Coil Puller Legs Com pressor Holding Fixture Clutch Hub Holding Tool 6 7 10 13 14 15 16 17 18 19 20 23 24 10 11 12 15 J 9398 J 9481 A J 9553 01 J 9625 A J 2...

Страница 59: ...Leak T e s tin g 1 S pecifications 1 Special T o o ls 1 B3 1 B3 2 B3 B3 B3 B3 B3 B3 8 B3 8 B3 8 B3 9 B3 9 B3 9 B3 10 B3 10 B3 11 B3 12 B3 12 B3 13 B3 14 DESCRIPTION The Harrison R 4 compressor is a four cylinder radial opposed with 10 0 cubic inch displacement Two belt driven systems are available V groove and poly groove The drive system affects minor repair proce dures Clean the compressor befor...

Страница 60: ...eed Assem bly B 08291 Figure 1 Compressor Component View Illustrations show the compressor removed from the ve hicle for easier viewing Refer to figure 1 for part names and location Clamp J 25008 A to the compressor figure 2 Mount J 25008 A and the compressor in a vise 1 Shaft nut 1 with J 9399 figure 3 I j j l CLUTCH DRIVE HUB REPLACEMENT Clean The compressor with solvent and blow dry with air Re...

Страница 61: ...Tools Required J 9399 Thin Wall Socket J 9408 B Clutch Plate and Hub Installer J 25030 Clutch Hub Holding Tool 1 Shaft key 2 figure 5 Allow the shaft key 21 to extend 4 8 mm 3 ie inch out of the key way The shaft key 2 is curved slightly to give an interference fit in the groove 2 Clutch drive hub 3 figure 6 Install J 9480 B Hold the hex portion of J 9480 B with a wrench and tighten the center scr...

Страница 62: ...31 Rotor and Bearing J 8092 Driver Handle 1 Clutch drive hub 3 2 Snap ring 4 with J 6083 figure 7 Mark the location of the clutch coil terminals 3 Rotor 6 and bearing 5 assembly 9 Im portant If the clutch rotor and or rotor bearing are to be replaced bend the washers 9 away from the pulley rim m ounting screws 10 Remove the six mounting screws 10 and washers 9 Install J 25031 guide over the compre...

Страница 63: ...places 120 deqrees apart figure 12 R otor 6 and be arin g 5 a sse m b ly to the compressor with J 8092 figure 13 Retainer ring 4 with J 6083 Pulley rim mounting screws 10 and washers 9 Apply Loctite 601 or equivalent to the threads Hand spin the pulley to check for free rotation Tighten Screws to 11 N m 100 in lbs Bend the washers to lock the rim in place 5 Rotor 5 and hub 3 assembly CLUTCH ROTOR ...

Страница 64: ...t Figure 1 Tool Required J 25031 Rotor and Bearing Puller 1 Clutch drive hub 3 2 Rotor 5 and bearing 6 assembly 3 Pulley rim mounting screws 9 and washers 10 4 Pulley rim 11 Figure 14 Installing the Rotor and Bearing Assembly Poly Groove Type Clutch 7 pulley rim 8 clutch rotor 5 and bearing 6 figure 15 Im portant Use new screws 10 and washers 9 Apply Loctite 601 or equivalent to the screw threads ...

Страница 65: ...nd B e a rin g A sse m b ly Remover 1 Clutch drive hub 3 2 Rotor 5 and bearing 6 assembly Mark the location of the clutch coil terminals on the compressor 3 Clutch coil 7 from the front head 15 figure 16 Install J 25031 guide to the shaft 34 Install J 24092 with J 8433 Turn the screw in J 8433 to remove the clutch coil Install or Connect Figures 1 and 16 1 Clutch coil 7 to the front head 15 Positi...

Страница 66: ...ressor neck area 3 Shaft seal 12 Engage J 23138 A into the recessed portion of the seal by turning with a hand motion figure 17 Lift the seal with a rotary pulling motion 4 Seal o ring 13 with J 9553 01 figure 18 Install or Connect Figures 1 and 19 Tool Required J 33011 O Ring Installer 1 Seal o ring 14 to the shaft 22 figure 19 Dip the seal in clean 525 viscosity refrigerant oil Seal o ring to J ...

Страница 67: ...ect Figure 1 1 New seal 17 Dip the seal into clean 525 viscosity refrigerant oil before installing Position the seal into the groove in the front head 2 Front head 15 Place the oil hole in the UP position when assembled to the compressor to correspond with the UP position of the compressor Figure 20 Removing the Bearing from the Front Head Bolts 14 Tighten Bolts 14 to 27 N m 20 ft lbs Rotor 5 and ...

Страница 68: ...rust and Belleville Washers Do not loosen or remove the pulley rim mounting screws to remove the clutch rotor and bearing clutch coil and pulley rim 3 Shell retainer strap 32 figure 23 Pry the strap away from the cylinder and position it high enough to clear the cylinder when removing the shell 4 Shell 18 figure 24 Remove J 25008 A from the compressor R everse J 25008 A w ith the step block protru...

Страница 69: ...g strap to its original location Alternately tighten each bolt 1 4 turn to push the shell over the seals If one screw requires more force to turn than the other immediately turn the other screw to bring the screw threading sequence in step or the shell will be cocked and made more difficult to install Normal installation does not require much force on the wrench if the screws are kept in step whil...

Страница 70: ...ge port high side has a smaller internal opening into the compressor Open the low pressure control the high pres sure control and the refrigerant control on the charging station to allow refrigerant vapor to flow into the compressor Im portant Check for leaks at the pressure relief valve compressor front and rear head seals center cylinder seal through bolt head gaskets and the compressor shaft se...

Страница 71: ...ves are leaking an internal leak and or discharge valves leaking an internal leak or an inoperative valve Disassemble and check the compressor 12 After completing the pressure pump up test release the air pressure from the high side and remove J 5420 gage adapter and J 9625 test plate 13 Tilt the compressor to place the suction and dis charge ports downward 14 Drain oil from the compressor After 1...

Страница 72: ...em over 17 9 ie lnch Thin W all Socket Hub and Drive Plate A ssem bly In staller 18 Pulley Bearing and Pulley Insta ller 19 O ring Remover 20 Pressure Plate C onn ector 21 Seal Seat Rem over and In staller 22 Pulley Hub A dapter Set Used w ith J 8433 23 Bearing Insta ller 24 Bearing Remover 23 24 J 25031 J 25287 J 26271 A J 33011 J 34019 J 34614 C om pressor Shell Remover Insta ller and H olding F...

Страница 73: ...efrigerant oil Refer to Specifications figures 1 2 3 and 4 NOTICE Remove the oil drain plug to make sure the com pressor is drained com pletely o f oil fig ure 1 THEORY OF OPERATION The DA V5 is a variable displacement compressor that can match the automotive air conditioning demand under all conditions without cycling The basic compressor mechanism is a variable angle wobble plate with five axial...

Страница 74: ...s will be shipped from Harrison with 0 2268 kg 8 oz of oil in the crankcase The oil must be drained and retained Then replace the oil in the same amount as previously recorded from the old compressor Refer to Specifications IDENTIFICATION An identification label attached to the compressor provides the name of the manufacturer model number and build code If the label is removed or becomes dislodged...

Страница 75: ... C ontrol Valve Shaft Nut C lutch Plate and Hub A ssem bly Key Pulley Bearing R etainer Pulley Bearing Pulley C lutch Coil A ssem bly R etainer Seal O ring B olt G asket Front Head Shim W asher B elleville W asher Seal S haft and C ylind er Body Seal S uction Reed Valve Plate G asket Rear Head Seal R etainer Seal F 04536 Figure 4 Compressor Component View ...

Страница 76: ...ch the compressor to the holding fixture with thumb screws 1 Shaft nut 21 using J 33022 figure 5 Hold the clutch plate and hub assembly 22 steady using J 33027 2 Clutch plate and hub assembly 22 Thread J 33013 B into the clutch plate and hub assembly 22 Hold the body of J 33013 B with a wrench and tighten the center screw into the remover body figure 6 3 Shaft key 21 Retain shaft key 21 if usable ...

Страница 77: ...BLY REPLACEMENT Figure 8 Installing the Clutch Plate and Hub Assembly Remove or Disconnect Figures 4 9 10 11 and 12 Tools Required J 6083 Snap Ring Pliers J 8092 Driver Handle J 9398 A Pulley Bearing Remover J 33020 Pulley Puller J 33023 A Puller Pilot 1 Clutch plate and hub assembly 22 2 Pulley bearing retainer 24 using J 6083 figure 9 3 Pulley 26 Install J 33023 A to the front head figure 10 Ins...

Страница 78: ...aring 25 in the pulley bore Install or Connect Figures 4 13 14 15 and 16 Tools Required J 6083 Snap Ring Pliers J 8433 1 Puller Bar J 9481 Pulley Bearing Installer J 29886 Threaded Driver Handle J 33017 Pulley and Bearing Assembly Installer J 33019 Bearing Staking Tool with staking pin and retaining band J 33023 A Puller Pilot J 33026 Compressor Holding Fixture J 35372 Compressor Support Block 1 P...

Страница 79: ...tion J 8433 1 on J 33023 and assemble the through bolts and washers through the puller bar slots and thread them into J 33026 figure 16 Figure 16 Installing the Pulley Bearing Assembly The thread of the through bolts should enga ge the pull th ic k n e s s of the compressor holding fixture Tighten the center screw in J 8433 1 to force the pulley and bearing assembly onto the compressor front head ...

Страница 80: ...ure J 8433 1 and the clutch coil assembly 27 stay in line during installation When the clutch coil assembly 27 is seated on the front head 33 use a 3 mm Vs inch diameter drift punch to stake the head 33 at 3 places 120 degrees apart to assure the clutch coil assembly 27 remains in position figure 19 Stake size should be one half the area of the punch tip and 0 28 0 35 mm 0 010 0 015 inch deep figu...

Страница 81: ...all or Connect Figures 3 and 4 Tools Required J 5403 Snap Ring Pliers J 33011 O ring Seal Installer Valve 5 O ring seal 44 with J 33011 Dip the seals into new clean 525 refrigerant oil Retainer 45 with J 5403 MAJOR REPAIR TO THE COMPRESSOR Replacement of the shaft seal assembly or the pressure relief valve will require the discharge of the vehicle s refri gerating system figure 21 Other than clutc...

Страница 82: ...J 9553 01 figure 24 Inspect Make sure the compressor neck area is clean All parts Replace as necessary Install or Connect Figures 4 and 25 Tools Required J 5403 Snap Ring Pliers J 23128 A Seal Seat Remover and Installer J 33011 O Ring Seal Installer J 34614 Shaft Seal Protector Figure 23 Removing or Installing the Shaft Seal Dip the new O ring seal in clean 525 viscosity refrigerant oil 1 J 34614 ...

Страница 83: ...er 10 11 Install or Connect Figures 4 27 and 28 Tools Required J 9625 A Pressure Test Set with Schrader Valve J 33016 Cylinder Alignment Rods J 35372 Support Block Use new seals and gaskets Place the rear head on J 35372 with the control valve 5 facing the technician Cylinder Alignment Rods J 33016 in the mounting hole facing the technician and at the upper left position figure 27 Gasket 42 figure...

Страница 84: ...ors The suction port low side of the compressor has a large internal opening The discharge port high side has a smaller internal opening into the compressor Open the low pressure control high pressure con trol and the refrigerant control on the charging sta tion to allow the refrigerant vapor to flow into the compressor 2 j Im portant Check for leaks at the pressure relief valve 2 compressor front...

Страница 85: ...e gage at the completion of the tenth revolution of the com pressor shaft 38 The pressure reading for a good pumping compressor should be 690 kPa 100 psi or above A pressure reading of less than 620 kPa 90 psi would indicate one or more suction and or dis charge valves leaking an internal leak or an inoper ative valve Disassemble the compressor and repair as necessary Reassemble and repeat the pum...

Страница 86: ...over 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 29886 Support Block 12 J 33011 O ring Seal Installer 13 J 33013 A Hub and Drive Plate Remover and Installer 14 J 33016 Cylinder Alignm ent Rod 15 J 33017 Pulley and Bearing Assem bly Installer 16 J 33019 Bearing Staking Tool 17 J 33020 Pulley Puller 1...

Страница 87: ...ying means when tensioning the compressor drive belt There 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 with a torque cush ion the clutch hub holding tool J 25030 is used in place of J 33027 Figure 1 HR 6 Compressor V Groove Pulley and Standard ...

Страница 88: ...sor parts and system Keep the work area and tools clean Keep the parts clean at all times Clean assembled parts with Trichloroethane naphtha Stoddard solvent 1 S haft Nut 2 C lutch Plate and Hub A ssem bly 3 Pulley Bearing R etainer 4 Pulley Bearing 5 Pulley 6 C lutch C oil A ssem bly 7 Through B olts 6 8 S haft Seal Parts 11 Front Head 12 Head Gasket 13 Valve Plate D ischarge 14 S uction Reed Pla...

Страница 89: ...e and hub assembly 2 steady using J 25030 2 Clutch plate and hub assembly 2 Thread J 33013 B into the clutch plate and hub assembly 2 Figure 6 Removing the Clutch Plate and Hub Assembly Hold the body of J 33013 B with a wrench and tighten the center screw into the remover body figure 6 3 Shaft key 21 Retain shaft key 21 if usable Inspect All parts and replace as necessary s Install or Connect Figu...

Страница 90: ...late and hub assembly 2 and the pulley 5 The gap should be 0 38 0 64 mm 0 015 0 025 inch figure 8 Remove J 33013 B Figure 8 Installing the Clutch Plate and Hub Assembly I Inspect Position of the shaft 20 even with or slightly above the clutch hub Use J 33027 to hold the clutch plate and hub assembly 2 Tighten Shaft nut 1 to 16 N m 12 ft lbs with J 33022 Hand spin the pulley 5 to check for free rot...

Страница 91: ...ring 5 in the pulley bore n Install or Connect Figures 4 13 14 15 and 16 Tools Required J 21352 A Compressor Support Block J 9481 A Pulley Bearing Installer J 33019 Bearing Staking Tool with staking pin and retaining band J 33017 Pulley and Bearing Assembly Installer J 33023 A Puller Pilot J 8433 1 Puller Bar J 33026 Compressor J 6083 Snap Ring PI 1 Pulley 5 on J 21352 A Holding Fixture iers NOTIC...

Страница 92: ...take similar to the original is formed down to but not touching the bearing Position the stake pin after striking Figure 14 Staking the Pulley Bearing in the Rotor Bore 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 3 Pulley 5 on the front head Position J 33017 and J 33023 A over the ...

Страница 93: ...d 11 3 Clutch coil assembly 6 Install J 33023 A on the head 11 of the compressor Install J 8433 1 with J 33025 figure 17 T ighten J 8433 1 fo rcin g screw against J 33025 A Inspect Clutch coil assembly 6 Replace as necessary 0Install or Connect Figures 4 18 19 and 20 Tools Required J 8433 1 Puller Bar J 33024 Clutch Coil Installer Adapter J 33026 Compressor Holding Fixture 1 Compressor assembly on...

Страница 94: ...kbench and work area clean when servic ing the compressor and use proper clean service tools NOTICE Any attem pt to use m akeshift or inade quate service tools or equipm ent may result in damage and or im proper com pressor operation All parts used for servicing the compressor internally are protected by a preservative and packaged in a man ner which does not require cleaning washing or flushing T...

Страница 95: ...er J 23128 A Seal Seat Remover and Installer J 34614 Shaft Seal Protector J 5403 Snap Ring Pliers Dip the new O ring seal in clean 525 viscosity refrigerant oil J 34614 onto the shaft 20 1 O ring seal using J 33011 figure 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 t...

Страница 96: ...ief valve 32 and new seal with 525 viscosity refrigerant oil 1 Pressure relief valve 32 with new seal Tighten Pressure relief valve 32 to 9 N m 84 in lbs Im portant Leak test the compressor Refer to Leak Testing COMPRESSOR DISASSEMBLY INTERNAL CYLINDER AND SHAFT Remove or Disconnect Figures 4 27 28 29 and 30 Mark the front head 11 alignment with cylinders 16 23 and rear head 28 alignment 1 Clutch ...

Страница 97: ...hrough Bolt Hole 6 C Suction Pressure Outside Cavity D Discharge Pressure Inner Cavity E Opening to Rear Discharge Port F High Pressure Relief Valve G Drilled Opening into High Pressure Relief Valve Area 28 Rear Head B 06726 131 I Figure 31 Positioning the J 33016 Guide Pins Clean All parts Inspect All parts and replace as necessary COMPRESSOR ASSEMBLY INTERNAL CYLINDER AND SHAFT 2 Install or Conn...

Страница 98: ...n at the rear Apply refrigerant oil to the seal surface of the rear head to easy assembly Cylinder and shaft assembly gut pack Shaded parts shown in figure 3 are not serviceable A replacement kit gut pack is available for replacement Assemble cylinder and shaft assembly over the guide pins onto the rear head 28 figure 35 Using both hands press the cylinder and shaft assembly down into the rear hea...

Страница 99: ...sition B Tips of Suction Reeds M ust Lo cate Above Recess in C ylinder at Top C Discharge Crossover Opening 15 C ylinder Seal Front B 06735 Figure 36 Installing the Front Suction Reed Plate A A 12 o clo ck Reference P osition B S uction C rossover O penings C Through B olt H ole 6 D D ischarge C rossover O pening E D ischarge Valve Reed Retainers F S uction Intake O penings B 06736 Figure 37 Insta...

Страница 100: ...essor Holding Fixture Be sure the compressor has no oil internally 1 Install J 9625 A on the rear head of compressor fig ure 3 2 Install the center hose of the manifold gage set on J 23500 01 to a refrigerant drum standing in an up right position and open the valve on the drum 3 Install the charging station high and low pressure lines to corresponding fittings on J 9625 A using gage adapters or ho...

Страница 101: ...tely one revolution per second A slower rotation can result in a lower pump up pressure and disqualify a good pumping compressor Observe the reading on the high pressure gage at the completion of the tenth revolution of the compressor shaft 20 The pressure reading for a good pum ping com pressor should be 690 kPa 100 psi or above A pres sure reading of less than 620 kPa 90 psi would indicate one o...

Страница 102: ...2 O ring Seal Installer 13 Hub and Drive Plate Remover and Installer J 23128 A J 21352 A 29886 12 S X J 33011 J 33013 B J 33016 J 33017 J 33019 J 33020 14 C ylinder A lig n m e n t Rods 15 Pulley and Bearing A ssem bly Insta ller 16 Bearing S taking Tool 17 Pulley Puller 18 S haft Seal P rotector 19 6 Point 13 mm S ocket 20 P uller Pilot 21 C lutch C oil Insta lle r A dapter 22 C lutch Coil P ulle...

Страница 103: ...ive 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 sector teeth when the front wheels are in the straight ahead posi tion The sector teeth are slightly tapered so that a proper preload may be obtained by moving the pitman shaft end ways by means of a preload adjuster sc...

Страница 104: ...E TH R U ST BEARING 10 SEAL PITM AN SHAFT GREASE 11 HOUSING STEERING GEAR 12 SEAL STEERING SHAFT 13 G ASKET HOUSING 14 BUSHING OR NEEDLE BRG PITM AN SHAFT 15 GEAR PITMAN SHAFT 16 ADJUSTER PRELOAD 17 SHIM PRELOAD ADJUSTER 18 COVER ASSY HOUSING 19 NUT PRELOAD ADJUSTER 20 BOLT FLG HEX HD 21 SCREW ASSY B A L L GUIDE CLAMP 22 C LAM P BALL RETURN GUIDE 23 GUIDE BALL RETURN 4 24 B ALL 25 WASHER PITMAN SH...

Страница 105: ...earance is greater than 05 mm 002 a steering gear lash adjuster kit is available 1 Center steering gear 2 Remove parts as shown PRELOAD ADJUSTER NUT If replacing gasket only do not remove SIDE COVER BOLTS SIDE COVER PRELOAD ADJUSTER SHIM PRELOAD ADJUSTER PITMAN SHAFT 1 Before installing turn preload adjuster screw counter clockwise until it bottoms then back screw off one half turn 2 Install parts...

Страница 106: ... u p in to a d ju ste r u sin g Tool A 2 In s ta ll parts as show n Rem ove cu p usin g J 29369 1 p u lle r and s lid e ham m er WORM BEARING ADJUSTER LOWER WORM BEARING CUP LOWER WORM BEARING LOW ER BEARING RETAINER 5 DISASSEMBLE AND ASSEMBLE WORMSHAFT AND BALL NUT DISASSEMBLE ASSEMBLE 1 Disassemble parts as 1 A s s e m b le p a rts as shown shown 2 Clean and inspect all 2 Refer to Fig A for p a ...

Страница 107: ...ge of slot l l l 6 socket Due to tolerances some sock ets require a wrapping of card stock around the serrations 7 ADJUST OVER CENTER PRELOAD B a c k o ff p r e lo a d adjuster until it stops then turn it in one full With gear at center of travel check torque to turn stub shaft reading 1 Turn adjuster in until torque to turn stub shaft is 0 5 to 1 2 N m 4 to 10 in lbs more than reading 1 Torque ad...

Страница 108: ... orm Bearing Upper w orm Bearing Cup Pitm an S haft Seal H ousing W orm S haft Seal Side Cover G asket Pitm an S haft N eedle Bearing Pitm an S haft Preload A d ju ste r Preload A d ju ste r Shim Side Cover Preload A d ju ste r Nut Side Cover B olts Ball G uide C lam p Screw Ball G uide C lam p Ball G uide Balls Lockw asher Pitm an Arm Nut Top S tuded Side Cover B olt Used on som e m odels F 04650...

Страница 109: ...adjuster screw counterclockwise until it bottoms then back screw off one half turn 2 Install parts as shown Checking end clearance If clearance is greater than 05 mm 002 a steering gear lash adjuster kit is available PRELOAD ADJUSTER NUT If replacing gasket only do not remove PITMAN SHAFT PRELOAD ADJUSTER FEELER GAUGE Select to get proper clearance SHIM PITMAN SHAFT LUBRICATION The steering gear r...

Страница 110: ... with screwdriver Remove cup using J 29369 1 puller and slide hammer WORM BEARING ADJUSTER ASSEMBLE 1 Press cup into adjust using Tool A 2 Install parts as shown LOWER WORM BEARING CUP LOWER WORM BEARING LOWER BEARING RETAINER 5 DISASSEMBLE AND ASSEMBLE WORMSHAFT AND BALL NUT DISASSEMBLE 1 Disassemble parts as shown 2 Clean and inspect all parts for excessive wear BALLS ASSEMBLE 1 Assemble parts a...

Страница 111: ...toms then loosen one quarter turn 2 Carefully turn the worm shaft all the way to end of travel then turn back one half turn 3 Tighten adjuster plug until torque wrench reads 0 6 to 1 0 N m 5 to 8 in lbs 4 Tighten locknut using punch against edge of slot 11 16 socket Due to tolerances some sockets require a wrapping of card stock around the serrations 8 ADJUST OVER C EN TER PRELOAD A Back off prelo...

Страница 112: ... SAGINAW MODEL 525 MANUAL STEERING GEAR Gear to Frame B o lts Pitman Shaft Nut Side Cover B o lts Pitman Shaft Adjusting Screw Locknut Coupling Flange To Gear Pinch B o lt Coupling Clamp Nut S ta rfire Clamp To Ball Nut S cre w Maximum N m Ft Lbs 95 70 251 185 40 30 34 25 40 30 70 50 5 5 4 SAGINAW MODEL 535 MANUAL STEERING GEAR N m Ft Lbs Gear to Frame B o lts 95 70 Side Cover B o lts 18 13 Pitman...

Страница 113: ... Bearing Cup Installer 438 F 05905 J 29369 1 J 6278 J 35469 J 35365 J 8092 W orm Bearing A d ju ste r Cup P uller Use w ith J 2619 01 Pitm an S haft Bearing Rem over Pitm an S haft Bearing In sta lle r W orm Bearing Cup Installer Treaded Universal Driver H andle 3U 10 Thread F 05814 ...

Страница 114: ...3B2 12 MANUAL STEERING GEAR ...

Страница 115: ...vane type design There are two types submerged and nonsubmerged Submerged pump P models have a housing and internal parts that are inside the reservoir and operate submerged in oil The nonsubmerged pump TC models with or without reser voir function the same as the submerged pump except that the reservoir is separate from the housing and inter nal parts There are two bore openings at the rear of th...

Страница 116: ... Side Cover 226 Bolt 227 Nut 228 Housing 229 Connectors 230 Seal 231 Seal 232 Rings 233 Spacer 234 Bearing Retainer 235 Spacer 236 Race 237 Bearing 238 Race 239 Seal 240 Adjuster Plug 241 Bearing 242 Seal 252 243 Washer 230 244 Retaining Ring 250 23 1 245 Nut 246 Races 247 Bearing 248 Worm Shaft 249 Seal 250 Valve Body 251 Stub Shaft 252 Valve Spool 231 232 231 233 23235 236 237 238 239 240 241 24...

Страница 117: ...ll be speci fied to lubricate parts upon assembly In these cases GM Power Steering Fluid part no 1050017 or equivalent should be used DO NOT use brake fluid automatic trans mission fluid or other non approved fluids DISASSEMBLY Rem ove or Disconnect Figures 2 through 12 Tools Required J 4245 Internal Snap Ring Pliers J 21552 Ball Retainer Tool J 8524 1 Bearing Remover J 7624 Spanner Wrench J 7079 ...

Страница 118: ...ge on the tool This will prevent the end circuit balls from falling out 11 Adjuster nut 245 12 Adjuster plug 240 using J 7624 figure 6 Retaining ring 244 using J 4245 Washer 243 seal 242 and bearing 241 240 A d ju ste r Plug Figure 8 Removing the Needle Bearing Bearing retainer 234 Pry the retainer with a screwdriver at the raised area figure 7 Seal 239 and needle bearing 241 Use J 8524 1 and J 70...

Страница 119: ...t assembly if necessary Pitman shaft 221 for excessive wear or scoring Check the sector gear teeth for wear R eplace the p itm a n sh a ft a sse m b ly if necessary Adjuster screw 222 threads for wear The adjuster screw must be free to turn with no end play 2 Rack piston Worm 248 and rack piston 214 grooves and all balls 213 for scoring BOTH MUST BE REPLACED as a matched assembly Seal 216 and ring...

Страница 120: ...nnectors Brass inverted flare connectors 229 for looseness ASSEMBLY In stall or C o n n ect F ig u res 1 4 and 10 through 15 Tools Required J 4245 Snap Ring Pliers J 6217 Valve Connector J 21552 Ball Retainer J 22407 Bearing Installer J 8092 Bearing Driver J 7079 Bearing Remover and Installer J 8524 1 Driver J 7624 Bearing Preload Spanner Wrench 1 Connectors 229 using J 6217 figure 12 2 Balls 213 ...

Страница 121: ...alve assembly into the steering gear housing 12 Adjuster plug 240 into the steering gear housing Use spanner wrench J 7624 Adjust Figures 16 through 23 Tools Required J 7624 Spanner Wrench J 7754 01 Torque Wrench 1 Bearing preload Use tool J 7624 Turn the adjuster plug 240 to A Mark B Adjuster Plug Hole 251 Stub Shaft B 06532 Figure 18 Remarking the Housing the left until the plug and bearing 237 ...

Страница 122: ...n lbs repeat the adjustment procedure Lubricate the stub shaft 251 area outside the dust seal 206 with chassis lubricant or an all purpose grease 2 Rack piston 214 using J 21552 figure 4 3 Bearing 209 using J 22407 and J 8092 4 Washers 207 and seals 208 using J 6219 figure 21 5 Retaining ring 205 6 Pitman shaft 221 gasket 224 and side cover 225 7 Bolt 226 and nut 227 Adjust Figure 22 Tool Required...

Страница 123: ... be disassembled inspected cleaned and flushed before servicing is complete Service information is shown in figures 24 25 26 27 and 28 The ball nut and control rings seals generally need not be replaced unless cut or damaged If cut or 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 lubric...

Страница 124: ... O L VALVE 26 SEAL PITMAN SHAFT 44 GEAR A S M PITM AN SHAFT 9 SEAL O R IN G SPO O L 27 WASHER SEAL BAC K U P P ITM A N SHAFT 45 SEAL A S M GASKET 10 _ BO DY VALVE 30 RING RETAINING P ITM A N SHAFT SEAL 46 COVER A S M HO U S IN G SIDE 11 _ R IN G VALVE BO DY 3 31 WASHER PITM AN SHAFT LOCK 47 BOLT HEX HEAD SIDE COVER 4 12 _ SEAL O RING VALVE B O D Y 3 32 NUT PITMAN SHAFT 48 NUT LASH ADJUSTER 13 _ RE...

Страница 125: ...r j Remove Pitman Arm nstaM Sea 2 REMOVE AND INSTALL PITMAN SHAFT AND SIDE COVER REMOVE INSTALL 1 If pitman shaft and 1 If removed install side cover are to be gasket seal by separated remove bending tabs around preload adjuster nut cover edges 2 Rotate stub shaft to 2 Install parts center gear then as shown remove parts as shown SIDE COVER BOLTS c j j f Torque to 60 Newton Metres to 40 Ft Lbs j j...

Страница 126: ...flon SPOOL TO BODY O RING A Loosen shaft cap Tap lightly on wood block u C Remove and install spool Rotate while removing or installing Lubricate spool and body with power steering fluid B Remove and install stub shaft Pull cap out approx 6 mm V4 Pin on shaft and hole in spool Disengage to remove D Engage stub shaft Notch must fully engage pin and cap must seat against shoulder F 05862 REMOVE 1 Lo...

Страница 127: ...ing worm counterclockwise GUIDE Alternately install remainder of balls and retain with grease at each end of guide CLAMP SCREW Tighten to 5 Newton Metres 4 Ft Lbs 10 REMOVE AND INSTALL PITMAN SHAFT SEALS AND BEARING Re m o v e in s t a l l 1 Clean end of housing thoroughly to prevent dirt from entering and be extremely careful not to score the housing bore 2 Use screw driver to remove pitman shaft...

Страница 128: ... adjuster counterclockw ise until mark on face of adjuster lines up w ith second mark on housing Using spanner wrench J 7624 tighten adjuster plug until thrust bearing is firmly bottomed 27 Newton Metres 22 Ft Lbs Measure back counterclockw ise 13mm Vi and place a second mark on housing Using punch in notch tighten lock nut securely Hold adjuster plug to m aintain alignm ent of the marks Mark hous...

Страница 129: ...owel pins 8 19 Pressure plate 7 20 O ring 6 21 Pressure plate spring 5 22 O ring seal 4 23 Dowel pin 3 24 Sleeve 2 figure 39 jjjl CLEANING AND INSPECTION Clean All parts with solvent and blow dry Inspect Figure 39 1 Rotating group components 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 Rotor slots f...

Страница 130: ...ate 14 Thrust Plate Retaining Ring 15 Return Tube 16 Drive Shaft Seal 17 Drive Shaft 18 Bearing 19 Retaining Ring 20 Flow Control Spring 21 Control Valve 22 O Ring Seal 23 Fitting 24 Reservoir 25 O Ring Seal 26 Clips F 01875 Figure 29 Power Steering Pump Components Model TC Use a press to compress the thrust plate figure 46 Opening of ring 14 centered with bolt hole nearest to access hole 15 Drive...

Страница 131: ...ly into the housing while rotating the driveshaft so that the shaft serrations engage with the rotor 17 Retaining ring 19 Use a suitable pair of snap ring pliers figure 33 F Press G Support Ring 17 Drive Shaft 18 Bearing G F 01880 F Press K Bar Stock 13 Thrust Plate 14 Thrust Plate Retaining Ring E Note the position of the large lug 17 Drive Shaft 19 Retaining Ring F 01879 F 02151 Figure 34 Remove...

Страница 132: ...nts Figure 41 Install Sleeve Assembly Figure 39 Removing the Sleeve Assembly Make sure the beveled side of ring 19 is properly located 18 Flow control spring 20 19 Flow control valve 21 20 O ring seal 22 21 O ring 25 22 Reservoir 24 figure 31 23 Clips 26 figure 30 i I a i i O il INSTALL TUBE REMOVE TUBE F 02154 Figure 42 Installation of the Pin Seal and Pressure Plate Spring F 02153 A 2 Punch Slee...

Страница 133: ...9 and O ring 60 5 Pressure plate 65 Tap lightly on the driveshaft with a rubber mallet 6 Pump ring 64 and vanes 63 Shaft retaining ring 62 pump rotor 61 and thrust plate 56 7 Driveshaft 50 8 Seal 51 from the housing 53 Dowel pins 55 and O rings 54 Seal 52 a y 1 CLEANING AND INSPECTION Clean All parts with solvent and blow dry Inspect Figure 47 Rotating group components Vane 63 tips for scoring or ...

Страница 134: ...e 56 Rotor 61 Make sure the counterbore faces the driveshaft end of the housing Vanes 63 the rounded edge faces away from the rotor Shaft retaining ring 62 pump ring 64 and pressure plate 65 O ring 60 control valve spring 59 and control valve 58 Pressure plate spring 66 and end plate 67 End plate retaining ring 68 Seal 69 and reservoir 70 Bolt 71 and fitting 73 SAGINAW POWER STEERING PUMP MODEL CB...

Страница 135: ...9 Clean Exterior of the pump with solvent CONTROL VALVE Remove or Disconnect Figure 48 Tool Required J 7728 Seal Installation Tool 1 Pump from the vehicle if necessary for access Protect the drive shaft 8 with shim stock Use a small chisel to cut the drive shaft seal 3 and discard the seal Install or Connect Figure 50 1 Pump from vehicle if necessary for access 2 Fitting 7 and O ring 6 3 Control v...

Страница 136: ...ng a punch in the access hole Gently push on the drive shaft 8 to assist in removing end cover 19 O ring 18 pressure plate spring 17 pump ring 11 pump vanes 12 and drive shaft sub assembly consisting of Pump rotor 13 Thrust plate 10 Drive shaft 8 Shaft retaining ring 14 2 O ring 16 from housing 2 3 Dowel pins 9 4 Drive shaft seal 3 5 Pressure plate 5 pressure plate spring 17 and O ring 18 from the...

Страница 137: ...ctly onto the dowel pins 9 in the housing 2 Lubricate new O ring 16 with power steering fluid 8 O ring 16 into the groove in the housing 2 9 Pressure plate 15 10 Pressure plate spring 17 Lubricate new O ring 18 with power steering fluid 11 O ring 18 into the end cover 19 Lubricate the outer edge of the end cover 19 with power steering fluid Press the end cover into the housing 2 12 Retaining ring ...

Страница 138: ... 40 ft lbs Pitman Shaft N u t 244 N m 180 ft lbs Ball Return Guide S crew s 5 N m 4 ft lbs Integral Power Steering Gear CK GMT 400 Pitman Shaft N u t 250 N m 180 ft lbs Side Cover B o lts 60 N m 40 ft lbs Ball Return Guide S crew s 5 N m 4 ft lbs Pitman Shaft Preload Adjuster Screw Jam N u t 27 N m 20 ft lbs Power Steering Pump Model TC and P F ittin g 55 N m 75 ft lbs Power Steering Pump Model CB...

Страница 139: ...sta ller 3 Ball Retainer 4 A d ju ste r Plug Bearing Insta ller 5 Driver 6 S panner W rench 7 Driver 8 Pitm an S haft Bearing P uller 9 P uller Form erly J 6632 10 Seal In staller 11 Rack Piston Seal C om pressor 12 Bearing Installer 13 Seal Installer J 6278 J 29107 J 6219 J 7576 J 8947 J 22407 J 7728 F 05888 ...

Страница 140: ...3B3 26 ...

Страница 141: ...orted 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 preload is set by crushing a collapsable spacer between the bearings in the axle housing The ring gear is bolted onto the differential case with 10 left hand thread bolts The differential case is supported i...

Страница 142: ...he case 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 ifferential side bearings using J 8107 2 and J 22888 figure 3 The jaws of J 22888 must pull from beneath the bearing cone and not the cage 12 Ring gear bolts 25 Ring gear bolts use left handed th...

Страница 143: ...se 7 A xle S haft Oil Seal 25 Ring Gear Bolt 8 A xle S haft Bearing 26 D ifferential Gears 9 A xle H ousing 27 Pinion T hrust W ashers 10 A xle A ir Vent 28 Side Gear T hrust W ashers 11 Pinion Nut 29 Pinion S haft 12 W asher 30 P inion S haft Lock B olt 13 Pinion Flange 31 Bearing Cap 14 Pinion Oil Seal 32 B olt 15 P inion O uter Bearing 33 G asket 16 Plug 34 Cover 17 18 C ollapsable Spacer Pinio...

Страница 144: ...iameter 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 any cracks are found The housing for foreign material such as metal chips dirt or rust Refer to Cleaning in this section DIFFERENTIAL Inspect Pinion gear shaft for unusual wear Pinion gear and side gear teeth ...

Страница 145: ...arings 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 load Do not replace a bearing for this reason Bearing cups for cracks or chips SHIMS Inspect Shims for cracks and chips Damaged shims should be replaced with an equally sized service shim ASSEMBLY OF THE REAR AXLE Insta...

Страница 146: ...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 use the nominal pinion setting to select a shim 18 Remove bearing caps 31 and depth gaging tools 19 Install the correct pinion shim 19 according to this procedure to the pinion Install or Connect Figu...

Страница 147: ...thick Service shims are available from 1 02 mm to 2 54 mm 0 040 to 0 100 inch in 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 ric a te the axle b e a rin g s w ith axle lubricant 2 Insert the service spacer between the bearing cup and the axle housing Place ...

Страница 148: ...oint just before additional drag begins is the correct feeler gage thickness This is the zero setting without pre load Remove the left bearing cap and shim s from the axle h o u sin g M easure the shim s using a micrometer The shim pack needed is the total of the shim s and the feeler gage An additional pre load of 0 10 mm 0 004 inch will be added to each side of the differential case after the ba...

Страница 149: ...oint within 0 05 mm 0 002 inch If the ba ckla sh 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 measured should be between 0 13 and 0 23 mm 0 005 and 0 009 inch for all new gear sets Figure 17 Differential Bearing Preload Shim Installation 8 If the backlash is not within specifications move the ring gea...

Страница 150: ...refully 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 used the area of pinion tooth contact will be visible when hand load is applied 3 Tighten the bearing cap bolts to the specified torque 4 Expand the brake shoes until a torque of 40 to 50 ft lbs is req...

Страница 151: ... AXLE FASTENER Ring Gear B o lts Bearing Cap Bolts Axle Cover Bolts SPACER AND SHIM SIZES Differential Side Bearing Spacer N m FT LBS 120 90 75 55 27 20 SIZE 0 170 inch Differential Side Bearing Shim Kits 0 040 0 046 0 052 0 058 0 064 0 072 0 080 0 088 0 096 0 044 0 050 0 056 0 062 0 070 0 078 0 086 0 094 0 100 nch nch nch nch nch nch nch nch nch Pinion Bearing Shim Kits 0 025 0 029 inch 0 030 0 0...

Страница 152: ...e Bearing Remover Plug 4 Pinion Flange Remover 5 Side Bearing Remover 6 Rear Pinion Bearing Cone Installer 7 Pinion Oil Seal Installer 8 Differential Side Bearing Installer 9 Rear Pinion Bearing Remover 10 Driver Handle 11 Dial Indicator Refer to Figure 9 for these tools J 21777 40 Rear Pilot Washer J 21777 42 Front Pilot Washer J 21777 43 Stud Assem bly Bolt J 21777 45 Side Bearing Discs J 23597 ...

Страница 153: ...e 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 to allow the wheels to turn at different rates of speed while the rear axle continues to transmit the driving force This prevents tire scuffing when going around corners and prevents premature wear on inter...

Страница 154: ...Differential 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 Wheel Stud 13 Brake Line Clip 33 Axle Shaft 14 Bolt 34 C Clip 15 Pinion Shaft Lock Screw 35 Pinion Nut 16 Washer 36 Washer 17 Pinion Shaft 37 Pinion Flange 18 Bolt 38 Pinion Seal 19 Side Gear Thrust Washer 39 Outer Pinion Bearing 20 Pinion Thru...

Страница 155: ...erential 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 gear bolts use left handed threads NOTICE Do not pry the ring gear from the case T his w ill d am a ge th e rin g g e a r a n d th e differential case 13 Ring gear 7 from the differential case Driv...

Страница 156: ...hem 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 subsequent replacement of worn parts will eliminate costly drive component repair after reassembly AXLE HOUSING I Inspect The carrier bore for nicks or burrs that would prevent the outer diameter of the pini...

Страница 157: ... Low mileage 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 Shims for cracks and chips Damaged shims should be replaced with an equally sized service shim ASSEMBLY OF THE REAR AXLE n Install or Connect Tools Required J 8608 Rear Pinion Bearing Cup Instal...

Страница 158: ...heck 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 thousandths to the nominal 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 0 035 inch If the pinion is stamped with a minus numb...

Страница 159: ...rings 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 small increments Check the preload after each tightening Each tightening increases the bearing preload by several pounds If the bearing preload is exceeded the pinion will have to be removed and a new collapsible spacer installed Once the preload ...

Страница 160: ...ial 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 the case far enough to start the bolts using J 8107 4 to protect the differential from the press ram figure 18 6 New ring gear bolts 23 Tighten the ring gear bolts alternately in stages gradually pul...

Страница 161: ... is produced figure 21 Tighten the lock bolt on the side of the tool Figure 21 Measuring Side Bearing Shim Requirements Leave the tool in place 6 Install a service spacer 9 and a service shim 9 between the right bearing cup and the axle housing 7 D e te rm in e b e a rin g preload by in s e rtin g progressively larger feeler gage sizes between the carrier and the service shim Push the feeler gage ...

Страница 162: ...nd the ring gear 7 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 gear in or out from the pinion by increasing the th ickn e ss of one shim and decre asing the thickness of the other shim by the same amount This will maintain the correct rear axle side bearing pre...

Страница 163: ...ted by means of the side bearing adjusting shims which move the entire case and ring gear assembly closer to or farther from the drive pinion The adjusting shims are also used to set side bearing preload If the thickness of the right shim is increased along with decreasing the left shim thickness backlash will increase The backlash will decrease if the left shim thickness is increased along with a...

Страница 164: ...CER AND SHIM SIZES SIZE Differential Side Bearing S p a ce r 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 0 046 0 050 Pinion Bearing Shim K its 0 020 0 024 0 025 0 029 0 030 0 034 0 035 0 039 nch nch nch nch nch nch nch nch nch nch nch nch nch Lubricant 80W 90 GL 5 ...

Страница 165: ...r 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 Installer 11 Differential Side Bearing Installer 12 Side Bearing Backlash Gauge 13 Rear Pinion Bearing Cone Installer Not Shown J 21777 1 Arbor J 21777 29 Gauge Plate J 21777 35 Rear Pilot Washer J 21777 42 Front Pi...

Страница 166: ...4B2 14 8 1 2 INCH RING GEAR ...

Страница 167: ...d 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 differential is used to allow the wheels to turn at different rates of speed while the rear axle continues to transmit the driving force This prevents tire scuffing when going around corners and prevents premature w...

Страница 168: ...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 the adjusting nut 17 9 Differential bearing cap bolts 20 10 Differential bearing caps 19 Mark the caps and the housing as left and right NOTICE Be careful when prying the differential case out o f the axle ...

Страница 169: ...ion assembly for looseness by moving it back and fo rth L oo se n e ss in d ic a te 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 flange using J 8614 01 figure 6 18 Pinion 15 from the axle housing Thread the pinion nut halfway onto the pinion Replace the differential cover 34 with two bolts 35 to keep the pinion from falli...

Страница 170: ...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 any cracks are found The housing for foreign material such as metal chips dirt or rust Refer to Cleaning in this section DIFFERENTIAL Inspect L 1 I Pinion gear shaft for unusual wear Pinion gear and s...

Страница 171: ...r 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 rear pinion bearings with axle lubricant Place the bearings 10 and 13 into the pinion bearing cups In sta ll J 21777 8 J 217 7 42 J 21777 85 and J 21777 43 to the pinion bore figure 11 Hold the stud stationary ...

Страница 172: ... 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 for the pinion from the nominal setting If the pinion is stamped with a plus number add that many thousandths to the nominal setting If the nominal setting is 0 033 inch and the pinion is marked 2 the co...

Страница 173: ...eal 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 pinion washer 7 and a new nut 6 while holding the pinion flange with J 8614 01 figure 16 Tighten The nut until the pinion end play is just taken up Rotate the pinion while tightening the nut to seat the bearings Once there is ...

Страница 174: ...e 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 C heck that the m ating surfaces of the differential case and the ring gear are clean and burr free 5 Ring gear 15 to the differential case 27 Thread two left hand threaded studs into the ring gear on opposite sides ...

Страница 175: ...ing Ring Gear Backlash BACKLASH 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 rotation and perpendicular to the tooth angle 3 Check and record the backlash at three or four points around the ring gear figure 22 The pinion must be held stationary when chec...

Страница 176: ...the 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 brush When properly used the area of pinion tooth contact will be visible when hand load is applied 3 Tighten the bearing cap bolts to the specified torque 4 Expand the brake shoes until a torque of 40 t...

Страница 177: ...91 2 INCH RING GEAR 4B3 11 TOE CONTACT INCREASE BACKLASH LOW FLANK CONTACT DECREASE PINION SHIM HIGH FACE CONTACT INCREASE PINION SHIM HEEL CONTACT DECREASE BACKLASH F 02018 Figure 24 Gear Tooth Pattern ...

Страница 178: ...9 mm 0 220 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 nch 6 20 mm 0 244 nch 6 25 mm 0 246 nch 6 30 mm 0 248 nch 6 35 mm 0 250 nch 6 40 mm 0 252 nch 6 45 mm 0 254 nch 6 50 mm 0 256 nch 6 55 mm 0 258 nch Pinion Bearing Shim K it 0 5080 0 5842 mm 0...

Страница 179: ...nion Bearing C one In staller 6 Front Pinion Bearing Cup Installer 7 Driver Handle 8 Dial Indicator 9 D ifferential Side Bearing Installer 10 Side Bearing Remover 11 Rear Pinion Bearing Cone Installer 12 P inion Oil Seal Installer 13 Pinion Flange Remover 14 J 22306 Rear Pinion Bearing Cup Installer Not Refer to Figure 53 for these tools J 21777 1 J 21777 8 J 21777 42 J 21777 43 J 21777 85 J 21777...

Страница 180: ...4B3 14 91 2 INCH RING GEAR ...

Страница 181: ...fferential 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 nuts in or out The differential side bearing preload is accomplished by tightening the differential bearing adjusting nuts after the ring gear backlash has been set Two bearing caps are used to hold the differen...

Страница 182: ...e 19 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 in figure 7 and press the pinion from the cage Do not let the pinion fall to the floor 22 Collapsible spacer 12 from the pinion 23 Inner bearing 13 from the pinion 14 Press the bearing from the p...

Страница 183: ...nion 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 Brake Line Clip 46 Bolt 1 Pinion Nut 10 Pinion Cage 47 Axle Shaft 2 Washer 11 Shim 48 Gasket 3 Pinion Flange 12 Collapsable Spacer 49 Wheel Stud 4 Slinger 13 Pinion Rear Bearing 50 Wheel Hub 5 Pinion Oi...

Страница 184: ...4B4 4 1 0 1 2 INCH RING GEAR Figure 7 Pressing the Drive Pinion from the Cage ...

Страница 185: ... wear is most evident Bearing 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 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 preload Do not replace a b...

Страница 186: ...e the 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 Installation in this section PINION INSTALLATION Install or Connect Tools Required J 34943 Pinion Pilot Bearing Installer J 8092 Driver Handle Pinion pilot bearing 15 using J 34943 and J 8092 figure...

Страница 187: ...l 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 clean and burr free 5 Ring gear 14 to the differential figure 16 Thread two left hand threaded studs into the ring gear on opposite sides Place the ring gear onto the case and align the holes in the case with the studs Press the r...

Страница 188: ...approximately two slots to obtain the initial backlash adjustment 5 Adjusting nut lock 21 and lock bolt 22 to the left nut Do not tighten Tighten the right adjusting nut firmly to force the case into solid contact with the left adjusting nut Rotate the pinion several times to seat the bearings Loosen the right adjusting nut until it is free from its bearing Tighten the right adjusting nut until it...

Страница 189: ...shoes 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 wrench so that the ring gear rotates one full revolution then reverse the rotation so that the ring gear rotates one revolution in the opposite direction 5 Observe the pattern on the ring gear teeth and compare this with fig...

Страница 190: ...4 10 1 0 1 2 INCH RING GEAR TOE CONTACT INCREASE BACKLASH LOW FLANK CONTACT DECREASE PINION SHIM HIGH FACE CONTACT INCREASE PINION SHIM HEEL CONTACT DECREASE BACKLASH F 02018 Figure 21 Gear Tooth Pattern ...

Страница 191: ...olts 183 135 Axle Cover B o lts 27 20 Adjusting Nut Lock B o lts 30 22 SPACER AND SHIM SIZES SIZE Pinion Bearing Shims 0 006 nch 0 007 nch 0 008 nch k 0 009 nch 0 010 nch 0 011 nch 0 012 nch 0 013 nch 0 014 nch 0 015 nch 0 016 nch 0 017 nch 0 018 nch 0 019 nch 0 020 nch 0 021 nch 0 022 nch 0 023 nch 0 024 nch L u b rica n t 80W 90 GL 5 ...

Страница 192: ... 2 Side Bearing Rem over 3 Rear Pinion Bearing Cup Insta ller 4 Driver Handle 5 Rear Pinion Bearing Cone Insta ller 6 Side Bearing A d ju stm e n t Spanner 7 Rear Pinion Bearing Cone Remover 8 Pinion P ilot Bearing In staller N ot Illustrated Special Tools J 8092 J 24433 J 24429 J 22912 01 F 04662 ...

Страница 193: ... 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 deleted from one side and an equal amount are added to the other side Differential side bearing preload is set by the axle housing The axle housing is spread to remove the differential from the hous...

Страница 194: ...sing a rawhide hammer Ring gear 2 from the vise Put the differential case in the vise 12 13 14 15 Lock pin 29 from the differential using a hammer and a punch figure 8 Pinion shaft 28 using a hammer and a brass drift figure 9 Differential pinion gears 24 and thrust washers 26 Rotate the side gears until the pinion gears are in the opening of the differential figure 10 Differential side gears 25 an...

Страница 195: ...olt 3 Inner Pinion Bearing 14 Cover 24 Pinion Gear 4 Shims 16 Plug 25 Side Gear 6 Preload Shims 17 Bolt 26 Pinion Thrust Washer 7 Bearing 18 Bearing Cap 27 Side Gear Thrust Washer 8 Slinger 19 Bolt 28 Pinion Shaft 9 Pinion Oil Seal 20 Bearing 29 Roll Pin 10 Pinion Flange 21 Shim 37 ID Tag F 05909 Figure 1 Rear Axle Components ...

Страница 196: ...4B5 4 DANA REAR AXLES w i G fteHSf plll B j a z l li U lf F 04757 Figure 4 Spreading the Differential Case Figure 7 Removing the Ring Gear ...

Страница 197: ...DANA REAR AXLES 4B5 5 Figure 10 Removing the Pinion Gears Figure 13 Pinion Flange Removal ...

Страница 198: ...or 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 inside diameter and result in an oil leak Replace all worn or broken parts Ring and pinion gears are matched sets and are both replaced any time a replacement of either is necessary BEARINGS Inspect Bear...

Страница 199: ...pinion thrust washers Pinion shaft 28 Align the lock pin holes in the case and the shaft Lock pin 29 figure 18 Peen metal from the case over the lock pin Check that the mating surfaces of the differential case and the ring gear are clean and burr free Ring gear 20 to the differential case 22 Thread two studs into the ring gear on opposite sides Figure 18 Installing the Lock Pin Press the ring gear...

Страница 200: ...nt of the shim pack 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 differential PINION DEPTH ADJUSTMENT Tools Required D 120 Master Pinion Block Miller D 116 1 Pinion Height Block Miller D 116 2 Master Discs Miller D 115 3 Arbor Miller D 115 Scooter Gage ...

Страница 201: ...indicates 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 number of thousandths A pinion etched zero 0 will use the nominal setting as determined in this procedure 9 Measure each shim separately with a micrometer and add them together to obtain the total sh...

Страница 202: ...rings 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 and arbor into the differential bearing bore Place the pinion height block on top of the pinion Set the dial indicator at zero 0 and slide the scooter gage across the arbor figure 32 The indicat...

Страница 203: ...oad 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 the differential case 22 with master bearings installed to the axle housing The pinion must be installed 2 Mount a dial indicator havi ng a minimum travel of 0 200 inch with a magnetic base on the ring gear bolt side...

Страница 204: ...on the differential side bearing hub opposite the ring gear and drive the differential bearing onto the hub using J 23690 and J 8092 12 Assemble J 24385 01 to the axle housing as shown in figure 38 13 Assemble the dial indicator as shown in figure 38 Preset the gage at least 0 020 inch and then rotate the indicator housing to zero the dial NOTICE Do not spread the differential carrier m o re th a ...

Страница 205: ...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 The splined end of the shaft is supported by the differential The pinion gear is supported by two tapered roller bearings The pinion depth is set by a shim pack between the inner pinion bearing cup and the rear a...

Страница 206: ...Shims 21 Shims 35 Wheel Hub 7 Bearing 22 Differential Case 37 Inner Lock Nut 8 Slinger 23 Bolt 38 Lock Washer 9 Pinion Oil Seal 24 Pinion Gear 39 Outer Lock Nut 10 Pinion Flange 25 Side Gear 40 Axle Shaft 11 Washer 26 Pinion Thrust Washer 43 Differential Bearing 12 Pinion Nut 27 Side Gear Thrust Washer Preload Shim 14 Cover 28 Pinion Shaft 15 Spacer 29 Roll Pin F 05910 Figure 42 Rear Axle Componen...

Страница 207: ...e 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 The differential cover bolts 17 and the differential cover 14 figure 43 D rain the gear lu b ric a n t into a proper container 2 Axle shafts 40 Refer to the proper service manual Figure 44 Removing the Bea...

Страница 208: ...n D 166 Miller tool and put the holding fixture into the vise 12 13 14 15 Lock pin 29 from the differential using a hammer and a punch figure 49 Turn the differential over on D 166 Pinion shaft 28 using a hammer and a brass drift figure 50 Differential pinion gears 24 and thrust washers 26 Rotate the side gears until the pinion gears are in the opening of the differential figure 51 Differential si...

Страница 209: ...ims 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 cups out of the housing evenly moving the punch back and forth between one side of the cup and the other 24 Pinion adjusting shims 4 and baffle 5 Keep the shims together on the bench 25 P inion in n e r be...

Страница 210: ...s 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 for foreign material such as metal chips dirt or rust Refer to Cleaning in this section DIFFERENTIAL Inspect Pinion gear shaft for unusual wear Pinion gear and side gear teeth for wear cracks scoring and spalling Thrust washers for...

Страница 211: ... case 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 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 4 New pinion thru...

Страница 212: ...K 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 with a magnetic base on the ring gear bolt side of the housing figure 62 3 Install the outboard spacer between the master bearing and the axle housing on the ring gear side 4 Force the differential assembly as far as possibl...

Страница 213: ...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 block While applying pressure set the dial indicator at zero 7 Slide the gage over the arbor figure 67 8 R ecord the reading at the point of greatest deflection when the dial indicator needle is centered between movement to...

Страница 214: ...im pack figure 68 PINION INSTALLATION Install or Connect Tools Required J 7818 Front Pinion Bearing Cup Installer J 5590 Rear Pinion Bearing Cone Installer C 4204 Cup Installer Miller C 4171 Handle Miller J 8092 Handle J 8614 01 Pinion Flange Remover D 116 1 Pinion Height Block D 116 2 Arbor Discs D 115 3 Arbor D 115 2 Scooter Gage Block 1 Place the required amount of shims and baffle if used in t...

Страница 215: ...ading is within 0 05 mm 0 002 inch of the pinion marking the pinion is correctly set If the pinion depth does not meet Figure 73 Checking the Pinion Depth Setting specifications change the shim pack by the amount the indicator needle is from the pinion marking Remove the pinion nut 12 washer 11 pinion flange 10 slinger 8 and bearing cone 7 10 Preload shims 6 Install the shim s that were rem oved o...

Страница 216: ...ement 6 Force the differential case 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 bearings from the differential case 9 Using the total shim pack size determined earlier Refer to Determining Total Differential Shim Pack Size in this section subt...

Страница 217: ... spreading the carrier can damage or distort the carrier 14 Spread the ca rrier w hile exam ining the dial indicator 15 Remove the dial indicator 16 Place the bearing cups 20 onto the bearings 17 Install the differential assembly into the carrier Use a rawhide hammer to seat the differential assembly in the axle housing figure 80 18 Remove the spreader 19 Install the bearing caps 18 in their origi...

Страница 218: ...g gear 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 housing as shown in figure 79 15 Assemble the dial indicator as shown in figure 161 Preset the gage at least 0 020 inch and then rotate the indicator housing to zero the dial NOTICE Do not spread ...

Страница 219: ... n t 80W 90 GL 5 101 2 INCH rin g g e a r a x le FASTENER Ring Gear Bolts Bearing Cap Bolts Axle Cover Bolts L u b rica n t SHIM SIZES Differential Bearing Adjusting Shim Outer Pinion Bearing Shim N m FT LBS 142 105 115 85 47 35 80W 90 GL 5 SIZE 0 003 inch 0 005 inch 0 010 inch 0 030 inch 0 003 inch 0 005 inch 0 010 inch 0 030 inch 0 003 inch 0 005 inch 0 010 inch Inner Pinion Bearing Cup and Cone...

Страница 220: ...ster Discs Miller 10 Rear Pinion Bearing Cup Installer 2 Arbor Miller 11 Driver Handle 3 Pinion Height Block Miller 12 Rear Pinion Bearing Cone Installer 4 Scooter Gage Miller 13 Pinion Flange Remover 5 Master Pinion Bearings Miller 14 Differential side Bearing Installer 6 Master Pinion Block Miller 15 Differential Side Bearing Remover 7 Cup Installer Miller 16 Differential Carrier Spreader 8 Hand...

Страница 221: ...ont Pinion Bearing Cup Installer 4 Scooter Gage Miller 13 Front Pinion Bearing Cone Installer 5 Master Pinion Bearings Miller 14 Pinion Flange Remover 6 Master Pinion Block Miller 15 Differential Side Bearing Installer 7 Cup Installer Miller 16 Differential Side Bearing Remover 8 Handle Miller 17 Differential Carrier Spreader 9 Preload Shim Installer Miller 18 Side Bearing Adapters F 04664 ...

Страница 222: ...4B5 30 DANA REAR AXLES ...

Страница 223: ...nship 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 bearing preload is accom plished by tightening the differential bearing adjusting nuts after the ring gear backlash has been set Two bearing caps are used to hold the differential into the differential carrier as well ...

Страница 224: ...4B6 2 1 2 INCH RING GEAR ROCKWELL F 04734 Figure 1 Rear Axle Components ...

Страница 225: ...ider 61 Washer 20 Axle Housing 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 adjusting screw 48 figure 4 Center punch one differential carrier leg and bearing cap to identify the cap for reassembly figure 5 4 Bearing cap bolts 23 5 Bearing caps 25 figure 6 6 Adjusting nuts 32 7 D...

Страница 226: ...4B6 4 12 INCH RING GEAR ROCKWELL F 04758 F 04770 Figure 6 Removing the Bearing Cap Figure 7 Removing the Differential Figure 10 Removing the Differential Side Bearing ...

Страница 227: ...1 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 in a suitable solvent All parts should be disassembled before cleaning Parts should be thoroughly dried immediately after cleaning Use soft clean lintless rags Parts may be dried with comressed air Do...

Страница 228: ...ssure 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 replaced as sets If the rear axle was operated for an extended period of time with very loose bearings the ring gear and drive pinion will also require replacement Low mileage bearings may have minu...

Страница 229: ...flector 59 11 Pinion flange 60 to the pinion figure 16 Press the flange onto the pinion Figure 18 Removing the Pinion Nut 12 Pinion washer 61 and a new nut 62 using J 3453 to hold the pinion figure 17 Tighten Nut 62 to 325 N m 240 ft lbs PINION INSTALLATION Install or Connect n a new pinion Measure the pinion bearing shims 50 If pinion and ring gear set is installed the bearing shim pack must be a...

Страница 230: ... bolts 44 Tighten Bolts 44 to 61 N m 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 water to 160 180 F for 10 minutes before assembly Ring gear 37 to the differential Thread two studs into the ring gear on opposite sides Place the ring gear onto t...

Страница 231: ...g gear enough to notice end play on the indicator 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 the cause BACKLASH ADJUSTMENT The differential side bearing preload is adjusted by two adjusting nuts in the differential bearing bore The bore and the ...

Страница 232: ...ING GEAR AXLE ROCKWELL FASTENER Piston N u t Pinion Cage B olts Case Half B olts Ring Gear Bolts Bearing Cap Bolts SHIM SIZES Drive Pinion Bearing Retainer Shim Outer Pinion Bearing S h im N m FT LBS 325 240 48 35 61 45 136 100 176 130 SIZE Inner Pinion Bearing Shim 0 003 inch 0 005 inch 0 003 inch 0 005 inch 0 010 inch 0 030 inch 0 003 inch 0 005 inch 0 010 inch Drive Pinion Bearing Spacer 0 172 ...

Страница 233: ...12 INCH RING GEAR ROCKWELL 4B6 11 SPECIAL TOOLS Special Tools ...

Страница 234: ...4B6 12 12 INCH RING GEAR ROCKWELL ...

Страница 235: ...ate 16 and disc pack 12 as an assembly cam unit 14 Side gear thrust washer 13 CAM UNIT DISASSEMBLY 71 2 AND 8V2 INCH Remove or Disconnect Figures 1 and 3 1 Snap ring 22 2 Clutch plates 3 Guide clips 20 4 Wave spring 5 Cam plate 16 6 Cam side gear 21 CAM UNIT DISASSEMBLY 91 2 INCH Remove or Disconnect Tools Required J 22912 01 Bearing Remover Measure and record the overall length of the gear assemb...

Страница 236: ... lnch Ring Gear 10 Side Gear 20 G uide C lip 1 D ifferential Case 11 Latching Bracket 2 1 Side Cam Gear 2 S top Pin 91 2 Only 12 C lutch Plates 2 2 R etaining Ring 3 Lock Screw 13 Side Gear T hrust W asher 23 G overnor 4 G overnor B ushing 14 Side T hrust Sleeve 91 2 Only 5 Latching Bracket B ushing 15 Wave W asher F 05914 Figure 1 Differential Components Figure 2 Removing the Governor Bushings Fi...

Страница 237: ...ive 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 as the proper clearances between parts is necessary for the proper operation of the units There are three adjustments to be made 1 Left side gear backlash 2 Right side gear backlash 3 Thrust block clearance Left Side Gear Backlash Ad...

Страница 238: ...inch 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 4 1 Left thrust washer 13 to the differential Cam unit to the differential Right thrust washer 8 to the differential Clutch plates with guide clips to the differential Assemble alternatively as shown in figure 1 Right side ge...

Страница 239: ... assembly 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 14 Guide clips 34 15 Wave spring 16 Cam plate 33 17 Cam side gear 40 CLEANING AND INSPECTION Clean All parts with solvent Inspect All parts for excessive wear and breakage Pinion gear and side ...

Страница 240: ... Governor 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 adjusted The differential is adjusted by using selective thickness thrust washers behind each side gear and selective thickness reaction blocks between the side gears It is important to build up ...

Страница 241: ...shers 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 case half figure 14 5 Loosen the nut and index one pinion gear tooth to point downward perpindicular to the case half face Tighten the nut 6 Mount a dial indicator on the case half face using a magnetic base figure 15 ...

Страница 242: ...e gear back 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 readings The backlash should be between 0 051 and 0 254 mm 0 002 and 0 010 inch If the backlash is too high use a thicker thrust washer If the backlash is too low use at thinner washer 9 10 11 12 1...

Страница 243: ...2 nch 1 618 G reen 1 284 nch 1 346 nch 1 622 B lu e Black 1 288 nch 1 350 nch 1 626 1 630 91 2 lnch inch nch nch inch inch inch nch nch nch REACTION BLOCK SIZES IOV2 INCH 0 675 inch 0 672 inch 0 669 inch 0 666 inch RIGHT HAND SIDE GEAR THRUST WASHER 71 2 75 s 8V2 and 91 2 Inch Axles 0 10 inch 0 15 inch 0 20 inch 0 25 inch 0 30 inch 0 35 inch 0 40 inch 0 45 inch 101 2 Inch Axles 0 027 inch 0 032 in...

Страница 244: ...4B7 10 LOCKING DIFFERENTIALS SPECIAL TOOLS Special Tools ...

Страница 245: ...ar set to transmit 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 are retained in the housing by retaining clips in the hubs The pinion gear is supported by two tapered roller bearings The pinion depth is set by a shim pack located bwtween the gear end o...

Страница 246: ...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 Differential bearing cap bolts 18 7 Differential bearing caps 10 Mark the caps and the housing as left and right NOTICE Be careful when prying the differential case out o f the axle housing so as not to d a ...

Страница 247: ... Pinion Shaft Lock Screw 35 Pinion Nut 6 Shim 17 Pinion Shaft 36 Washer 7 Ring and Pinion Gear Set 18 Bolt 37 Pinion Flange 8 Differential Side Bearing 19 Side Gear Thrust Washer 38 Pinion Seal 9 Shim Pack including spacer 20 Pinion Thrust Washer 39 Outer Pinion Bearing 10 Bearing Cap 21 Pinion Gear F 04548 Figure 1 Front Axle Components Figure 2 Prying the Differential Case from the Axle Housing ...

Страница 248: ...AR A Soft Drift F 04695 Figure 7 Removing the Drive Pinion 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 ...

Страница 249: ...g Thrust washers for wear 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 Inspect Pinion and ring gear teeth for cracking chipping scorring or excessive wear Pinion splines for wear Pinion flange splines for wear Fit of the pinion on the pinion flange Sealing surface of the pinion ...

Страница 250: ...lace 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 the stud nut to 2 2 N m 20 in lbs 6 Rotate the gage plate and bearings several complete revolutions to seat the bearings 7 Tighten the stud nut until a torque of 1 6 to 2 8 N m 15 to 25 in lbs is o...

Страница 251: ... Installer 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 using J 8609 01 Press the bearing onto the pinion until the bearing cone seats on the pinion shims 2 A new collapsable spacer 4 Lubricate the pinion bearings with axle lubricant 3 Pinion 7 to the axl...

Страница 252: ...inion 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 5 Pinion thrust washers 20 Rotate the pinion gears toward the differential opening just enough to slide in the pinion thrust washers C heck that the m ating surfaces of the differential case and the ring ...

Страница 253: ...ing onto the case using J 22761 and J 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 differential side bearing preload is adjusted by changing the thickness of both the left and right shims equally This will m aintain the original backlash Production shims ...

Страница 254: ... drag begins is the correct feeler gage thickness 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 th re e places using a micrometer Average the readings figure 22 10 Add the dimensions of the service spacer service shim and the feeler gage 11 For an initial backlash set...

Страница 255: ...ssary 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 substitute for adjusting pinion depth and backlash as previously outlined It is a final check to veryify the correct running position of the ring gear and the drive pinion Gear sets which are not ...

Страница 256: ...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 of the rear bearing The shim is used in the differential to com pensate for manufacturing tolerances Increasing the shim thickness will move the pinion closer to the centerline of the ring gear Decrea...

Страница 257: ...earing Kits 0 170 inch 0 172 inch 0 064 0 040 0 046 0 052 0 058 0 072 0 080 0 088 0 096 0 070 0 044 0 050 0 056 0 063 0 078 0 086 0 094 0 100 Pinion Bearing Shim Kits 0 020 0 024 0 025 0 029 0 030 0 034 0 035 0 039 nch nch nch nch nch nch nch nch nch nch nch nch nch PINION PRELOAD AND BACKLASH Pinion Preload New Bearings 2 2 2 8 N m 20 25 in lbs Used Bearings 1 1 1 6 N m 10 15 in lbs Backlash New ...

Страница 258: ...icator 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 Installer 11 Differential Side Bearing Installer 12 Side Bearing Backlash Gauge 13 Rear Pinion Bearing Cone Installer Not Shown J 21777 1 Arbor J 21777 29 Gauge Plate J 21777 35 Rear Pilot Washer J 21777 42 Fro...

Страница 259: ... 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 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 deleted from one side and an equal amount are added t...

Страница 260: ...e carrier 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 bearings as left and right and place them with the proper bearing caps and cups 9 Differential shims 21 Mark the shims as left or right 10 Ring gear bolts 23 and discard Place shop towels over the vise ...

Страница 261: ...earing 14 Cover 24 Pinion Gear 4 S him s 15 Spacer 25 Side Gear 5 B affle 16 Plug 26 P inion T hrust W asher 6 Preload Shim s 17 Bolt 27 Side Gear T h ru st W asher 7 Bearing 18 Bearing Cap 28 Pinion S haft 8 Thrust W asher 19 B olt 29 Roll Pin 9 Pinion Oil Seal 20 Bearing 44 S linge r 10 Pinion Flange 21 Shim 45 A xle Seal F 05784 Figure 1 Front Axle Components ...

Страница 262: ...4C2 4 93 4 INCH RING GEAR FRONT AXLE Figure 3 Removing the Bearing Cap Figure 4 Spreading the Differential Case F 04756 F 04757 ...

Страница 263: ...93 4 INCH RING GEAR FRONT AXLE 4C2 5 Figure 10 Removing the Pinion Gears Figure 13 Pinion Flange Removal ...

Страница 264: ...4C2 6 93 4 INCH RING GEAR FRONT AXLE Figure 16 Removing the Pinion Inner Bearing ...

Страница 265: ... 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 RING GEAR Inspect lv Pinion and ring gear teeth for cracking chipping scoring or excessive wear Pinion splines for wear Pinion flange splines for wear The fit of the pinion on the pinion flange The sealing...

Страница 266: ...ears 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 the lock pin holes in the case and the shaft 7 Lock pin 29 figure 19 Peen metal from the case over the lock pin Check that the mating surfaces of the differential case and the ring gear are clean an...

Страница 267: ...usandths 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 the axle 8 Remove the differential case from the axle housing Do not remove the master bearings from the differential PINION DEPTH ADJUSTMENT Tools Required D 120 Master Pinion Block Miller D 116 1 ...

Страница 268: ... centerline and the pinion head must increase by the num ber of thousandths marked on the pinion This means that the shim pack will decrease by the same number of thousandths A negative pinion marking indicates 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 sam...

Страница 269: ...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 and C 4171 The cup must be seated on the shims figure 29 Drive the outer bearing cup into the axle assembly using J 7818 and J 8092 figure 30 Inner bearing cone and slinger if used on the pinion Drive th...

Страница 270: ...o the right if the pinion is marked 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 amount the indicator needle is from the pinion marking Remove the pinion nut 12 washer 11 pinion flange 10 slinger 8 and bearing cone 7 Preload shims 6 Install the shim...

Страница 271: ...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 6 will be the shim size on the ring gear side The remaining portion of the shim pack will be used on the side opposite the ring gear Add an additional 0 38 mm 0 015 inch of shims to the side opposite the ring gear to preload...

Страница 272: ...he 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 differential case must be removed from the housing then the differential bearings removed and the proper number of shims moved from one side to the other FINAL ASSEMBLY Install or Connect Figure 1 1 Drive a...

Страница 273: ... B o lts 47 35 AVAILABLE SHIM SIZES Differential Bearing Adjusting S h im 0 003 inch 0 005 inch 0 010 inch 0 030 inch Outer Pinion Bearing S h im 0 003 inch 0 005 inch 0 010 inch 0 030 inch Inner Pinion Bearing Shim 0 003 inch 0 005 inch 0 010 inch PINION PRELOAD AND BACKLASH Pinion Preload Backlash 2 26 4 53 N m 20 40 in lbs 0 13 0 23 mm 0 005 0 009 in ...

Страница 274: ...er 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 Rear Pinion Bearing Cup Installer 11 Driver Handle 12 Rear Pinion Bearing Cone Installer 13 Pinion Flange Remover 14 Differential side Bearing Installer 15 Differential Side Bearing Remover 16 Different...

Страница 275: ...upported in the axle housing ditions by two tapered roller bearings The differnetial and ring The axle uses a conventional ring gear and pinion gear gear are located in relationship to the pinion by using set to transmit the driving force of the engine to the threaded adjusters wheels This gear set transfers this driving force at a 90 The differential is used to allow the wheels to turn at degree ...

Страница 276: ...24 Shaft 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 the carrier case 29 Insert a screwdriver into the slots provided and pry to separate the case figure 6 Differential case 35 Bolts 18 and lock tabs 19 from the side bearing adjuster sleeves 32 figu...

Страница 277: ...T TRUCK FRONT AXLE 4C3 3 Figure 1 Axle Components ...

Страница 278: ...Ring 23 O utput Shaft 38 Shim 53 T hrust W asher 9 C arrier C onnector 24 W asher 39 Bearing 54 Side Gear 10 S hift Cable 25 Plug 40 S pacer 55 T h ru st W asher 11 S h ift Cable H ousing 26 W asher 41 Bearing 56 D ifferential Pinion 12 Gasket 27 Pin 42 Seal Gear 13 Indica tor S w itch 28 Bolt 43 D eflector 57 Cover 14 Spring 29 C arrier Case 44 Flange 58 B olt 15 Seal 30 Bearing 45 W asher 59 S h...

Страница 279: ...nts F 01390 Figure 6 Separating the Carrier Case Halves 18 Bolt 29 Carrier Case 19 Lock Tab 32 Sleeve F 01780 Figure 7 Removing the Lock Tabs 30 Bearing 32 Sleeve F 01782 Figure 9 Remove the Sleeve Bearing Figure 8 Removing the Side Bearing Cup ...

Страница 280: ...C3 6 T TRUCK FRONT AXLE Figure 13 Removing the Inner Pinion Bearing Cup Figure 15 Replacing the Case Bushings INSTALLATION J 33791 3 J 33791 2 J 33791 1 33791 2 95 95 C arrier A ssem bly F 01670 REMOVAL ...

Страница 281: ...and ring 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 nicks burrs or rough tool marks which would cause damage to the seals inside diameter and result in an oil leak Replace all worn or broken parts Ring and pinion gears are matched sets and are bot...

Страница 282: ... in both pinion gears line up 3 Thrust washers 55 Rotate the pinion gears toward the opening just enough to perm it the sliding in of the thrust washers 4 Shaft 52 and bolt 36 5 Ring gear 37 onto the differential case 35 6 Bolts 34 Im portant Always install new bolts Never reuse the old bolts Tighten Bolts 34 alternating in progressive steps to 80 N m 60 ft lbs 7 Side bearings 33 using J 33790 fig...

Страница 283: ...ould 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 Rotate the pinion with the torque wrench and observe the reading 2 If the preload torque is below specifications c o n tin u e to rq u in g the p in io n nut in sm all in cre m e n ts C heck the p re lo a d a fte r each ...

Страница 284: ...4C3 10 T TRUCK FRONT AXLE A B utton Located in Bearing Bore B B utton Moved O ut of Bearing Bore F 05791 Figure 19 Measuring Pinion Depth ...

Страница 285: ...ne notch using J 33792 7 Rotate 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 Figure 23 Installing the Sleeve Bearing Figure 22 Measuring Pinion Bearing Preload ...

Страница 286: ...klash at the Pinion 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 amount 10 When the backlash is correct mark the position of the sleeves so they can be kept in the same location MEASURING BACKLASH ALTERNATE METHOD 1 Use this method if the tools specified ...

Страница 287: ...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 tests These adjustments should be within specifications before proceeding with the backlash and the drive pinion adjustments It may be necessary to adjust both pinion depth and the backlash to obtain...

Страница 288: ...18 ft lbs Shaft 59 with deflector 2 Tap into place Bearing 4 Use J 33844 Seal 3 Use J 33893 figure 31 Seal 15 Use J 33799 fiuge 32 Differential pilot bearing 21 Use J 33842 figure 33 Washer 24 to the output shaft 23 Output shaft to the carrier assembly Sleeve 22 Thrust washer 20 Use grease to hold it in place Spring 16 and shift shaft and fork 17 Thrust washer 7 Use grease to hold it in place Alig...

Страница 289: ...15 I Inspect Figure 35 Tool Required J 33798 Engagement Tool 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 remove the tube and check for dam aged or improperly installed parts Figure 33 Installing the Differential Pilot Bearing ...

Страница 290: ...Attaching B olts 25 18 Left Hand Output Shaft Cover B olts 25 18 Carrier Case B o lts 47 35 Adjusting Sleeve Lock B o lts 8 0 71 Differential Ring Gear Bolts 80 60 AVAILABLE SHIM SIZES Pinion Shim K its 0 53 0 64 mm 0 66 0 79 mm 0 81 0 94 mm PINION PRELOAD AND BACKLASH Pinion Preload Backlash preferred 1 7 2 8 N m 15 25 in lbs 0 08 0 25 mm 0 003 0 010 inch 0 13 0 18 mm 0 005 0 007 inch ...

Страница 291: ...aring Insta ller 5 O utput S haft Bearing Installe r 6 D ifferential Side Bearing Installe r 7 Side Bearing A d ju ste r W rench 8 D ifferential Side Bearing Rem over 9 A xle Lock Cable Seal Installer 10 Pinion Bearing Cup Rem over and Installer 11 Pinion Shim S etting Gage 12 O utput Shaft P ilot Bearing Installer 13 A xle Tube Bearing In staller 14 O utput S haft Seal Installer 15 O utput S haft...

Страница 292: ... TRUCK FRONT AXLE SPECIAL TOOLS J 29307 J 8001 J 33791 J 34037 0 1 Slide Hammer 2 Bushing Remover 3 Dial Indicator Set 4 Dial Indicator 5 Dial Indicator Stand Part of J 25025 B 6 Engagement Tool J 33798 F 05790 ...

Страница 293: ... the axle housing The ring gear is bolted onto the differential case with left hand thread bolts The differential case is supported in the axle housing by two tapered roller bearings The differential and ring gear are located in relationship to the pinion by using threaded adjusters The differential is used to allow the wheels to turn at different rates of speed while the front axle continues to t...

Страница 294: ...4C4 2 K TRUCK FRONT AXLE Figure 1 Front Axle Components K15 25 Models ...

Страница 295: ...with deflector 2 10 Seal 3 and bearing 4 Use J 29369 1 K15 25 models or J 29369 2 K35 models with J 29307 figure 6 11 Output shaft 23 12 Differential pilot bearing 21 Use J 34011 figure 7 13 Shaft 59 with deflector 2 Pry on the shaft flange on one side while tapping with a soft faced hammer on the other side figure 8 14 Seal 3 Pry out with a screwdriver 15 Bearings 30 Use the tools listed in step ...

Страница 296: ...4C4 4 K TRUCK FRONT AXLE Figure 3 Front Axle Components K35 Models ...

Страница 297: ...aft 24 Bolt 60 Vent Plug 25 Plug 61 A d ju ste r Plug 26 W asher 62 O Ring 27 Pin 63 Lock 28 B olt 64 Bolt 29 C arrier Case 30 Bearing 31 Insert 32 Sleeve 33 Side Bearing 34 B olt 35 D ifferential Case 37 Ring and Pinion Gears F 05796 Figure 4 Front Axle Components K35 Models 35 Bolt 24 K35 models 36 Shaft 52 37 Differential pinion gears 56 and side gears 54 Roll the pinion gears out of the case w...

Страница 298: ...4C4 6 K TRUCK FRONT AXLE 59 29 C arrier Case 59 S haft F 01389 Figure 8 Removing the Left Shaft Figure 9 Turning the Adjuster Sleeve ...

Страница 299: ...K TRUCK FRONT AXLE 4C4 7 Seal Figure 17 Removing the Side Bearings ...

Страница 300: ...s will help prevent costly drive component repair after reassembly AXLE HOUSING Inspect 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 cup surfaces for nicks or burrs Remove any burrs that are found Housing for cracks Replace the housing if any cracks are found Housing for foreign material such as metal ...

Страница 301: ...place as required Shift fork 17 for 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 switch 13 for damage and frayed wiring SOLENOID CHECK Apply 12 volt battery voltage to the solenoid terminals The plunger should extend within several seconds Disconne...

Страница 302: ... and bearing cones Install or Connect 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 the pinion gear 37 The shim must be of the proper size as selected previously 2 Bearing 39 onto the pinion gear using J 35512 K15 25 models or J 36614 K35 models fig...

Страница 303: ... 39 41 B utton Located In Bore B earing Swung Out of Bore N ut W asher P ilot Flats Bearing Inner Pinion Bearing O uter Pinion J 21777 35 K15 25 J 21777 8 K35 J 29763 F 05869 J 36601 4 K15 25 J 36601 3 K35 Figure 22 Measuring Pinion Depth ...

Страница 304: ...eads Im portant Always install new bolts Never reuse the old bolts Tighten Bolts 34 alternating in progressive steps to 120 N m 88 ft lbs 7 Side bearings 33 using J 22761 K15 25 models or J 29710 K35 models and J 8092 figure 26 DIFFERENTIAL ASSEMBLY INSTALLATION n Install or Connect Figures 1 through 4 and 27 through 30 Tools Required J 36612 Bearing Installer K15 25 Models J 36613 Bearing Install...

Страница 305: ...at this time If the carrier halves do not make complete contact back out the right sleeve 32 Use J 36599 figure 28 7 Bolts 28 Tighten to 47 N m 35 ft lbs ADJUSTING BACKLASH Tools Required J 34047 Dial Indicator Set J 8001 Dial Indicator Set J 34047 3 Dial Indicator Adapter 1 Refer to figures 1 through 4 2 Tighten the right sleeve 32 to 140 N m 100 ft lbs Use J 36599 figure 28 3 Tighten the left sl...

Страница 306: ...n and turn the left sleeve out an identical amount Changing the sleeves one notch will change backlash about 0 08 mm 0 003 inch F 05875 Figure 32 Measuring Backlash at the Pinion Flange MEASURING BACKLASH ALTERNATE METHOD 1 Use this method if the tools specified previously are not available 2 If the specified tools are not available it is possible to read backlash at the pinion flange as follows 3...

Страница 307: ...im thickness between the pinion head and the inner race of the rear bearing The shim is used in the differential to com pensate for manufacturing tolerances Increasing the shim thickness will move the pinion closer to the centerline of the ring gear Decreasing the shim thickness will move the pinion farther away from the centerline of the ring gear Backlash is adjusted by means of the side bearing...

Страница 308: ...Seal Installer K15 25 Models J 22833 Seal Installer K35 Models 1 Bearing 4 Use J 36609 Drive into place with a hammer 2 Seal 3 Use J 36600 K15 25 models or J 22833 K35 models figure 36 3 Shaft 1 with deflector 2 to the axle tube 4 Washer 7 Align the tabs with the slots in the tube 5 Gear 9 with retaining ring 8 K15 25 models Drive gear into place with a plastic hammer 6 Washer 11 and new snap ring...

Страница 309: ... and shaft to the carrier Use no sealer at this time 3 Bolts 6 Tighten to 40 N m 30 ft lbs Measure Figure 39 Tool Required J 8001 Dial Indicator or equivalent Shaft 1 end play 1 Install a dial indicator J 8001 or equivalent on the axle tube end The plunger of the indicator must be at a right angle to the axle flange figure 39 1 2 Move the shaft 1 back and forth and read the end play Correct end pl...

Страница 310: ...4C4 18 K TRUCK FRONT AXLE f t 1 d L C Measure with Axle Shaft Forced Outboard 1 Shaft 5 Tube 9 Carrier Connector 23 O utput Shaft 29 Carrier Case F 05877 Figure 37 Measuring to Calculate Shim Size ...

Страница 311: ...K TRUCK FRONT AXLE 4C4 19 MEASURING DIMENSION B MEASURING DIMENSION A K15 25 SHOWN F 05878 Figure 38 Measuring to Calculate Shim Size ...

Страница 312: ...ZES Pinion Shaft Shims K15 25 Models 0 020 0 024 inch 0 025 0 029 inch 0 030 0 034 inch 0 035 0 039 inch K35 M o d e ls 0 508 0 5842 mm 0 6096 0 7112 mm 0 7366 0 8382 mm 0 8386 0 9398 mm Output Shaft Shims K15 25 M odels 1 27 1 78 2 29 2 70 3 30 3 81 mm K35 M odels 1 80 2 30 2 80 3 30 3 80 4 30 4 80 mm PINION PRELOAD AND BACKLASH Pinion Preload Backlash Preferred 1 7 2 8 N m 15 25 in lbs 0 08 0 25...

Страница 313: ...r K15 25 M odels 6 Side Bearing Rem over P ilot K35 20 Pinion Bearing Installer K35 M odels 7 P inion Bearing Rem over K15 25 M odels 2 1 Pinion Seal Installer 8 Pinion Bearing Rem over K35 M odels 2 2 A xle Seal In sta lle r K15 25 M odels 9 Pinion Flange Remover 23 A xle Seal In sta lle r K35 M odels 10 Case B ushing Replacer 24 H olding Fixture and Pinion Service Tool 11 D ifferential Side Bear...

Страница 314: ...4C4 22 K TRUCK FRONT AXLE ...

Страница 315: ... Always use proper tools and follow recommended procedures or personal injury may resu lt Do not apply heat to accum ulator Do not attem pt to repair an inoperative accumulator always replace with a new accumulator Dispose of an inoperative accumulator by drilling a 1 i6 inch diameter hole through the end of the accum ulator can opposite the O ring Tools Required J 26889 Accumulator Compressor Pla...

Страница 316: ...onnect Figure 1 Tools Required J 26889 Accumulator Compressor J 24551 A Seal Protector J 25083 Seal Protector NOTICE For steps 8 and 9 see N o tice on page 5 1 o f this section Lubricate all the seals and metal friction points with power steering fluid 1 Seal 10 and return line fitting 12 2 Accumulator valve 11 3 Spool valve 13 4 Seal 23 and piston assem bly 22 by using J 24551 A or J 25083 figure...

Страница 317: ...3 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 1 Release the C clamp Remove J 26889 17 Jam nut from the repair kit onto the pedal rod 18 Eyelet onto the pedal rod Adjust Eyelet to the required length R efer to BRAKES SEC 5 in the 1988 Light Duty Truck Service Manual 8 Housing J 24551 ...

Страница 318: ...d apply a small amount of air pressure to the front port Seals 8 and 10 Spring retainer 7 and spring 6 Clean All the metal parts in denatured alcohol All the rubber parts in clean brake fluid Stained or discolored cylinder bore with crocus cloth 4 Inspect Diaphragm for cuts cracks or a swollen condition Cylinder bore for scoring or corrosion If corrosion is present replace the cylinder Do not atte...

Страница 319: ...o the front port 6 Secondary seals 29 from the secondary piston 28 figure 16 7 Spring retainer 26 and primary seal 27 8 Spring 25 9 Tube seats if necessary figure 17 Thread a self tapping screw into the tube seat and remove with locking jaw pliers jjjl Clean All the metal parts in denatured alcohol All the rubber parts in clean brake fluid Stained or discolored cylinder bore with crocus cloth Insp...

Страница 320: ...eans 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 m aster cylinder bore When the brake master cylinder is overhauled it is recom m ended that the cylinder body be replaced rather than cleaned u p by honing the bore The m aster cylinder has a hard highly p o lis h e d b e a rin g iz e d su rfa ce w h ich i...

Страница 321: ...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 or other surface to catch the piston when it comes out of the bore Apply low air pressure very carefully to ease the piston out of the bore Never point the open end of the bore at anyone when applying air pressure The pis...

Страница 322: ...r bore with clean brake fluid 1 Secondary spring 48 2 Secondary piston assembly 49 3 Piston return spring 50 26 27 28 29 Spring Retainer Primary Seal Secondary Piston Secondary Seals F 04398 4 Primary piston assembly 51 and snap ring 52 The primary piston must be depressed to install the snap ring 5 O ring 55 and springs 47 6 Valve poppets 46 and compensating valve seals 45 Depress and hold the pr...

Страница 323: ... 3 Front housing seal 5 Scribe a mark 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 2 1 4 Return spring 9 and power piston group 5 Power piston bearing 6 from the rear housing 7 6 Reaction body retainer 25 7 Piston rod 10 and reaction retainer 11 8 Filter 12 using an awl or similar tool 9 Power piston...

Страница 324: ... 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 reaction retainer 11 and piston rod 10 Reaction body retainer 25 6 Power piston bearing 6 into the rear housing Lubricate the inside and outside of the bearing with silicone grease 7 Power piston group into the rear housing 7 8...

Страница 325: ...iner 15 Primary diaphragm 16 and primary support plate 17 from the housing divider 19 Primary diaphragm 16 from the primary support plate 17 Secondary diaphragm 20 and secondary support plate 21 from the housing divider 19 Secondary piston bearing 18 from the housing di vider 19 12 13 14 15 16 17 19 Secondary diaphragm 20 from the secondary sup port plate 2 1 Reaction body retainer 24 Reaction bod...

Страница 326: ...eaction 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 inside diameter of the primary dia phragm 16 lip and the secondary piston bearing 18 with a thin layer of silicone grease 10 Secondary diaphragm 20 into the secondary sup port plate 2 1 11 Secondary diaphragm 20 and support...

Страница 327: ...g 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 a vac uum source to the booster Lubricate the inside and outside diameters of the grommet 4 and front housing seal 7 with a thin layer of silicone grease 21 Grommet 4 and vacuum check valve 3 22 Front housing seal 7 23 Silencer 2 and boot 1 Gage the pist...

Страница 328: ... 05894 Figure 28 Assembling the Secondary Diaphragm Figure 29 Assembling the Housing Divider and Support SPECIFICATIONS 18 19 20 41 J 28458 Secondary Piston Bearing H ousing D ivider Secondary D iaphragm Power Piston A ssem bly F 05895 N m Ft Lbs Hydro Boost Housing to Cover B o lts 30 22 Hydi Boost N u t 149 110 ...

Страница 329: ...5083 1 Power Brake Push Rod H eight Gage 2 Piston Seal P rotector 3 Piston Seal P rotector 4 Power Brake B ooster D isassem bly and R eassem bly Tool 5 A ccu m u la to r Piston 6 Valve C o nnector Seat Installer 7 Power Piston Seal P rotector J 6217 J 28458 F 05896 ...

Страница 330: ...5 16 BRAKES ...

Страница 331: ... s 6 A 3 Cylinder Bore Reconditioning 2 8 L E n g in e s 6 A 4 Cylinder Bore Reconditioning All Except 2 5 L and 2 8 L Engines 6 A 4 B o rin g 6 A 4 H o n in g 6 A 5 Piston and Connecting Rod A s s e m b lie s 6 A 5 Piston Selection 2 5 L and 2 8 L E n g in es 6 A 8 Piston Selection All Except 2 5 L and 2 8 L E ngines 6 A 8 Camshaft Bearings 6A 12 Camshaft Bearing Replacem ent 2 5 L and 6 2 L E n ...

Страница 332: ...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 rigid parts are disassembled and no sealer or gasket is re a d ily notice able the parts were proba bly assembled using gasket eliminator USING RTV SEALER 1 Do not use RTV when extreme temperatures are expec...

Страница 333: ...INES 1 Measure the 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 the head gasket surface Cylinder bores can be measured by setting the cylinder gage dial at zero in the cylinder at the point of desired measurement Lock the dial indicator at zero bef...

Страница 334: ... 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 measurement Lock the dial indicator at zero before rem oving from the cylinder and measure across the gage contact points with outside micrometer with the gage at the same zero setting when removed from ...

Страница 335: ...surface 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 particles and torn or folded metal 6 By measuring the piston to be installed at the sizing point specified in the proper section and adding the average of the clearance specification the finish h...

Страница 336: ...e 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 connecting rod Figure 5 Removing the Piston Rings Figure 7 Piston and Components 6 2 L ...

Страница 337: ...ston pin diam eter figure 8 Check against Specifications Piston pin bushing ID Use an inside micrometer figure 10 Piston pin to bushing clearance Subtract the piston pin diam eter from the piston Compare with Specifications excessive try a new piston Din pin bushing ID If the clearance is If the clearance is 04980 6A 7 MEASURING PISTON PIN TO PISTON CLEARANCE ALL EXCEPT 6 2 L Measure Figures 8 and...

Страница 338: ...e piston and connecting rod must be installed 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 n g in e s The bevel on the connecting rod should face the outside of the engine 4 8 L Engines The flat side of the piston crown depression and the connecting rod bearing tang slot must be on the same side All Others T...

Страница 339: ...iston for freedom of movement on the piston pin Assembling the Piston and Connecting Rod 6 2 L Engines Assemble Figures 7 14 and 15 Tool Required J 29134 A Piston Pin Clip Installer 1 Piston to the connecting rod Installing the Piston Rings All Measure Figures 4 and Ring end gap as follows 1 Except 6 2 L 16 Select rings comparable in size to the piston being used 2 Slip the compressing ijing in th...

Страница 340: ... occurs at any point the cause should be determined If binding is caused by the ring groove co rre ct by depressing the groove with a fine cut file If the binding is caused by a distorted ring check a new ring Assemble Figures 4 and 5 Tool Required J 25220 Ring Expander or equivalent All compression rings are marked on the upper side of the ring When installing the compression rings make sure the ...

Страница 341: ... 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 mm 1 4 inch above ring travel Be sure the ring is square with the cylinder wall 3 Measure the space or gap between the ends of the ring with a feeler gage figure 16 R efer to S p e cifica tio n s in the...

Страница 342: ...from its bore R e peat th is p ro ce d u re to rem ove the remaining inner camshaft bearings Note that the rear inner bearing must be removed with the pilot fitted into the rear camshaft bearing 3 Outer camshaft bearing Use J 6098 01 figure 20 IQ i Figure 20 Removing or Installing the Outer Camshaft Bearings Assemble the bearing tool and driver handle Drive the outer camshaft bearings out of the b...

Страница 343: ...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 assembly No internal parts are available Service is limited to a disas sembly cleaning and test operation It is understood that most technicians discard any suspicious valve lifters This information is o...

Страница 344: ...l Spring 229 Retainer 225 Check Ball B 05236 230 221 223 225 227 229 3jW j TLfl I 9 222 224 226 228 221 L ifte r Body 226 Plunger 222 P lunger Spring 227 M etering Valve 223 C heck Ball R etainer 228 Pushrod Seat 224 C heck Ball Spring 229 R etainer 225 C heck Ball 230 R oller B 09402 Figure 24 Roller Type Hydraulic Lifter Components Im portant Do not attempt re conditioning by taking parts from o...

Страница 345: ...own solidly Do not attempt to force or pump the plunger At this point oil holes in the lifter body and plunger assembly will be aligned Insert a 1 5 mm 1 i6 inch drift through both oil holes to hold the plunger down against the plunger spring tension figure 28 Remove the 3 mm Vs inch drift Refill the assembly with SAE 10 oil 6 Metering valve 227 and pushrod seat 228 7 Retainer Push down on the pus...

Страница 346: ...rs Use J 8089 figure 30 Valve guides Use J 8101 figure 31 Valve stems and heads on a wire wheel Carbon and old gasket from the cylinder head gasket surface Inspect m Cylinder head for cracks in the exhaust ports combustion chambers or external cracks to the coolant chamber Gasket surfaces should be free of damage Valves for burning pitting or warpage Grind or replace as needed Refer to Valve G rin...

Страница 347: ...e cifica tio n s chart S prings 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 Stem to Bore Clearance Typical REPAIR VALVE GRINDING Valves that are pitted must be refaced to the proper angle Valve stems which show excessive wear or valves that are warped excessively must be re...

Страница 348: ...k may result in damage to the valve seats 4 8 L sm all block and 7 4 L engines are equipped w ith hardened non replaceable valve seat inserts REAMING VALVE GUIDES The valve guides used in engines covered by this manual are simply holes bores into the cylinder head The valve guides are therefore not replaceable If the valve stem to bore clearance as measured previously in this manual is excessive t...

Страница 349: ...en the bearing and journal surfaces without damaging them Proceed as follows Clean All oil from the crankshaft journal and main bearing inserts Install or Connect Figure 37 Refer to the proper section for additional informa tion Main bearing inserts and crankshaft as outlined in the proper section Gaging plastic Begin with the rear main bearing Wipe the oil from the crankshaft journal and the lowe...

Страница 350: ...e both 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 the crankshaft journal for use with the next undersize bearing Do not grind rolled fillet crank shafts such as used on 2 5 L 2 8 L and 6 2 L en gines After selecting the new bearing recheck the clear...

Страница 351: ... A Measure W idest Point of Gaging Plastic w ith Graduated Scale B 04997 Figure 40 Measuring the Gaging Plastic Measure Figure 40 0 Gaging plastic at its widest point using the scale at the gaging plastic envelope figure 40 If the clearance exceeds specifictions select a new correct size connecting rod bearing and remeasure the clearance A standard or undersize bearing may produce the proper clear...

Страница 352: ...or Valve S pring Tester Intake O pening Cover 0 13 mm 0 005 inch Oversize Valve G uide Reamer 2 5 L Engines Valve G uide Ream er Set All Engines E xcept 6 2 L and 7 4 L C o n sists of J 5830 1 0 08 mm 0 003 inch oversize J 5830 2 0 38 mm 0 015 inch oversize J 5830 3 0 76 mm 0 030 inch oversize Valve G uide Ream er Set 6 2 L and 7 4 L Engines C o nsists of J 7049 1 0 08 mm 0 003 inch oversize J 704...

Страница 353: ...Removing the C rankshaft 6A1 Camshaft Removal 6A1 Cleaning Inspection and Repair 6A1 B lock 6A1 Cylinder B o res Piston and Connecting Rod Assemblies Piston Selection Intake and Exhaust Manifold Camshaft Camshaft Bearings Front Cover 6A1 6A1 6A1 6A1 6A1 6A1 6A1 Water P u m p 6A1 Oil Pan and Rocker Arm Covers 6A1 Oil P um p 6A1 Valve Train Components 6A1 Cylinder Head 6A1 Thermostat and Housing Cra...

Страница 354: ...entification 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 bypass valve in the pickup screen insures adequate oil flow if the screen becomes restricted The gear type oil pump has a pressure regulator valve which controls lubrication system pressure by bypassi...

Страница 355: ...2 5 LITER L4 ENGINE 6A1 3 A Oil Pump Drive Gear Oiling B Oil Pressure Sending Unit C Splash Oiling D Full Flow Oil Filter E Filter Bypass System B 07950 Figure 1 Engine Lubrication Diagram ...

Страница 356: ...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 to engine exterior surfaces After removing the TBI unit distributor fuel pump oil filter etc cover the openings with tape to prevent the entry of water solvent and dirt Methods used to clean the engine...

Страница 357: ...2 5 LITER L4 ENGINE 6A1 5 Figure 3 Cylinder Head Manifolds and Components ...

Страница 358: ...ock 69 Clutch Pilot Bearing 95 Crankshaft Pulley 120 Cylinder Head Dowel Pin 70 Crankshaft Insert 96 Bolt 121 Hydraulic Roller Lifter 71 Crankshaft Rear Oil Seal 97 Crankshaft and Power Steering 122 Valve Lifter Guide 72 Crankshaft Rear Bearing Pulley 123 Lifter Guide Retainer 73 Oil Pan Drain Screw 98 Bolt 124 Main Bearing Cap 74 Gasket 99 Washer 125 Bolt 75 Bolt 100 Crankshaft Pulley Hub 126 Rea...

Страница 359: ...2 5 LITER L4 ENGINE 6A1 7 Figure 5 Block and Components ...

Страница 360: ... LITER L4 ENGINE 37 W asher 38 B olt 42 Stud 43 Intake M anifold 44 G asket F 01984 Figure 6 Intake Manifold Components 2 B olt 3 Stud 5 E xhaust M anifold 7 G asket F 01985 Figure 7 Exhaust Manifold Components ...

Страница 361: ...s during assembly A simple 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 fo u r nuts from the cover attaching studs reverse two of the nuts so the washers face outward and screw them back onto the inner two studs Assemble the two remaining nuts to the same two inner studs with washers facing inwa...

Страница 362: ...c Lifters and Components 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 gasket surfaces 3 Gasket 17 CRANKSHAFT PULLEY HUB REMOVAL Remove or Disconnect Figure 5 and 14 1 Bolt 98 and washer 99 2 Pulleys 96 and 97 and hub 100 F 01990 60 121 122 123 Valve Lift...

Страница 363: ... 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 stroke Place a soft cloth on top of the piston Rem ove or Disconnect Figures 5 and 15 1 Bolts 117 2 Plate 118 3 Bearing 113 4 Shaft and gear assembly 115 and 114 OIL PUMP REMOVAL Remove or Disconnect Figure 5 1 Bolts 84 ...

Страница 364: ...ock Push 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 mark the connecting rod and piston assembly and the cylinder bore to assure that each assembly is returned to its original bore Repeat this procedure on the rem aining connecting rod assemblie...

Страница 365: ...THOUT REMOVING THE CRANKSHAFT Remove or Disconnect Tool Required J 8080 Main Bearing Remover Installer Main bearing caps 124 and 126 Check the main bearing caps for location markings Mark the caps if necessary The caps m ust be returned to th e ir original locations during assembly Lower main bearing inserts 86 from the main bearing caps Upper main bearing inserts 86 Insert J 8080 into the cranksh...

Страница 366: ...to perform properly 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 coolant passages y Inspect 1 All expansion plugs for looseness or leakage 2 Valve lifter bores for deep scratches and varnish deposits 3 Block for cracks especially in the following areas C...

Страница 367: ...iston to cylinder bore clearance Measure Figures 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 measuring at this point the smallest bore diameter will be obtained Piston diameter with a micrometer Measure the piston skirt at a right angle to the piston p...

Страница 368: ...ce Camshaft 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 journals are more than 0 001 inch out of round replace the camshaft Camshaft journal diameter Use a micrometer The proper diameter is 1 869 inch Thrust plate 105 to camshaft 108 clearance This clear...

Страница 369: ...s 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 engine Front cover for cracks large dents etc Sealing flange for straightness Disassemble Figure 5 Seal 101 Pry the seal out with a screwdriver Assemble Figure 31 Tool Required J 34995 Crankshaft Front Cover Oil Seal Installer New seal 101 using tool J 349...

Страница 370: ...damage Oil pan for rock damage or cracks Drain plug threads for stripping 77 79 80 81 82 83 85 127 128 129 Pum p Body Spring R etaining Pin S pring 7 9 Cover Screw s Cover Cover G asket a 80 Pressure R elief Valve 1 Idler Gear I Drive Gear and S haft f l 127 Pick Up Screen 85 and Pipe 1 _____ 80 85 p M fflE E g f i l i 79 129 F 02000 Figure 32 Oil Pump Components OIL PUMP Disassemble Figure 32 1 C...

Страница 371: ...p 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 pan when installed VALVE TRAIN COMPONENTS PUSHRODS PUSHROD GUIDES ROCKER ARMS AND BALLS Clean Parts in solvent Blow dry with compressed air Make sure the oil passages in the pushrods are clear Inspect Figure...

Страница 372: ...N G IN E MECHANICAL 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 order to aid in assembly 2 Valves 18 and 19 Lubricate the valve stems with engine oil Insert the valves into the proper ports 3 Valve spring 35 and shield 34 4 Cap 28 5 Valve keepers 30 Figur...

Страница 373: ...thermostat application Disassem ble Figure 3 1 Bolts 8 and 9 2 Water outlet 10 3 Thermostat 12 4 Gasket 11 Inspect Figure 3 Water outlet 10 and housing 13 for cracks or damage Assemble Figure 3 1 Thermostat 12 2 Gasket 11 3 Water outlet 10 4 Bolts 8 and 9 Tighten Bolts 8 and 9 to 23 N m 17 ft lbs CRANKSHAFT AND BEARINGS i Clean Figure 5 Crankshaft 88 with solvent Do not scratch the bearing journal...

Страница 374: ... clearance Refer to GENERAL ENGINE MECHANICAL SEC 6A in this manual 3 Engine oil to the lower main bearing inserts 4 Main bearing caps except the rear cap with the selected lower main bering inserts 86 and 72 Be sure to put the main bearing cap in their original positions with the arrows facing the front of the engine 5 Bolts 125 Make sure the special bolt which retains the oil pump pickup tube an...

Страница 375: ...R OIL SEAL INSTALLATION Install or Connect Figures 5 and 41 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 mandrel of the tool until the dust lip back of seal mates squarely against the collar 3 Lubricate the seal outside diam eter with engine oil 4 Position the tool with the seal in place...

Страница 376: ...1396 or equivalent Coat the bearing journals with engine oil 1 Camshaft 108 into the block 119 Take care not to damage the camshaft bearings 109 104 108 105 103 A T im ing M arks 87 C rankshaft Gear T hrust Plate B olts C am shaft Gear T hrust Plate C am shaft F 05719 Figure 43 Camshaft and Timing Gears Im portant Align the timing marks 2 Screws 103 Tighten Screws 103 to 9 0 N m 80 in lbs FRONT CO...

Страница 377: ... 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 Without 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 ...

Страница 378: ...ecting rod side clearance Use a feeler gage between the connecting rod and the crankshaft The c o rre ct cle a ra n c e is 0 15 0 60 mm 0 006 0 022 inch 0 iTp ENGINE LEFT ENGINE FRONT ENGINE RIGHT c E A Oil Ring Rail Gaps B 2nd Compression Ring Gap C Notch In Piston D Oil Ring Spacer Gap Tang In Hole Or Slot W ith Arc E Top Compression Ring Gap B 07895 Install or Connect Figure 5 Oil pump Align th...

Страница 379: ...l 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 the block and cylinder head sealing surfaces are clean 1 Head gasket to the block Install over the dowel pins 2 Cylinder head Carefully guide the head into place over the dowel pins This may requir...

Страница 380: ... 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 Tighten the bolts in the specified sequence Draw a line across the head of each bolt with a marking crayon to mark the position of each bolt 3 All head bolts 90 degrees 1 4 turn Tighten Figure 5 2 O il Pump Drive...

Страница 381: ... 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 pushrods into the sockets of the hydraulic lifters Coat the mating surfaces of the rocker arms 33 and balls 32 with a molybdenum disulfide grease 7 Rocker arms 33 8 Balls 32 9 Bolts 31 St Tighten DO NOT B olts to 30 N m 22 ft lbs OVERTIGHTEN Apply a 5 mm 3 ie i...

Страница 382: ... figure 60 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 m 55 ft lbs Manual transmissions 90 N m 65 ft lbs Figure 58 Thermostat Housing Components ENGINE ACCESSORY INSTALLATION Install the engine accessories distributor TBI unit oil filter generator etc as di...

Страница 383: ...llation Tightening Sequence Tighten bolts in number sequence as shown Or A group bolts can be tightened first then B group bolts Torque Specifications A Group Bolts 50 N m 36 Ft Lbs B Group Bolts 43 N m 32 Ft Lbs B 07994 Figure 60 Exhaust Manifold Installation ...

Страница 384: ...gine 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 operating temperature 5 Listen for improperly adjusted valves or sticking lifters or other unusual noises 6 Check for oil and coolant leaks while the engine is running 7 Using the proper Truck Service Manual...

Страница 385: ... Thrust Side 0 005 Maximum PISTON Clearance 0 0014 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 Gap 0 020 0 060 PISTON PIN Diameter 0 938 0 942 Clearance in Piston 0 0002 0 0004 Fit In Rod Press OIL PUMP Gear Lash 0 009 0 015 Gear Pocket Depth 0 995 0 998 Gear Pocket Diameter ...

Страница 386: ...nal 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 Clearance in Bore 0 0025 Plunger Travel 0 125 Pushrod Length 8 299 Valve Lash NOT ADJUSTABLE Rocker Arm Ratio 1 75 1 Face Angle Intake Exhaust 45 Seat Angle Intake Exhaust O CD Seat Runout Intake Exhaust 0 00...

Страница 387: ...nkshaft Pulley Hub to Crankshaft B o lt 220 160 Flywheel Bolts A utom atic 75 55 Flywheel Bolts Manual 90 65 Intake Manifold B o lts 34 25 Exhaust Manifold Bolts Front and Rear Exhaust Tubes 43 32 Center Exhaust T ube 50 36 Distributor Clamp B o lt 17 13 Water Outlet Housing Bolts 27 20 Thermostat Housing Bolts 27 20 Water P um p 34 25 Timing Gear Cover B olts 10 0 90 Rocker Arm B olts 30 22 Cylin...

Страница 388: ...1 Piston Ring C om pressor 2 Front C rankshaft Seal Installer 3 Main Bearing R eplacer 4 Valve S pring C om pressor 5 Cam Bearing R eplacer 6 Oil Pum p P ickup Tube Installer 7 R ocker Arm Cover Rem over 8 Rear C rankshaft Oil Seal Installer 9 Valve Seal C hecker 10 H ydraulic L ifte r Remover 11 Dial In d ica to r 11 J 7872 F 04487 ...

Страница 389: ...nnecting Rod R em o val 6A2 10 Flywheel R em oval 6A2 11 Crankshaft Removal 6A2 11 Main Bearing Removal Without Removing C rankshaft 6A2 11 Cleaning Inspection and Repair 6A2 12 B lock 6A2 12 Piston and Connecting Rod Assem blies 6A2 13 Intake and Exhaust Manifolds 6A2 13 Camshaft 6A2 14 6A2 14 6A2 14 6A2 14 6A 2 15 6A 2 15 6A 2 15 Camshaft Bearings Timing Chain and Sprockets Front Cover Water P u...

Страница 390: ...ydraulic 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 pins are a press fit in the connecting rods The pistons are cast aluminum alloy The piston pins are a floating fit in the piston For Engine Identification refer to GENERAL INFORMA TION SEC OA in this ma...

Страница 391: ...2 8 LITER V 6 6A2 3 Figure 1 Engine Lubrication Diagram ...

Страница 392: ...6A2 4 2 8 LITER V 6 Figure 2 Engine Lubrication Diagram ...

Страница 393: ... brication Ends 154 BTDC E C ylinders 2 4 And 6 F 190 D uration O f Lubrication G Lub rica tion Ends 134 BTDC H For C ylinders 1 3 And 5 J V iew s S how ing In te rm itte n t O iling Of C on necting Rod Bearing Through Groove On U pper H alf O f M ain B earings B 09548 Figure 3 Engine Lubrication Diagram ...

Страница 394: ...s for which they are intended The use of these tools will also m inim ize possible damage to engine components Some precision measuring tools are required for inspection of certa in critica l com ponents Torque wrenches will be necessary for correct assembly of various parts ACCESSORY REMOVAL This manual assumes that the engine accessories have been removed These accessories may include one or mor...

Страница 395: ...drain 0Install or Connect 1 Oil pan drain plug and washer 2 Block drain plugs Si 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 injection tube from the manifold A Front 80 Bolt 81 EGR Valve 82 Gasket B 09442 Figure 6 EGR Valve EGR VALVE REMOVAL Remove or Disconnect Figure 6 1 Bolts 80 2 EGR valve 81 3 Gasket 82 EXHAUST MANIFOLD R...

Страница 396: ...CYLINDER HEAD REMOVAL Remove or Disconnect 1 Bolts 2 Cylinder heads Use care when handling the cylinder heads to prevent damage to rocker arm studs or gasket sealing surface 3 Gaskets TORSIONAL DAMPER REMOVAL Figure 8 Rocker Arm Cover Installation NOTICE The in e rtia l w e ig h t section o f the torsional dam per is assem bled to the hub w ith a rubb er sleeve The rem oval and installation p ro c...

Страница 397: ...ER 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 studs from the oil pan 2 Oil pan OIL PUMP REMOVAL Remove or Disconnect Figure 12 1 Bolt 40 2 Pump 41 3 Shaft 42 TIMING CHAIN AND CAMSHAFT SPROCKET REMOVAL Figure 10 Removing the Hydraulic Lifter with J 3049 Remove or Disconnect 1 Chain damper 2 Spr...

Страница 398: ...h on 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 mark the cylinder number on all pistons connecting rods and caps Starting at the front of the crankcase the cylinders in the right bank are numbered 1 3 5 and the left bank is numbered 2 4 6 Conn...

Страница 399: ...e 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 09405 Figure 16 Crankshaft Installation MAIN BEARING REMOVAL WITHOUT REMOVING CRANKSHAFT Remove or Disconnect Tool Required J 8080 Main Bearing Remover Installer 1 Main bearing caps Check the main bear...

Страница 400: ...leakage Valve lifter bores for deep scratches and varnish deposits Block for cracks Cylinder walls Coolant jackets Main bearing webs Engine mount bosses Main bearing bores and main bearing caps All main bearing bores should be rounded and uniform in ID at all bearing supports The area where the main bearing inserts contact the main bearing bore should be smooth If a main bearing cap is damaged and...

Страница 401: ... 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 the piston is correctly fitted to the bore If the piston slides freely through the bore it is too small and a larger piston is required Mark the proper piston and bore for assembly 4 When checking more ...

Страница 402: ... wear 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 chain CRANKSHAFT SPROCKET REPLACEMENT Remove or Disconnect Figure 20 Tool Required J 5825 A Crankshaft Sprocket Puller 1 Crankshaft sprocket using J 5825 A 2 Key if necessary Figure 20 Replacing the ...

Страница 403: ...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 183 103 103 Oil Pump Drive Shaft 180 Body 181 Drive Gear and Shaft 182 Cover 183 Pressure Relief Valve 184 Spring 185 Spring Retaining Pin 186 Cover Screws 187 Pick up Screen and Pipe 188 Idler Gear Ijji 5 B 09404 Figure 21 Oi...

Страница 404: ...ese 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 smooth and free of damage and wear Rocker arm nuts Pushrods for bending Roll the pushrod on a flat surface to determ ine if it is bent Replace if necessary Pushrod ends for scoring or roughness HYDRAULIC LIFTERS Refer to...

Страница 405: ... Figure 25 1 Rocker 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 H Install or Connect Figures 23 and 24 Tool Required J 8062 Valve Spring Compressor 1 Valves 20 and 21 Lubricate the valve stems with engine oil Insert the valves into the proper seats 2 Seals 2...

Страница 406: ...ckness 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 Figure 27 Bolts 2 Water outlet 3 Gasket 4 Thermostat Inspect Water outlet for cracks Install or Connect Figure 27 1 Thermostat 2 New gasket 3 Water outlet 4 Bolts Tighten Bolts for 21 N m 15 ft lbs CRANKSHAFT AND BEARINGS CL...

Страница 407: ...26 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 of a 0 032 mm undersize insert which will decrease the clearance 0 016 mm from using a full standard bearing Install or Connect 1 Upper main bearing inserts to the block Im portant If any undersized bea...

Страница 408: ...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 bearing B A A lig n m e n t H ole In C rankshaft B D ust Lip C Dowel Pin D C ollar E M andrel F Screw s 85 C rankshaft Rear Oil Seal B 07973 Figure 31 Installing the Crankshaft Oil Seal REAR CRANKSHAFT OIL ...

Страница 409: ...procket 4 Bolts 30 Draw the camshaft sprocket onto the camshaft using the mounting bolts Tighten Bolts 30 to 23 N m 5 Chain damper 31 6 Bolts 32 17 ft lbs Tighten Bolts 32 to 21 N m 15 ft lbs FRONT COVER PUMP INSTA AND WATER LLATION Install or Connect Lubricate the lips of the front crankshaft oil seal with engine oil 1 New gasket Make sure all sealing surfaces are clean Take care not to damage se...

Страница 410: ...with new and used standard size crankshafts 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 cylinder with the notch forward Connecting rod bearing inserts Be certain that the inserts are of the proper size Install the inserts in the connecting rod and connecting rod cap Piston and connectin...

Страница 411: ... 38 NOTICE Before installing the o il pan check that the sealing surfaces on the pan cylinder case and front cover are clean and free o f oil Make sure that all RTV is rem oved from blind attaching holes 1 Gasket A pply sealer GM Part No 1052914 or equivalent to the area shown in figure 38 2 Oil pan to the cylinder block 3 Reinforcement 37 nuts bolts and studs Tighten Bolts 36 to 25 N m 18 ft lbs ...

Страница 412: ...provides additional oil to the cam lobe and lifter surfaces Im portant Replace all hydraulic lifters if a new camshaft was installed Install or Connect Figure 40 Lubricate the hydraulic lifter bodies and feet with Engine Oil Supplement GM Part No 1051396 or equivalent 1 Hydraulic lifters 10 to the block 2 Pushrods 9 Seat the pushrods into the socket in the hydraulic lifters Coat the mating surface...

Страница 413: ...nt This is the number four firing position The following valves may be adjusted Exhaust 4 5 6 Intake 2 3 4 I INTAKE MANIFOLD INSTALLATION Install or Connect Figure 42 1 RTV to the front and rear sealing surfaces on the block Apply a 5 mm 3 ie inch bead of RTV part number 1052917 or equivalent to the front and rear of the block as shown Make sure that no oil or water is present on the surfaces to b...

Страница 414: ...Installation EXHAUST MANIFOLD INSTALLATION Clean Mating surfaces of the manifold 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 Figure 6 1 Gasket 82 2 EGR valve 81 3 Bolts 80 3 Tighten Bolts to 25 N m 18 ft lbs ...

Страница 415: ...unusual 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 leaks while the engine is running Using the proper Truck Service Manual or Emission Control Label for specifications adjust the ignition timing and idle speed Bolts to 70 N m 52 ft lbs ENGINE ACCESS...

Страница 416: ...a 500 RPM 205 380 kPa fa 2000 RPM 10 psi fa 500 RPM 30 55 psi fa 2000 RPM 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 RING C 0 M P R E S S 1 0 N Groove Clearance Top 0 030 0 070 Second 0 040 0 095 Gap Top 0 25 0 50 Second 0 25 0 50 0 1 L Groove Clearance 0 199 Maximum Gap 0 51 1 40 PISTON PIN Diameter 22 9937 23 ...

Страница 417: ... Maximum Out of Round 0 005 M aximum 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 SYSTEM Lifter Hydraulic Rocker Arm Ratio 1 50 1 Valve Lash Intake One And One Half Turns Down From Zero Lash Exhaust Face Angle Intake Exhaust 45 Seat Angle Intake Exhaust o CO Seat Runout Intake ...

Страница 418: ...an 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 70 Flywheel B olts 70 52 Spark Plugs 30 22 Water Outlet Bolts 21 15 Water Pump N u t 10 7 Water Pump Bolt M6 x 1 0 10 7 Water Pump Bolts M8 x 1 25 24 18 EGR Valve 25 18 Oil Pump Cover S crew s 9 7 Rock...

Страница 419: ...haft Sprocket Installer 3 Crankshaft Sprocket Puller 4 Valve Spring Com pressor 5 Ring Compressor 6 Main Bearing Remover Installer 7 Pick up Tube and Screen Installer 8 Hydraulic Lifter Remover Slide Hammer Type 9 Puller 10 Puller 11 Torsional Damper Installer 12 Seal Installer 13 Seal Installer J 9290 1 J 23523 E J 24420 B J 29113 J 34686 J 35468 F 04357 ...

Страница 420: ...6A2 32 2 8 LITER V 6 ...

Страница 421: ...A 3 9 Rear Crankshaft Oil Seal Retainer R em oval 6A 3 9 Crankshaft Removal 6A3 9 Main Bearing Removal Without Removing C rankshaft 6A3 10 Cleaning Inspection and Repair 6A3 10 B lock 6A3 10 Piston and Connecting Rod A ssem b ly 6A 3 10 Intake and Exhaust Manifolds 6A3 11 Camshaft 6 A 3 1 1 Camshaft Bearings 6A3 11 Timing Chain and Sprockets 6A3 11 Front Cover 6A3 12 Water P u m p 6A3 12 Oil Pan a...

Страница 422: ... transmit 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 bearings The piston pins are a press fit in the connecting rods The pistons are cast aluminum alloy The piston pins are a floating fit in the piston For identification refer to GENERAL INFOR...

Страница 423: ...4 3 LITER V 6 6A3 3 Figure 1 Engine Lubrication Diagram B 07857 ...

Страница 424: ...h Of Oil To Timing 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 Bypass Valve Figure 2 Engine Lubrication Diagram ...

Страница 425: ...ressed 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 dam age to engine components Special tools are illustrated throughout this section and are listed at its end These tools or their equivalents are specially designed to quickly and safely accomplish the operations for w...

Страница 426: ...VAL 0Remove 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 Im portant Store used components in order so they can be reassembled in the same location 2 Bolts 40 3 Retainer 41 with restrictors 46 4 Hydraulic lifters Remove the lifters one at a time and place them in an or...

Страница 427: ...earing 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 Installation CAMSHAFT REMOVAL Remove or Disconnect Figures 7 and 8 1 Camshaft sprocket bolts 2 Camshaft sprocket and timing chain The sprocket is a light interference fit on the camshaft Tap the sp...

Страница 428: ...loth and 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 Connecting rod cap Check the connecting rod and cap for identification marks Mark the parts if required The connecting rod and cap must be kept together as mating parts Connecting rod and piston Attach J 5239...

Страница 429: ... RETAINER REMOVAL 0Remove 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 crankshaft Refer to Crankshaft and Main Bearing Installation later in this section The main bearings and rear oil seal can be replaced without removing the crankshaft as outlined later in this section 1 Main bearin...

Страница 430: ...lock gasket surfaces 3 Cylinder bores 4 Oil galleries and passages 5 Scale deposits from the coolant passages Inspect 1 All expansion plugs for lack of fit or leakage 2 Valve lifter bores for deep scratches and varnish deposits 3 Block for cracks Cylinder walls Coolant jackets Main bearing webs Engine mount bosses 4 Main bearing bores and main bearing caps All main bearing bores should be rounded ...

Страница 431: ...lant passages of the intake manifold EGR passage of excessive carbon deposits Inspect Figure 14 Manifolds for cracks broken flanges and gasket surface damage Alignment of manifold flanges Use a straight edge and feeler gage If the flanges do not align the manifold is warped and should be replaced CAMSHAFT Im portant m Whenever the camshaft needs to be replaced a new set of lifters must also be ins...

Страница 432: ...the bearings 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 pump Water pump body at the drain hole If there is evidence of coolant leakage the water pump shaft seal is leaking and the water pump should be replaced OIL PAN AND ROCKER ARM COVERS Clean Part...

Страница 433: ...e installing the pum p 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 in an air leak and loss of oil pressure Mount the oil pump in a soft jawed vise Apply sealer to the end of the pipe Tap the pickup screen and pipe into place using J 21882 and a hammer The pump screen ...

Страница 434: ...rm the following r j i V Clean Components as outlined Inspect Components as outlined Measure Figure 19 Valves and Components Valve stem clearance Valve spring tension and free length Other information outlined includes Valve and seat grinding Valve guide reaming ROCKER ARM STUD REPLACEMENT 0Remove or Disconnect Figure 21 Tool Required J 5802 01 Rocker Arm Stud Remover Figure 21 Removing the Rocker...

Страница 435: ...for 0 003 inch oversize studs J 6036 for 0 013 inch 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 the cylinder head ASSEMBLY 0Install or Connect Figures 19 20 and 24 Tools Required J 8062 Valve Spring Compressor J 23738 A Vacuum Pump 4 3 LITER V 6 6A...

Страница 436: ...t under the specified figure THERMOSTAT AND WATER OUTLET Remove or Disconnect 1 Bolts 2 Water outlet 3 Gasket 4 Thermostat L 4 Inspect Water outlet for cracks Install or Connect 1 Thermostat 2 New gasket 3 Water outlet 4 Bolts Tighten Bolts to 28 N m 21 ft lbs CRANKSHAFT AND BEARINGS Clean Crankshaft with solvent Do not scratch the bearing journals Blow all sludge from the oil passages with compre...

Страница 437: ... fitted to the proper journals 2 Crankshaft 3 Lower main bearing inserts to the main bearing caps m Measure Main bearing clearance Refer to GENERAL ENGINE MECHANICAL SEC 6A Apply engine oil to the main bearing inserts Main bearing caps except rear cap and bolts to the block Tighten Main bearing cap bolts to 100 N m 75 ft lbs 5 Rear main bearing cap Apply engine oil to the bearing inserts 6 Rear ma...

Страница 438: ... Coat the camshaft lobes and journals with a high quality engine oil supplem ent 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 holes Use these bolts to handle the camshaft 2 Camshaft to the engine figure 30 Handle the cam shaft carefully to prevent dam age to the camshaft bearings 3 Thrust plate 87 and screws 88 Tighten Sc...

Страница 439: ... per is assem bled to the hub with rubber type material The correct installation p roce dures w ith the p ro p e r to ol m ust be fo llo w e d or m ovem ent o f the inertia w eight section o f the hub w ill destroy the tuning o f the torsional damper 2 Stud item A figure 32 to the crankshaft Thread the stud fully into the tapped hole in the crankshaft ...

Страница 440: ...recision 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 undersize for use with new and used standard size crankshafts Install or Connect Figures 33 through 35 Tools Required J 5239 Connecting Rod Guide Set J 8037 Ring Compressor Lubricate the cylinder walls ...

Страница 441: ...rod side clearance figure 36 The proper clearance is 0 006 to 0 014 inch OIL PUMP INSTALLATION j Install or Connect 1 Oil pump to the engine Align the slot in the oil pump shaft with the tang on the distributor shaft The oil pump should slide easily into place No gasket is used 2 Oil pump to main bearing cap bolt Tighten Oil pump to main bearing cap bolt to 90 N m 65 ft lbs OIL PAN INSTALLATION In...

Страница 442: ...6A3 22 4 3 LITER V 6 A Forward B Sealant 70 Gasket 71 Reinforcement F 04488 Figure 37 Oil Pan Installation ...

Страница 443: ...he right bank odd numbered cylinders are in the left bank when viewed from the rear of the engine 3 Back out the adjusting nut until lash is felt at the pushrod then turn in the adjusting nut until all lash is removed This can be determined by rotating the pushrod while turning the adjusting nut When the play has been removed turn the adjusting nut in one full additional turn to center the lifter ...

Страница 444: ...ON Figure 39 Valve Train Components FLYWHEEL INSTALLATION 0Install or Connect 1 New gasket 2 EGR valve 3 Bolts Tighten Bolts to 31 N m 23 ft lbs Install or Connect 1 Flywheel 2 Flywheel bolts Tighten Bolts to 100 N m 75 ft lbs ENGINE ACCESSORY INSTALLATION Install the engine accessories distributor carburetor oil filter generator etc as directed in the proper Truck Service Manual Connect all vacuu...

Страница 445: ...n the vehicle If a suitable test 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 hydraulic lifters were a INITIAL TIGHTENING SEQUENCE icpj gig dJ FINAL TIGHTENING SEQUENCE A Front Of Engine B 07873 Figure 41 Intake Manifold Bolt Tightening Sequence ...

Страница 446: ...that 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 sticking lifters and other unusual noises 8 Check for oil and coolant leaks while the engine is running 9 Using the proper Truck Service Manual or Emission Control Label for specifications adjust the i...

Страница 447: ...iui i Relief Side 0 001 Maximum Service 0 001 Maximum PISTON Production 0 0007 0 0017 v iearanue Service Limit 0 0027 Maximum PISTON RING C 0 M P Groove Production Top 0 0012 0 0032 2nd R Service Limit Hi Limit Production 0 001 b s Production Top 0 010 0 020 s 1 Gap 2nd 0 010 0 025 0 N Service Limit Hi Limit Production 0 010 Groove Production 0 002 0 007 0 Clearance Service Limit Hi Limit Producti...

Страница 448: ...Round Service Limit 0 001 Maximum Rod Bearing Production 0 0013 0 0035 Clearance Service Limit 0 0030 Rod Side Clearance 0 006 0 014 CAMSHAFT Lobe Intake 0 357 Lift 0 002 Exhaust 0 390 Journal Diameter 1 8682 1 8692 Camshaft End Play 0 004 0 012 VALVE SYSTEM Lifter Hydraulic Rocker Arm Ratio 1 50 1 Valve Lash Intake One Turn Down From Zero Lash Exhaust Face Angle Intake Exhaust 45 Seat Angle Intak...

Страница 449: ...1 3 Oil Pump B olt 90 65 Rear Crankshaft Oil Seal Retainer Screws and N u ts 15 3 Camshaft Sprocket B o lts 28 21 Connecting Rod Cap Nuts 60 45 Oil Filter Adapter Bolts 20 15 Main Bearing Cap Bolts 110 80 Oil Pump Cover B o lts 9 0 Flywheel B o lts 100 75 Spark P lu g s 30 22 Water Outlet B o lts 28 21 Water Pump B o lts 40 30 Flywheel Housing B olts 44 32 Hydraulic Lifter Restrictor Retainer B o ...

Страница 450: ...738 A 1 Torsional Damper Remover and Installer 8 Stud Remover 2 Valve Spring Compressor 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 Compressor 12 Crankshaft Gear Puller 6 Guide Set 13 Crankshaft Gear Installer 7 Vacuum Pump 14 Rear Crankshaft Seal Installer F 04490 ...

Страница 451: ...C rankshaft 6A4 12 Camshaft Removal 6A4 13 Cleaning Inspection and Repair 6A4 14 B lock 6A 4 14 Main Bearing Cap Replacem ent 6A4 14 Cylinder B o res 6A4 15 Piston and Connecting Rod Assem blies 6A4 15 Intake and Exhaust Manifolds 6A4 15 Camshaft 6A4 16 Camshaft Bearings 6A 4 17 Timing Gear Cover 6A 4 17 Water P u m p 6A 4 17 Oil Pan and Rocker Arm Cover 6A4 18 Oil Pum p 6A4 18 Valve Train Compone...

Страница 452: ...pickup 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 gallery at the right side of the block figure 1 This gallery supplies oil to the camshaft bearings hydraulic lifters and main bearings The con necting rods are supplied oil from the main bearings by...

Страница 453: ...4 8 LITER L6 6A4 3 B 09222 A Oil Pressure Sending Unit B D istributor Shaft O iling C Splash O iling D F ilter Bypass System E Full Flow Oil F ilter Figure 2 Lubrication Diagram Front View ...

Страница 454: ...ely 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 of certain critical components Torque wrenches will be necessary for correct assembly of various parts ACCESSORY REMOVAL This manual assumes that the engine accessories have been removed These accessories...

Страница 455: ...4 8 LITER L6 6A4 5 1 1 1 3 9 1 4 n n 0 V 7 B 07997 Figure 4 Cylinder Head Manifolds and Components ...

Страница 456: ...6A4 6 4 8 LITER L6 107 112 T 108 3 I ft 109 165 129 B 05056 Figure 5 Block and Components ...

Страница 457: ... C o nnecting Rod Bearing Insert 164 B olt 113 Lower C o nnecting Rod Bearing Insert 165 Plug 114 Gasket 166 Gasket 115 B lock 167 N ipple 116 Plug 168 Plug 117 Rear C am shaft Plug 169 G asket 118 Flyw heel 170 B olt 119 Flyw heel H ousing 171 W ater Pum p 120 Bolt 172 N ipple 121 Dowel 173 C onn ector 122 Bolt 174 Oil F ilte r 123 Plug 175 B olt 124 Dowel 176 Fuel Pum p 125 Extention 177 G asket...

Страница 458: ...INJECTION TUBE REMOVAL Remove 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 air injection tubes will not come out they may be easier to remove after the manifolds 31 and 37 are removed as described later MANIFOLD REMOVAL The intake and exhaust manifolds are removed as an assembly...

Страница 459: ...ts 51 2 Thermostat housing 50 3 Gasket 49 WATER PUMP REMOVAL I Remove or Disconnect Figures 5 and 11 1 Bolts 170 2 Water pump 171 3 Gasket 169 o A 22 mm 7 s w B 55 mm 2 1 s C 40 mm I V2 D 10 mm 3 8 drill 25 mm 1 deep Holes for Pushrods E 22 mm 7 s drill 25 mm 1 deep Holes for Valve Lifters F 50 mm x 155 mm 2 x6 Lumber G 50 mm 2 pegs for Rocker Arms and Balls F 04942 Figure 12 Valve Train Component...

Страница 460: ...emove 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 J 9290 01 figure 14 Figure 15 Removing the Torsional Damper CYLINDER HEAD REMOVAL Remove or Disconnect Figure 4 1 Bolts 21 2 Cylinder head 26 Use care when handling the cylinder head to prevent damag...

Страница 461: ...he studs 109 figure 17 Use of the specified guide set will prevent the connecting rod from scratching the bore or crankshaft journal during the removal process The tool will also prevent the rod bearing half from falling out of the connecting rod during removal 3 Connecting rod 108 and piston 107 from the block 115 Push on the guide rod item A figure 17 to push the piston and connecting rod out Us...

Страница 462: ...s 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 Figure 19 Removing the Lower Seal Half CRANKSHAFT REAR OIL SEAL REMOVAL WITHOUT REMOVING CRANKSHAFT Remove or Disconnect Figures 5 19 and 20 1 Rear main bearing cap 137 2 Lower seal half 135 figure 19 3 Upper seal half 132 Tap on the upper seal half ...

Страница 463: ...r 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 Remove or Disconnect Figures 5 and 23 Turn the camshaft 182 until the screws 93 are visible through the holes in the camshaft gear 94 figure 23 1 Screws 93 2 Camshaft 182 Pull the camshaft out of the block Support the camshaft carefu...

Страница 464: ...es 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 m The area where the main bearing inserts 130 133 136 and 153 contact the main bearing bore should be smooth If a main bearing cap is damaged and requires replacement replace it as outlined later in this section IjJ Measure Figure 24 Head gasket surface distort...

Страница 465: ...clearance 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 Clean Old pieces of gasket from the gasket surfaces Figure 25 Main Bearing Cap Shim Location Manifolds for cracks broken flanges etc Gasket surfaces for heavy scratches Manifold heat control valve if used The heat control valve is...

Страница 466: ...al Indicator or equivalent Figure 28 Measuring Camshaft Thrust Plate Clearance Camshaft End Play Cam shaft 182 runout figure 26 M ount the camshaft between centers or in V blocks Using J 7872 or equivalent check the interm ediate camshaft journals If runout exceeds 0 020 inch the cam shaft is excessively bent and should be replaced along with the camshaft bearings Camshaft journal out of round Use...

Страница 467: ...r gage fig u re 28 The c o rre c t cle a ra n ce is 0 003 0 008 inch CAMSHAFT BEARINGS Refer to GENERAL ENGINE MECHANICAL SEC 6A TIMING GEAR COVER Clean Old gasket from the gasket surfaces L Inspect Timing tab for damage Timing gear cover for cracks large dents etc Disassemble Figure 5 Seal 158 Pry the seal out with a screwdriver Assemble Figure 31 Tool Required J 35468 Seal Installer Seal 158 Use...

Страница 468: ...pressed air 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 would permit oil to leak past the ends of the gears The pump gears cover and body are not serviced separately Pressure relief valve 201 for fit The regulator valve should slide freely in its...

Страница 469: ...ts 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 surface to determ ine if it is bent Replace if necessary Ends of the pushrods for scoring or roughness HYDRAULIC LIFTERS Refer to GENERAL ENGINE MECHANICAL SEC 6A CYLINDER HEAD DISASSEMBLY Disassemble Fig...

Страница 470: ...eads 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 washer Remove the stud by turning the nut figure 36 2 Ream the hole to th e p ro p e r size for the replacement oversize stud Use reamer J 5715 for 0 003 inch oversize studs ream er J 6036 for 0 013 inch oversize stud figure 37 3 Coat lower...

Страница 471: ... vacuum it may have been damaged or improperly installed ii i i n m JTT r n M T I 1 1 1 2 3 4 j I A Grind out this portion B 05248 Figure 40 Scale for Checking Valve Spring Installed Height t j j Measure Figures 34 40 and 41 Valve spring installed height of each valve spring 1 Use a narrow thin scale A cutaway scale figure 40 may be helpful 2 Measure from the valve shim or spring seat to the top o...

Страница 472: ...e 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 upper insert is also satisfactory If the lower insert shows evidence of wear or damage both upper and lower inserts must be replaced Crankshaft gear for chipped or damaged teeth Measure Figures 42 and 43 Main bearing and con...

Страница 473: ... Use a 9 ie inch thin wall deep socket to tap it into place Tool Required J 24420 B Puller Crankshaft gear using J 24420 B ASSEMBLY OF ENGINE PRIOR TO ASSEMBLY The importance of cleanliness during the assembly procedure cannot be overstressed Dirt will cause premature wear of the rebuilt engine Lubricate all moving parts lightly with engine oil or engine assembly lubricant unless specified otherwi...

Страница 474: ...l mating ends Insert the seal half into the rear main bearing cap 135 Use the tool to protect the seal half from the sharp edge of the seal seat Feed the seal half into the rear main bearing cap using light finger pressure Make sure the oil seal lip faces the front of the engine figure 48 3 Rear main bearing cap 135 as outlined later WITH CRANKSHAFT REMOVED n Install or Connect Figures 5 and 48 1 ...

Страница 475: ...shims for adjustment If clearances are found 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 undersize Selective fitting of the main bearing inserts is necessary in production in order to obtain close tolerances For this reason you may use one standar...

Страница 476: ...k or the bearing cap 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 s h a ft lo bes w ith E ngine O il S u p p le m e n t GM p a rt num ber 1051396 or equivalent Coat the bearing journals with engine oil Camshaft 182 into the block 115 Take care not to damage the camshaft bearings 98 and 99 Important Tighte...

Страница 477: ...ssive 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 crankshafts and in 0 010 inch and 0 020 inch undersize for use with reconditioned crankshafts The s im p le s t m ost a ccu ra te w ay to m easure connecting rod bearing clearance is with the use of gaging plastic This wax like materia...

Страница 478: ...inder bore 3 C onnecting 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 connecting rod bearing 4 Nuts 111 m Tighten Nuts 111 to 80 N m 60 ft lbs Measure Figure 57 Connecting rod side clearance Use a feeler gage The p ro p e r c le a ra n c e is 0 006 0 017 inch OIL PUMP INSTALL...

Страница 479: ...ure 59 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 with Engine Oil S u p p le m e n t GM p a rt nu m ber 1051396 or equivalent 1 Hydraulic lifters 100 into their mating bores in the block 115 2 Pushrods 20 Seat the pushrods into the socket in th...

Страница 480: ...ibration damper is aligned with the 0 mark on the timing marker 3 Position the dia l in d ica tor to m easure lifte r movement and set indicator at zero Turn the crankshaft 360 degrees and read the indicator On correctly tim e engines the indicator will read 0 012 0 020 inch 4 If the reading is not as shown reset the indicator at zero and turn the crankshaft 360 degrees then read the indicator aga...

Страница 481: ...ition 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 1000 rpm until the engine is at operating temperature 5 Listen for improperly adjusted valves or sticking lifters and other unusual noises 6 Check for oil and coolant leaks while the engine is running ...

Страница 482: ...um 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 niparanre Production Top 0 0020 0 0040 M p 2nd R C Service Limit Hi Limit Production 0 001 S Production Top 0 010 0 020 s 1 Gap 2nd 0 010 0 020 0 N Service Limit Hi Limit Production 0 010 0 Groove Production 0 005 0 0055 Clearance Service Limit Hi ...

Страница 483: ...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 Camshaft End Play 0 003 0 008 VALVE SYSTEM Lifter Hydraulic Rocker Arm Ratio 1 75 1 Valve Lash Intake One Turn Down From Zero Lash Exhaust Face Angle Intake Exhaust O CD Seat Angle Intake Exhaust 46 Seat ...

Страница 484: ...l 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 1 4 20 9 0 80 to block 5 i 6 18 18 6 165 Cylinder Head Bolts left front bolt 115 85 all others 130 95 Rocker Arm Cover Bolts 4 3 38 Pushrod Cover Bolts 9 0 80 Water Pump Bolts 20 15 Thermostat Housing to Block Bolts 38 28 Water Outlet to Thermostat Housing Bolts 28 20 Intake M...

Страница 485: ... Plate 4 C rankshaft Seal Installe r and C entering Tool 5 M ain Bearing Replacer 6 P iston Ring C om pressor 7 G uide Set 8 Vacuum Pum p 9 H ydraulic L ifte r Remover Slide H am m er Type 10 H ydraulic L ifte r Remover P lier Type 11 S tud Rem over 17 18 J 8520 J 21882 12 Ream er 0 003 inch oversize 13 Reamer 0 013 inch oversize 14 S tud Installer 15 C rankshaft Gear P uller 16 C rankshaft Gear I...

Страница 486: ...6A4 36 4 8 LITER L6 ...

Страница 487: ...ng Rod R em o va l 6A 5 9 Flywheel R em oval 6A5 13 Rear Crankshaft Oil Seal Retainer Removal 5 0 L and 5 7 L E ngines 6A5 13 Crankshaft Removal 6A5 13 Cleaning Inspection and Repair 6A5 14 B lock 6A5 14 Piston and Connecting Rod Assem blies 6A5 15 Intake and Exhaust Manifold 6A5 16 Camshaft 6A5 16 Camshaft Bearings 6A5 17 Timing Chain and Sprockets 6A 5 17 Front Cover 6A 5 17 Water P u m p 6A 5 1...

Страница 488: ...th 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 The pistons are cast aluminum alloy The piston pins are a floating fit in the pistons The gear type oil pump is driven through an extension shaft from the distributor driveshaft which is gear driven from...

Страница 489: ...V8 ENGINE 6A5 3 Figure 1 Lubrication Diagram 5 0L and 5 7L Engines ...

Страница 490: ...6A5 4 V8 ENGINE v B 09185 Figure 2 Lubrication Diagram 5 0L and 5 7L Engines ...

Страница 491: ...LTER AND DISTRIBUTOR OILING i C ylinde r w alls are oiled by oil throw n o ff pressure fed co nne cting rod bearings CYLINDER WALL AND CAMSHAFT LOBE OILING FUEL PUMP PUSH ROD OILING Figure 3 Lubrication Diagram 7 4L Engines ...

Страница 492: ...ade before removing accessories CLEANING Remove the engine accessories before cleaning to provide better access to engine exterior surfaces After removing the carburetor distributor fuel pump etc cover the openings with tape to prevent the entry of water solvent and dirt Methods used to clean the engine will depend on the aids which are available Steam cleaning pressure washing or solvent cleaning...

Страница 493: ...MANIFOLD 1 Exhaust M anifold 4 B olt S tud 6 Spark Plug W ire Heat Shield B 08004 Figure 5 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 the intake valve pushrods Every effort should be made to insure that these mating parts are installed in their...

Страница 494: ...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 23523 E figure 14 OIL PAN REMOVAL 4 Remove or Disconnect Figures 15 and 16 1 Oil pan bolts tim ing marker if used clips and reinforcements 2 Oil pan 3 Gasket or gaskets 4 Front and rear oil pan seals...

Страница 495: ... be replaced during assembly Remove or Disconnect Figure 18 1 Bolts 100 2 Cam shaft sprocket 101 and tim ing chain 102 together CAMSHAFT REMOVAL E3Remove or Disconnect Figure 19 Camshaft In s ta ll th re e 5 ie 1 8 b o lts 1 0 0 1 2 5 mm 4 5 inches long into the cam shaft tapped holes Use these bolts to handle the cam shaft Pull the cam shaft from the block Use care to prevent damage to the cam sh...

Страница 496: ...Cylinder Head and Components Typical Figure 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 reamer into the top of the cylinder figure 20 Perform the cutting operation After the ridge and or deposits are removed remove the ridge reamer Turn the cranksha...

Страница 497: ...rod 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 the bore or crankshaft journal during the removal process The tool will also prevent the rod bearing half from falling out of the connecting rod during removal 3 Connecting rod and piston from the b...

Страница 498: ...d Sprockets Use the guide rod to prevent the connecting rod from scoring the cylinder bore Assemble the connecting rod cap onto the connecting rod Do not tighten Repeat this procedure on the remaining piston and connecting rod assemblies 90 Gasket 91 Front Cover 92 Timing Marker Mark IV Engi 93 Bolt B 08011 B 08012 A 100 101 102 16 mm 5 s inch Maximum Bolt Camshaft Sprocket Tim ing Chain B 00515 F...

Страница 499: ...5 7 L ENGINES Remove or Disconnect Figure 23 1 Screws and nuts 2 Seal retainer 12 1 3 Gasket 120 CRANKSHAFT REMOVAL Remove or Disconnect Figures 24 and 25 C h e ck th e m ain b e a rin g ca p s fo r lo ca tio n markings Mark the caps if necessary The caps must be returned to their original locations during assembly 1 Bolts 134 A Rear of B lock 120 G asket 121 R etainer 122 Screw 123 Nut 124 Stud 1...

Страница 500: ...igure 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 A source of compressed air will be helpful in the cleaning operations Precision measuring tools will be required for the in spection procedure These include micrometers cylinder bore gage feeler ...

Страница 501: ...o Specifications Measure Figure 27 Main bearing vertical ID inside diameter Use an inside micrometer This dim ension should be the same as the other main bearing bore vertical diameters If it is necessary to increase the vertical ID use an equal thickness of special service bearing cap shims at each side of the cap to provide the same dim ension as at the other Figure 27 Main Bearing Cap Shim Loca...

Страница 502: ...m the coolant passages of the intake manifold EGR passage if used of excessive carbon deposits Inspect Figure 28 Manifolds for cracks broken flanges and gasket surface damage Alignm ent of exhaust manifold flanges Use a straight edge and feeler gage figure 28 If the flanges do not align the manifold is warped and should be replaced 13 AIR injection tubes for dam age Replace as needed CAMSHAFT Im p...

Страница 503: ...ools 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 engines or J 22102 7 4 L engines Make sure the timing mark faces outside FRONT COVER Clean Old gasket from the gasket surfaces 13 1 Inspect Tim ing marker for damage Front cover for damage dents or cracks Di...

Страница 504: ... there is evidence 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 from the gasket surfaces Inspect Gakset flanges for bending or damage Rubber grom mets and parts on the rocker arm cover for deterioration Oil pan for rock dam age or cracks Oil pan baffle for...

Страница 505: ...r 5 0 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 Idler gear 188 in the pump body 180 with the smooth side of the gear toward the pump cover opening Index the marks made during disassembly 7 Cover 182 gasket 190 7 4L engines and screws 186 Tighte...

Страница 506: ... be returned to their original position at assembly CLEANING AND INSPECTION OF COMPONENTS Refer to GENERAL ENGINE MECHANICAL SEC 6A and perform the following 13 1 Clean Components as outlined Inspect C om ponents as outlined Measure Valve stem clearance Valve spring tension and free length Other information outlined includes Valve and seat grinding Valve guide reaming ROCKER ARM STUD REPLACEMENT 5...

Страница 507: ...PLACEMENT 7 4 L ENGINES The rocker arm studs used in 7 4 L engines are threaded in place Disassemble Figure 38 1 Rocker arm studs 250 Use a deep socket 2 Pushrod guide 260 Assemble Figure 38 1 Pushrod guide 2 Rocker arm studs Use a deep socket Q Tighten Rocker arm studs to 68 N m 50 ft lbs Figure 38 Cylinder Head and Components 7 4L Engines Seal Exhaust Valve Intake Valve Pushrod G uide B 08019 40...

Страница 508: ... Figure 41 Reaming the Rocker Arm Stud Bore 5 0L and 5 7L Engines 2 Seals 257 intake valve only Install the seals over the valve stems and seat them against the head 3 Springs with dampers 256 4 Shields 255 5 Caps 253 intake valves only 6 Rotators 254 exhaust valves only 7 O ring seals 252 and valve keepers 251 A Nut B Flat Washer B 05245 Figure 40 Removing the Rocker Arm Stud 5 0L and 5 7L Engine...

Страница 509: ...serve the vacuum pump gage No air should be able to leak past the seal If the seal will not hold a vacuum it may have been damaged or improperly installed t j j Measure Figures 44 and 45 Valve spring installed height of each valve spring as follows 1 Use a narrow thin scale A cutaway scale figure 44 may be helpful 2 Measure from the valve shim or spring seat to the top of the shield 255 figure 45 ...

Страница 510: ...ct Water outlet for cracks Thermostat Check 1 Suspend the thermostat and a thermometer in water w ith the th e rm o m e te r loca ted close to the thermostat The thermostat must be completely submerged and the water thoroughly agitated while heating Apply heat to the water and record both the temperature at which the thermostat begins to open and the temperature at which the thermostat is fully op...

Страница 511: ...s 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 replace the crankshaft Crankshaft run out figure 48 Mount the crankshaft in V blocks or between centers Use a dial indicator as shown If the main journals are m isaligned the crankshaft is bent and mus...

Страница 512: ... assembly 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 installation tool figure 51 should be fabricated if not provided in the seal kit to prevent seal damage during installation Extreme care should be exercised when installing this seal to protect the sealing be...

Страница 513: ...e shims for adjustment If c a new bearing plus both upper dnd 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 engines only Selective fitting of both rod and main bearing inserts is necessary obtain close tolerances For this reason you may use for example one half o...

Страница 514: ...rin g cap b o lts to specifications 5 0 L and 5 7 L engines 110 N m 80 ft lbs 7 4 L engines 150 N m 110 ft lbs 2 With the crankshaft forced forward measure at the front end of the rear main bearing with a feeler gage figure 55 The proper clearance is 0 002 0 006 inch 5 0L and 5 7L engines 0 006 0 010 inch 7 4L engines 3 On 5 0 L and 5 7 L engines if correct end play cannot be obtained be certain t...

Страница 515: ... 35621 Position J 35621 against the crankshaft Thread the attaching screws into the tapped holes in the crankshaft T ig h te n the screw s s e cu re ly w ith a screwdriver This will ensure that the seal is installed squarely over the crankshaft Turn the handle until it bottoms Remove J 35621 Figure 57 Installing the Rear Crankshaft Oil Seal 5 0L and 5 7L Engines Install or Connect Figures 58 and 5...

Страница 516: ...ront seal crankshaft oil with engine oil 1 Gasket 90 2 Front cover 91 3 Tim ing 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 engines 11 3 N m 100 in lbs TORSIONAL DAMPER INSTALLATION 0Install or Connect Figure 61 Tools Required J 23523 E Torsional Damper Puller and Installer 1 Crankshaft key NOTICE The in e rtia w e ig h t se c...

Страница 517: ...example one half of a standard insert with one half of a 0 001 inch undersize insert which will decrease the clearance 0 0005 inch from using a full standard bearing INSTALLATION 0Install or Connect Figures 62 through 65 Tools Required J 5239 Connecting Rod Guide Set J 8037 Ring Compressor Lubricate the cylinder walls lightly with engine oil Make sure the piston is installed in the matching cylind...

Страница 518: ...ting 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 Figure 66 Measuring Connecting Rod Side Clearance m Measure Figure 66 C onnecting rod side clearance Use a feeler gage between the connecting rods figure 66 The proper clearance is as follows 5 0 L and 5 7 L engines 0 006 0 014 inch 7 4 L engines 0 013 0 023 in...

Страница 519: ...sket with a good sealer Spread the sealer thin and even One method 74 Gasket 75 Reinforcement 76 Rear Oil Pan Seal 77 Tim ing Marker Some Engines 78 Front Oil Pan Seal 79 Clip Number and Location Varies F 02382 Figure 68 Oil Pan 7 4L Engines 4 Oil pan Make sure the gasket and seals stay in place 5 Clips 79 reinforcem ents 75 and bolts Tighten Bolts to specifications Oil pan to block bolts 18 1 N m...

Страница 520: ...Im portant Replace all hydraulic lifters if a new cam shaft was installed Install or Connect Figure 69 Lubricate the hydraulic lifter bodies and feet with Engine Oil Supplem ent GM part no 1051396 or equivalent 1 Hydraulic lifters 44 to the block 2 Pushrods 43 Seat the pushrods into the socket in the hydraulic lifters Coat the m ating surfaces of the rocker arms 42 and balls 41 with Moly Kote or e...

Страница 521: ... the engine in this position the following valves may be adjusted Exhaust 2 5 6 7 Intake 3 4 6 8 INTAKE MANIFOLD INSTALLATION 5 0 L AND 5 7 L ENGINES Install or Connect Figures 74 and 75 1 Gaskets to the cylinder heads On TBI engines make sure the tab and or arrow faces the front of the engine The side stamped This Side Down must face the cylinder head 2 RTV sealant to the front and rear intake ma...

Страница 522: ... to specification 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 shields if used 3 Washers 2 tab washers 3 5 0 L and 5 7 L engines and bolts or studs 4 Bolts or studs to specifications 5 0 L and 5 7 L engines with cast iron manifolds Two center bolts 36 N m 26...

Страница 523: ...haft or hydraulic lifters were installed add Engine Oil Supplem ent GM part no 1051396 or e quivalent to the engine oil Fill the coolant system with the proper coolant With the ignition OFF or disconnected crank the engine several times Listen for any unusual noises or evidence that any parts are binding Start the engine and listen for unusual noses Run the engine at about 1000 until the engine is...

Страница 524: ...77 Intake Manifold Bolt Tightening Sequence 7 4L Engines 30 Nut 31 Reinforcement 32 Rocker Arm Cover 33 Stud 34 Gasket 35 Clip 36 Bolt 37 Washer TBI ENGINES CARBURETED ENGINES F 04496 Figure 78 Rocker Arm Cover Installation 5 0L and 5 7L Engines ...

Страница 525: ...34 Gasket 35 Clip Number and Location Varies 30 B 08008 Figure 79 Rocker Arm Cover Installation 7 4L Engines CAST IRON MANIFOLD TYPICAL STAINLESS STEEL MANIFOLD 1 Exhaust Manifold 2 Washer 3 Tab Washer 4 Bolt Stud F 04502 Figure 80 Exhaust Manifold 5 0L and 5 7L Engines ...

Страница 526: ...6A5 40 V8 ENGINE 1 E xhaust M anifold 4 B olt S tud 6 Spark Plug W ire Heat Shield Figure 81 Exhaust Manifold 7 4L Engines Figure 82 Water Pumps and Components ...

Страница 527: ...de 0 0005 Maximunn Relief Side 0 001 MaximumL _ Service 0 001 Maximum1 _ PISTON Clearance Production 0 0007 0 0017 Service Limit 0 0027 Maximunn PISTON RING C 0 M P R E S S I 0 N Groove Clearance Production Top 0 0012 0 0032 2nd Service Limit Hi Limit Production i 0 001 Gap Production Top 0 010 0 020 2nd 0 010 0 025 Service Limit Hi Limit Production 0 010 0 I L Groove Clearance Production 0 002 0 ...

Страница 528: ...on 0 0005 Maximum Service Limit 0 001 Maximum Rod Bearing Clearance Production 0 0013 0 0035 Service Limit 0 003 Maximum Rod Side Clearance 0 006 0 014 CAMSHAFT Lobe Lift 0 002 Intake 0 2336 0 2565 Exhaust 0 2565 0 2690 Journal Diameter 1 8682 1 8692 Camshaft End Play 0 004 0 012 VALVE SYSTEM Lifter Hydraulic Rocker Arm Ratio 1 50 1 Valve Lash Intake One Turn Down From Zero Lash Exhaust Face Angle...

Страница 529: ...Relief 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 0017 0 0032 Service Limit Hi Limit Production 0 001 Gap Production Top 0 010 0 018 2nd 0 016 0 024 Service Limit Hi Limit Production 3 010 0 1 L Groove Clearance Production 0 0050 0 0065 Service Lim...

Страница 530: ...rvice 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 9482 1 9492 VALVE SYSTEM Lifter Hydraulic Rocker Arm Ratio 1 70 1 Valve Lash Intake 3U Turn Down From Zero Lash Exhaust Face Angle Intake Exhaust 45 Seat Angle Intake Exhaust 46 Seat Runout Intake Exhau...

Страница 531: ...ing Cap Bolts Outer Bolts on 2 3 and 4 C a p s All O thers Oil Pump Cover B o lts Spark Plugs Water Outlet B olts Water Pump B o lts Flywheel Housing Bolts Ft Lbs In Lbs 65 io _ 90 48 35 36 26 28 20 36 26 90 65 95 70 11 100 22 J 200 11 100 90 65 36 26 15 135 28 21 60 45 26 20 95 70 110 80 9 0 80 10C 75 30 22 28 21 40 30 44 32 28 20 12 112 1 7 15 Item Rocker Arm Cover Nuts Intake Manifold Bolts Roc...

Страница 532: ...be Installer Mark IV Engines 5 Crankshaft Seal Installer 6 Piston Ring Com pressor 7 Guide Set 8 Vacuum Pump 9 Hydraulic Lifter Remover Slide Hammer Type 10 Hydraulic Lifter Remover Plier Type 11 Stud Remover 12 Reamer 0 003 inch oversize 13 Reamer 0 013 inch oversize 14 15 16 17 18 J 6880 J 5590 J 35621 J 1619 Stud Installer Crankshaft Sprocket Puller Small Block Engines Crankshaft Sprocket Insta...

Страница 533: ...Pump Rem oval 6A 7 Front Cover Removal i 6A7 Timing Chain and Sprocket Removal 6A7 Camshaft Removal 6A7 Oil Pan Removal 6A7 Oil Pump Rem oval 6A7 Piston and Connecting Rod R em o val 6A7 Flywheel R em oval 6A7 Crankshaft Removal 6A7 Cleaning Inspection and Repair 6A7 11 B lock 6A7 11 Cylinder B ores 6A7 12 Piston and Connecting Rod Assem blies 6A7 12 Intake and Exhaust Manifolds 6A7 12 Camshaft 6A...

Страница 534: ...aring The camshaft 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 arms The valve guides are integral in the cylinder head The connecting rods are forged steel with precision in sert type crankpin bearings The piston pins are retained by snap ring retainer...

Страница 535: ...y were intended The use of these tools will also minim ize possible damage to engine components Some precision measuring tools are required for inspection of certain components Torque wrenches will be necessary for correct assembly of various parts ACCESSORY REMOVAL This manual assumes that the engine accessories have been removed These accessories may include one or more of the following Hydrauli...

Страница 536: ...re washing or 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 pre ve n t d irt from e n te rin g c ritic a l areas d u rin g disassembly DRAINING THE ENGINE Remove or Disconnect 1 Oil pan drain plug Allow the oil pan to drain 2 Oil filter 3 Block drain plugs Allow the coolant to drain 0Install...

Страница 537: ... hex portion Failure to do so w ill result in damage to the injection nozzle j j j l INJECTION LINE REMOVAL Clean All injection line fittings at the nozzles and injection pump Remove or Disconnect Figure 4 1 Injection line clips at the brackets 2 Injection lines at the nozzles Cap the lines and nozzles immediately Do not bend injection lines 3 Injection lines at the pump Cap the lines and pump fit...

Страница 538: ...R ARM AND PUSHROD REMOVAL Remove or Disconnect Figure 7 1 Bolts 54 2 Rocker arm assemblies 55 Mark the assemblies so they can be returned to the original location at assembly 3 Pushrods 18 9 Remove or Disconnect Figure 7 1 Bolts 58 NOTICE Do n o t pry on the rocker arm cover Damage to sealing surfaces may result 2 Rocker arm covers 57 Im portant The pushrods must be installed in the original direc...

Страница 539: ...skets 52 F 05726 70 B olt 71 Front Cover 72 B affle G M odels 73 T im in g Pointer 74 Screw 75 W ater Pum p Plate 76 B olt S tud 77 G asket 78 B olt 79 Torsional D am per 80 B olt 81 W asher 82 W ater Pump 83 Oil F ille r Neck 84 Nut 85 G rom m et 86 B olt G M odels 87 Nut G M odels 88 B olt B 08065 52 53 Figure 8 Front Cover and Components B 07877 17 Hydraulic Lifter 18 Pushrod 50 Guide Plate 51 ...

Страница 540: ...ection pump 100 6 Gasket 103 Remove or Disconnect Figure 8 1 Oil pan to front cover 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 block 2 Position the dial indicator so that the plunger contacts the timing chain between the two gears 3 Pull the chain...

Страница 541: ...FLYWHEEL REMOVAL 1 Bolts 133 2 Oil Pan 134 3 Oil pan rear seal 132 OIL PUMP REMOVAL 0Remove or Disconnect Figure 12 1 Bolt 131 2 Oil pump 130 PISTON AND CONNECTING ROD REMOVAL Remove or Disconnect Figures 13 and 14 1 Ridge or deposits from the upper end of the cylinder bores Turn the crankshaft until the piston is at BDC Place a cloth on top of the piston Perform the cutting operation with a ridge...

Страница 542: ...ITER DIESEL Figure 12 Oil Pan and Oil Pump A Use short pieces of 10 m m 3 s inch hose to protect the crankshaft journal B 08045 Figure 13 Removing the Cylinder Ridge Figure 14 Removing the Piston and Connecting Rod ...

Страница 543: ... pected to perform properly if parts worn beyond accepta ble limits are reused BLOCK i g i Clean I Block in solvent Block gasket surfaces Cylinder bores Oil galleries and passages Scale deposits from the coolant passages Inspect 1 All expansion plugs for poor fit or leakage 2 Hydraulic lifter bores for deep scratches and varnish deposits 3 Block for cracks Cylinder walls Coolant jackets Main beari...

Страница 544: ...ecting 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 number Measure Ring end gap and ring clearance I Inspect Ring fit 13 1 1 L 9 L INTAKE AND EXHAUST MANIFOLDS Clean Old pieces of gasket from the gasket surfaces Soot deposits from the intake manifold Inspect Ma...

Страница 545: ...tion process 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 2 Im portant The bearing oil hole MUST align with the oil hole in the block This hole is located at about the 4 o clock position from the block upright viewed from the front of the block The seam in...

Страница 546: ...ith grease Im portant If a new front cover is installed the engine must be re timed as outlined later L JQi 1 Clean Old gasket from the gasket surfaces on the water pump and water pump plate 9 Im portant Do not immerse the pump in solvent The solvent may enter the pump s permanently lubricated bearings dissolve the bearings lubricant supply and cause premature bearing failure Inspect Water pump sh...

Страница 547: ...ets which contact the pushrods These areas should be smooth and free of damage and wear 170 Valve Keeper 171 Rotator 172 Shield 173 O Ring Seal 174 Seal 175 Valve Spring and Damper k 175 174 175 176 Shim 177 Exhaust Valve 178 Cap 179 Intake Valve 170 170 7 8 172 173 176 F 05727 Figure 20 Valves and Components Pushrods for bending Roll the pushrod on a flat surface to determ ine if it is bent Repla...

Страница 548: ...NACCEPTABLE CRACK LENGTH OVER 5 mm 3 ie A Head Gasket Sealing Bead Mark B Fire Slot B 08399 Figure 23 Prechamber Inspection 2 P re ch a m b ers for cra cks R eplace any pre chambers with facial cracks longer than 5 mm 3 ie inch figure 23 Service pre chambers are available in standard and 0 254 mm oversize Measure Figure 24 1 Valve stem clearance Refer to GENERAL ENGINE MECHANICAL SEC 6A 2 Cylinder...

Страница 549: ...rs 170 Compress the valve spring using J 8062 figure 2 1 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 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 Assemble the two valve keepers using the grease to hold t...

Страница 550: ... used in G m odels are shorter than nozzles used on C K R V P m odels They m ust n o t be in te rch a n g e d A tte m p ts to use the incorrect nozzle w ill damage the nozzle and or cylinder head INJECTION LINES Inspect Injection lines for kinks and damaged fittings Replace any damaged lines INJECTION PUMP L Inspect Injection pump body and m ounting flange for damage Injection pump for evidence of...

Страница 551: ...eplaced along with the main bearings n 0 013 mm 0 001 inch undersizes proper main bearing AVAILABLE BEARING SIZES M ain b e a rin g s are a va ila b le 0 0005 inch and 0 026 m for select fitting to attai clearance Connecting rod bearings are available in 0 026 mm 0 001 inch undersizes for select fitting Some VIN Code C RPO LH6 light duty emissions engines may have both standard and 0 08 mm 0 00 3 ...

Страница 552: ...e 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 tolerances For this reason you may use for example one half of a standard insert with one half of a 0 026 mm 0 001 inch undersize insert which will decrease the clearance 0 013 mm 0 0005 inch from using a full sta...

Страница 553: ...alves 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 ain bearing caps are to be tapped into place with a brass or leather m allet before the attaching bolts are installed Do not use the attaching bolts to p u ll the main bearing caps into their seats as this may damage the...

Страница 554: ...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 inch undersizes 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 with A B C D E Oil Co...

Страница 555: ...engine Cylinders 1J 3 5 and 7 are the left bank and 2 4 6 and 8 are 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 another new connecting rod bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder number...

Страница 556: ...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 inch If the deflection exceeds this limit the sprockets and timing chain must be inspected for w ear and replaced as necessary With new parts the deflection must not exceed 12 7 mm 0 50 inch FRONT CO...

Страница 557: ...d be in 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 nut to the upper housing stud to hold the tool flange The nut should be finger tight 6 Tighten the large bolt 18 mm head clockwise looking at the front of the engine to 48 N m 35 ft lbs 7 Tighten ...

Страница 558: ... 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 Im portant Align the timing marks figure 44 6 Bolts 105 Tighten Bolts 105 to 25 N m 20 ft lbs 7 Wires and hoses at the injection pump Adjust Figure 45 Injection pump timing For the engine to be properly timed the marks on the top of t...

Страница 559: ...re Install or Connect Figure 47 Bolts 88 to 22 N m 16 ft lbs Apply a bead of anaerobic sealer GM part no 1052357 or equivalent to the water pump plate as shown in figure 46 Water pump plate to the engine The sealer must be wet to the touch when installing the plate Apply sealant GM Part no 1052080 or equivalent to the threads of bolts and studs 76 Bolts and studs 76 Tighten Water pump to front cov...

Страница 560: ...uide plate CYLINDER HEAD INSTALLATION 0 Install or Connect Figures 47 and 48 Tool Required J 29664 Manifold Cover Set 1 Head gasket to the block over the dowel pins Im portant The block gasket surfaces must be clean DO NOT use a sealer on the head gasket The head gasket is manufactured with the proper amount of sealant printed on its surface A dditional sealer may cause leakage or malfunction In a...

Страница 561: ...ate the engine until 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 torsion al damper This measurement can be estimated by aligning the torsional damper mark with the first lower water pump bolt figure 49 This procedure will position the engine so no valves are close to a piston crown Install the bol...

Страница 562: ...se 48 and 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 Dipstick bracket bolt EXHAUST MANIFOLD INSTALLATION n Install or Connect Exhaust manifolds and bolts Tighten Bolts to 35 N m 26 ft lbs GLOW PLUG INSTALLATION Install or Connect Glow plugs Tighten...

Страница 563: ... using the 30 mm hex p o rtio n Failure to do so w ill re su lt in damage to the injection nozzle 1 Injection nozzle with gasket using J 29873 Tighten Nozzle to 70 N m 50 ft lbs 2 Fuel return hose 3 Fuel line clip INJECTION LINE INSTALLATION 0 3 Install or Connect Figures 53 and 54 1 Injection line brackets 2 Injection lines to the pump Uncap the lines before assembly Do not bend the injection lin...

Страница 564: ...if used 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 Service Manual Connect all vacuum hoses and electrical equipment the same way as removed ENGINE SET UP AND TESTING 1 After overhaul the engine should be tested before installation in the vehicle ...

Страница 565: ...er N um ber 4 G Cyl nder N um ber 3 H Cyl nder Num ber 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 Manual or Emission Control Label for specifications adjust idle speed fast idle speed etc as required Figure 54 Injection Line Routing ...

Страница 566: ...6A7 34 6 2 LITER DIESEL LEFT SIDE RIGHT SIDE B 08023 Figure 55 Intake Manifold Installation Figure 57 Vacuum Pump ...

Страница 567: ...6 2 LITER DIESEL 6A7 35 A Front of Engine Figure 58 Vacuum Pump Installed ...

Страница 568: ...and 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 Groove Clearance 0 040 0 096 Gap 0 25 0 51 PISTON PIN Diameter 30 9961 31 0039 Clearance 0 0101 0 0153 Fit in Rod 0 0081 0 0309 CRANKSHAFT Diameter 1 2 3 4 74 917 74 941 Main Journal 5 74 912 74 936 Ta...

Страница 569: ...Intake 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 Newtons mm Closed 356 N 46 0 mm Open 1025 N 35 3 mm Installed Height 46 Timing Chain Free Play New Chain 12 7 mm 0 500 inch Used Chain 20 3 mm 0 800 inch Hydraulic Lifter Diameter Standard 23 39 23 4...

Страница 570: ...s All except Rear Two Bolts 10 0 Rear Two B o lts 23 17 Injection Pump Gear Bolts 25 20 Injection Pump Flange N u ts 40 30 Oil Pan Drain P lu g 10 0 Block Drain P lu g 22 16 Torsional Damper B o lt 270 200 Water Pump Plate to Water Pump Bolts 22 16 Water Pump to Front Cover B o lts 42 32 Water Pump Plate to Front Cover B o lts 22 16 Hydraulic Lifter Guide Plate Clamp B olts 26 18 Cylinder Head Bol...

Страница 571: ...6 2 LITER DIESEL 6A7 39 SPECIAL TOOLS 1 Ring C om pressor 2 T im ing Fixture 3 Nozzle Socket 4 Seal Installer 5 Torsional Dam per Remover 6 M a nifold Cover Set F 05731 ...

Страница 572: ...6A7 40 6 2 LITER DIESEL ...

Страница 573: ... 6 Cleaning Inspection and R e p a i r 6C1 13 Carburetor R e a s s e m b ly 6C1 16 M etering Rod A d ju s tm e n t 6C1 18 Float A d ju s tm e n t 6C1 18 Choke Stat Lever A d ju s tm e n t 6C1 20 Choke Link Fast Idle Cam A djustm ent 6C1 20 Vacuum Break A djustm en t 6C1 21 Choke Unloader A d ju s t m e n t 6C1 21 S p ec ificatio n s 6C1 22 Special T o o l s 6C1 22 ...

Страница 574: ... odel N um be r Day O f Year S ource C ode Year A sse m b ly P lant C ode S h ift Id e n tific a tio n Figure 2 Model 1MEF Carburetor Front V iew F 0 1 47 7 GENERAL DESCRIPTION M odel 1MEF is a single stage single barrel carburetor o f the 1 M fa m ily Figure 2 Letters follow ing the 1M designate these features E It has an integral Electric choke F It has adjustable w ide open th ro ttle m ixture ...

Страница 575: ... Needle E Check Valve 234 Float Needle Seat F Valve Closing Spring F 01479 Figure 3 Float System 282 Jet M ain Metering 286 Idle Tube Assem bly 326 Needle Idle Mixture 333 Plug Idle Mixture Needle A Throttle Valve B Idle Channel Restriction C Top Idle Air Bleed D Lower Idle Air Bleed E O ff Idle Port F Idle Discharge Orifice G Timed Vacuum Port 286 282 333 A F 326 B 06642 Figure 4 Idle System ...

Страница 576: ...Main Well A ir Bleed K Main Well to Aspirator Bleed k J 3 A p F 01481 Figure 5 M ain M etering System 266 Rod Power Piston 274 Power Valve Piston Assembly 276 Spring Power Piston 279 Metering Rod and Spring Assem bly 282 Jet Main Metering 310 Lever Pump and Power Rod 314 Link Power Rod A Throttle Valve B Vacuum Channel C Main Discharge Nozzle D Lower Idle Air Bleed E Main Well F Metering Rod Adjus...

Страница 577: ...A Pump 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 Assembly Choke Shaft and Lever Assembly Choke Stat Lever 65 Bowl Side Vacuum Break Assembly 69 Vacuum Break Lever and Link Assembly A Choke Valve B Therm ostatic Coil C Plunger Bucking Spring not used on all model...

Страница 578: ... ixture needle 5 Remove all loose pieces of plug FUEL INLET NUT AND FILTER Support carburetor to avoid damaging external components E Remove or Disconnect Figure 10 1 Fuel inlet nut 210 2 Fuel inlet filte r 215 inlet nut gasket 212 and filte r spring 218 Discard gasket I Inspect Cut filte r open If clogged check tank s and fuel lines fo r source of m aterial IDLE STOP SOLENOID Remove or D isconnec...

Страница 579: ...oke link 20A Fast Idle Cam and Link Remove or Disconnect Figure 13 Fast idle cam attaching screw 12 cam 10 and cam link 15 Disconnect fast idle cam link from choke shaft lever 20 AIR HORN COMPONENTS Remove or Disconnect Figure 16 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 12 Choke Housing Assembly 20A 10 Fast I...

Страница 580: ...6C1 8 MODEL 1MEF CARBURETOR 420 B 06650 Figure 14 M onojet Model 1MEF ...

Страница 581: ...g Pump Plunger 252 Spring Pump Return 256 Guide Pump Discharge Spring 260 Ball Pump Discharge 266 Rod Power Piston 268 Seal Power Piston Rod 270 Retainer Power Piston Rod Seal 274 Power Valve Piston Assem bly 276 Spring Power Piston 279 Metering Rod Spring Assembly 282 Jet Main Metering 286 Idle Tube Assem bly 300 Throttle Body Assem bly 301 Gasket Float Bowl to Throttle Body 305 Screw Assem bly F...

Страница 582: ...r 310 from end o f th ro ttle shaft C Press d o w n on p o w e r v a lv e p is to n assembly 274 and disconnect pow er rod link 314 from p o w e r piston rod 266 D Press d o w n on p u m p rod 2 4 0 a n d disconnect pum p lin k 317 fro m slot in rod Pump rod 240 and pum p assembly 246 Disassemble Figure 21 Pump p lu n ge r spring 248 and cup 247 fro m pum p assembly 246 Pump rod seal 242 fro m bos...

Страница 583: ...66 314 310 F 01498 248 247 246 246 Pum p A ssem bly 247 Pum p P lunger Cup 248 Pum p P lunger Spring F 04359 Figure 19 Pump and Power Piston Linkage Figure 21 Pump Plunger Cup and Spring Figure 22 Power Piston M etering Rod and Jet F 01491 279 M etering Rod and Spring A ssem bly 282 Main M etering Jet 276 Power Piston S pring 274 Power Valve Piston A ssem bly ...

Страница 584: ...nvert carburetor and catch idle tube Pump Discharge Ball and Spring Remove or Disconnect Figure 24 1 Pump discharge spring guide 256 Use needle nose pliers 2 Pump discharge ball spring 258 and ball 260 Invert carburetor and catch sp rin g and ball THROTTLE BODY COMPONENTS Idle M ixture Needle Remove or Disconnect Figure 25 Tool required J 29030 B o r B T 7610B Id le M ix tu r e Socket A djusting T...

Страница 585: ...POWER PISTON SEAL Invert flo a t bow l 4 1 Remove or Disconnect Figure 27 P ower piston rod seal re ta in e r 270 Use small screw driver or aw l Power piston rod seal 268 268 Power Piston Rod Seal 270 Power Piston Rod Seal R etainer A Pum p S lide B ushing Do N ot Remove F 01494 Figure 27 Power Piston Rod Seal CLEANING INSPECTION AND REPAIR Inspect If an excessive a m o u n t o f fo re ig n m a te...

Страница 586: ...se and replace if necessary Float flo a t lever and hinge pin fo r distortion binds and burrs The flo a t fo r being loaded Check w eight of flo a t in comparison w ith a new float and replace if heavier Plastic parts fo r cracks damage etc PUMP SYSTEM CHECK Inspect Figures 21 24 7 Perform th is check w ith a new pum p cup installed on the pump plunger and w ith the pum p discharge ball ball sprin...

Страница 587: ...cover a tta ch in g rivets 52 Use 4 mm 5 32 d rill bit Choke cover retainers 50 Electric choke cover and stat assembly 47 R em aining pieces o f rivets in housing Use punch to drive o u t IDLE STOP SOLENOID CHECKING PROCEDURE Check the idle stop solenoid 400 e le ctrica lly using a 12 v o lt a u to m o tive battery 1 H old th e s o le n o id p lu n g e r in a g a in s t th e in ternal stop using f...

Страница 588: ...sing install choke cover w ith stat tang under stat lever B Rotate choke cover to line up notch in the cover w ith the projection on the housing Choke cover retainers 50 and attaching rivets 52 Use blind rivet tool to install rivets It may be necessary to use an adapter tube if the to o l in te rfe re s w ith the electrical connector on the electric choke cover and stat 47 Instructions are include...

Страница 589: ...ide 256 Install flush w ith casting surface Idle Tube Assembly Install or Connect i Figure 24 Idle tube assembly 286 Should be flush w ith casting surface Main M etering Jet and Float Needle Seat Install or Connect Figures 22 23 1 Main m etering je t 282 2 Float needle seat 234 w ith new gasket 235 Figure 34 Power Piston M etering Rod and Jet POWER PISTON AND PUMP Install or Connect Figures 3 4 2 ...

Страница 590: ... tw e e n th e end o f th e m etering rod hanger and th e to p o f th e casting A Back out idle stop solenoid and hold th ro ttle valve closed Remove m etering rod from hanger A Power Valve Piston A ssem bly H old Down W hile G aging B Plug Gage Slide Fit C Bend H anger Here to A d ju st D Bending Tool J 9789 111 or BT 3006M F 01499 B 4 Figure 36 M etering Rod Adjustm ent Use th e specified plug g...

Страница 591: ... a rd Fast idle cam attach ing screw 12 Figure 38 Air Horn Screw Location and Tightening Sequence Choke Housing Install or Connect 4 Figure 12 1 2 Connect choke lin k 20A to choke sh a ft and lever assembly 40 th e n position choke housing and bearing assembly 35 on flo a t bow l C hoke s h a ft le v e r s h o u ld be fa c in g upw ard In s ta ll c h o ke h o u s in g a tta c h in g screw s as fo ...

Страница 592: ...ole in th e lever and in to th e hole in the choke housing If gage does n o t pass freely th ro u g h both holes bend choke lin k a t p o in t show n in Figure 39 to align the holes CHOKE LINK FAST IDLE CAM ADJUSTMENT Adjust Figures 40 44 P osition th e fa s t id le cam fo llo w e r on th e second step o f th e fast idle cam against th e rise o f the high step Hold dow n on th e choke valve w ith ...

Страница 593: ...cking Spring F Plunger Stem Extended Spring Compressed G Leaf Type Bucking Spring H Spring Seated B 06662 Figure 41 Vacuum Break Adjustm ent Inform ation CHOKE UNLOADER ADJUSTMENT Adjust Figures 43 44 Hold the th ro ttle lever in the w id e open th ro ttle position Hold d o w n on the choke valve w ith th e fast idle cam lin k in the end o f the choke lever slot Check the gap betw een the lo w e r...

Страница 594: ...20 inch 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 J 23738 A or BT 7517 1 Idle M ixture Socket A djusting Tool 2 Hand O perated Vacuum Pump 3 Universal C arburetor Gauged Set 4 Float P ositioning Tool Set J 34817 A or BT 8426 F 04263 ...

Страница 595: ...tor M4MEF MODEL MODEL NUMBER M4MEF 17088040 M4MEF 17088041 M4MEF 17085004 M4MEF 17085212 APPLICATION FED 5 7L V8 W MT FED 5 7LV8 W AT FED 7 4LV8 W MT FED 7 4LV8 W AT The carburetor model identification number is stam ped v e rtic a lly on the flo a t b o w l near th e secondary th ro ttle lever as shown Figure 1 Refer to this part number when servicing the carburetor If replacing the flo a t bow l...

Страница 596: ...ISS V8 Engines W ith Manual Transmission The electric Idle Stop Solenoid ISS found on these applications is used to p ro vid e th e desired engine idle speed and to prevent dieseling w hen the ignition is switched off UNIT REPAIR FLOAT POWER IDLE PUMP MAIN METERING CHOKE Im portant The part th ro ttle adjusting screw was set at the factory and then plugged Any a tte m p t to readjust this screw co...

Страница 597: ...Stop Adjusting Bushing Do Not Turn Or Remove C Rich Stop Adjust Plug D Vacuum Channel J E Main Well K F Main Well Air Bleeds 213 G Main Discharge Nozzle 218 H Boost Venturi 248 Main Venturi Primary Throttle Valve Primary Metering Rod Power Piston Spring Primary Metering Jet F 04363 Figure 4 Main M etering System ...

Страница 598: ... turn or remove Secondary Well Bleed A djust Spring Secondary Well Bleed A djust Plug Secondary Discharge Nozzle Baffle Secondary Metering Rod Holder Secondary Metering Rod Air Horn Baffle Power Valve Piston Assem bly Primary M etering Rod Power Piston Spring Primary M etering Jet F 04364 Figure 5 Power System A Pump Suction Breaker B Pump Jet C Discharge Passage D Pump Plunger Head E Pump Duratio...

Страница 599: ...s depends on th e size o f th e punch to be used Cut d o w n to the plug b u t n o t m ore than 1 8 beyond the locator points Place a fla t punch at a p o in t near th e ends o f the saw marks Hold th e punch at a 45 angle and drive it in to the th ro ttle body to break casting away and expose th e plug Use ce nter p u n ch to bre a k p lu g a p a rt and uncover idle m ixture needle Remove all loo...

Страница 600: ...6C2 6 MODEL M4MEF CARBURETOR Figure 8 Model M4MEF ...

Страница 601: ...ary Side Front Vacuum Break 352 Fast Idle Cam Assembly Assembly Attaching 354 Lever Interm ediate Choke 57 Hose Primary Side Front Vacuum Break 356 Link Choke 58 Link Primary Side Vacuum Break Air Valve 360 Lever Secondary Throttle Lockout Lever 364 Seal Interm ediate Choke Shaft 67 Retainer Pump Stem Seal 370 Nut Fuel Inlet 68 Seal Pump Stem 372 Gasket Fuel Inlet Nut 200 Float Bowl Assembly 375 F...

Страница 602: ... prim ary side vacuum break air valve lever link 58 AIR HORN COMPONENTS Secondary M etering Rods Remove or Disconnect Figure 13 1 Secondary m etering rod holder attaching screw 30 2 M etering rod holder 31 and m etering rods 32 Choke Lever and Link 4 Remove or Disconnect Figure 14 1 Choke lever attaching screw 36 2 Choke lever 35 3 Choke link 356 30 SCREW SECONDARY METERING ROD HOLDER ATTACHING 31...

Страница 603: ... Remove or Disconnect Figure 16 A ir horn screws A ir h o rn to t h r o t t le b o d y s c re w assemblies 45 A ir horn to flo at bowl screw assemblies 46 A ir horn baffle 50 if used A ir horn to flo a t bow l countersunk screws 47 Figure 16 Air Horn Screw Location and Tightening Sequence 2 A ir horn assembly 10 Lift straight up Leave air horn gasket 201 on flo a t bowl N O T IC E U s ec a rew h e...

Страница 604: ...t 1 Figures 19 20 Power valve piston assembly 212 and prim ary m etering rods 213 Press down on piston stem and release it causing the p o w e r piston to snap up against retainer Repeat until free N O T IC E D on o t u s ep lie rso nm e te rin gro d h o ld e rtore m o v ep o w e rv a lv ep is to n a sth e h o ld e rc o u ldc o m elo o s efro m p is to n 205 203 SPRING PUMP PLUNGER 204 CUP PUMP PL...

Страница 605: ...238 Pull up on flo a t hinge pin 236 Primary M etering Jets Remove or Disconnect Figure 20 Primary m etering jets 248 from flo a t bowl N O T IC E D on o t re m o v es e c o n d a rym e te rin g d is c s T h e ya rep re s s e din top la c e a n dif d a m a g e d e n tireb o w lre p la c e m e n tisre q u ire d Pump Discharge Ball and Pump W ell Baffle 1 2 Remove or Disconnect Figure 18 Pump discha...

Страница 606: ... 25 Tool Required J 29030 B or BT 7610B Id le M ix tu re Socket Adjusting Tool 35 LEVER CHOKE 36 SCREW CHOKE LEVER ATTACHING 322 LINK SECONDARY SIDE REAR VACUUM BREAK TO CHOKE NOT USED ON ALL MODELS 340 CHOKE HOUSING ASSEMBLY 341 SCREW AND WASHER ASSEMBLY CHOKE HOUSING TO FLOAT BOWL 345 SCREW CHOKE STAT LEVER ATTACHING 348 LEVER CHOKE STAT 350 INTERMEDIATE CHOKE SHAFT LEVER AND LINK ASSEMBLY 352 F...

Страница 607: ...s electric choke cover a n d s ta t assem bly flo a t a n d flo a t b o w l insert p u m p p lu n ge r seals etc in cleaner as they m ay becom e n o n fu n ctio n a l sw e ll harden o r d isto rt The plastic cam on the air valve shaft w ill withstand normal cleaning 1 Blow dry w ith compressed air Do Not pass drill bits or w ire through jets or other passages Inspect Check the fo llo w in g item s...

Страница 608: ...nd to push pump assembly down slowly in pump w ell Pump assembly should n o t tra v e l to bottom of well Only m ovement should be compressing of the duration spring If pump assembly moves dow n in w ell this may indicate that the pump cup is not sealing properly the pum p w ell is w orn or scored or the pum p discharge plug is leaking as indicated by bubbles around plug W ith clean solvent in flo...

Страница 609: ...and 12 volts to the solenoid body 3 If the solenoid plunger does not extend when the voltage is applied replace the solenoid w ith a new one CARBURETOR REASSEMBLY THROTTLE BODY COMPONENTS Throttle Body Invert flo a t bowl 200 Install or Connect Figure 26 4 1 2 3 New flo a t bowl to th ro ttle body gasket 401 Install over locator pins on flo a t bowl Throttle body assembly 400 Float bowl to th ro t...

Страница 610: ...Y 354 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 L B Guide interm ediate choke shaft through slot in interm ediate choke lever Choke housing to flo a t bowl screw and washer assembly 341 Inspect Linkage for freedom o f movement Im portant Electric choke cover and s...

Страница 611: ... Connect 1 Power piston spring 218 2 Install power valve piston assembly and prim ary m etering rods as follow s A A lign pin on piston w ith slot in bore and prim ary m etering rods in jets B Press plastic retainer flush w ith to p o f flo a t bowl If necessary use a small punch and hammer Pump Assemble Figure 18 Pump assembly 205 w ith new pump plunger cup 204 and spring 203 4 Install or Connect...

Страница 612: ... in th e lever 2 Pump lever 41 A Pump link in specified hole S pecification is in fig u re 50 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 lever hinge pin 42 in u n til flush w ith casting boss Choke Lever and Link Install or Connect Figure 14 1 Choke lin k 356 in to in te rm e d ia te choke lever 354 Hold fast idle ...

Страница 613: ...um Break In fo rm a tio n Figure 45 Prim ary Side Vacuum Break Figure 46 A ir Valve Link Figure 47 U nloader Figure 48 Secondary T h ro ttle Lockout Figure 49 Specifications are in Figure 50 ELECTRIC CHOKE COVER AND STAT Insta ll or Connect f 4 1 Figure 38 42 Place fast idle cam 352 on high step against cam fo llo w e r lever Electric choke cover and stat assembly 335 in the choke housing 340 Be s...

Страница 614: ...ROM SPECIFICATION USE J 34817 25 OR BT 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 8227A 1 F 01925 Figure 39 Float A d ju stm e n t 2 W ith the fast idle cam o ff the cam fo llo w e r lever turn the th ro ttle stop screw out so it does not touch the th ro ttle lever 3 M easure the di...

Страница 615: ...r Valve Return Spring Adjustm ent If riveted drill out and remove rivets Remove Choke Cover and Stat Assembly 2 Place Fast Idle Cam on high step against Cam Follower Lever 3 Push up on Choke Stat Lever to close Choke Valve Check Stat Lever for correct orientation by inserting 120 plug gage in hole Gage should fit in hole and touch edge of lever 5 Adjust if necessary by bending Choke Link J 9789 11...

Страница 616: ...lve Angle Gage 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 specification Place Fast Idle Cam on second step against Cam Follower Lever g with Lever contacting rise of High Step If Lever does not contact Cam turn Fast Idle Adjusting Screw in additional turn s 5 Adjust if bubble is not recentered by...

Страница 617: ...ak Lever of Intermediate Choke Shaft 2 Open Throttle to allow Choke Valve to close 3 Set up Angle Gage and set to specification 4 Plug Vacuum Break Bleed Holes if applicable Apply 15 Hg 51 k Pa vacuum to seat Vacuum Break Plunger Seat Bucking Spring if applicable On Quadrajets if necessary Bend Air Valve Link to permit full plunger travel Reapply vacuum Adjust if bubble is not recentered by turnin...

Страница 618: ...934 Figure 47 Air Valve Link Adjustm ent j 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 specification 4 On Quadrajet hold Secondary Throttle Lockout Lever away from pin B 5 Hold Throttle Lever in wide open position 6 Adjust if bubble is not recentered by bending Fast Idle Lever J 26701 A or BT 7704...

Страница 619: ...f 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 pin F 01937 CARBURETOR NUMBER FLOAT SETTING 2 32 PUMP SETTING AIR VALVE SPRING TURNS CHOKE STAT LEVER CHOKE LINK CAM 2 5 VAC BRK FRONT 2 5 AIR VALVE LINK UN LOADER 4 17088040 13 32 Inner 9 32 7 8 0 120 G 46 27 0 025 35 17088041 13 32 Inner 9 32 7 8 0 ...

Страница 620: ...738 A or BT 7517 J 26701 A or BT 7704 J 9789 111 or BT 3006M 1 Universal C arburetor Gage Set 7 C hoke Lever Installer 2 C arburetor H olding Stand 8 Float Level T Scale 3 Pump Lever Pin Punch N ot Shown 9 Float P ositioning Tool Set 4 N eedle Seat Tool 10 C hoke Valve A ngle Gage 5 Idle M ixture S ocket A djusting Tool 11 Linkage B ending Tool 6 Hand O perated Vacuum Pump F 04264 ...

Страница 621: ...al T ools 6D 42 DELCO REMY 12 SI SERIES TYPE 100 AND 17 SI SERIES TYPE 100 GENERATORS DESCRIPTION The generators shown in figures 1 and 2 feature a solid state regulator mounted inside the slip ring end frame The Sl series indicates Systems Integral generator with built in regulator All regulator components are enclosed in a solid mold This unit along with the brush holder assembly is attached to ...

Страница 622: ...through them Now the engine control switch is closed allowing current to flow from the battery through the indicator lamp to the No 1 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 indicator lamp current When the generator is spinning AC voltages are generated in the Y...

Страница 623: ...tor No 1 terminal and the battery 2 Slowly increase the generator speed and observe the voltage 3 If the voltage is uncontrolled with speed and increases above 15 5 volts on a 12 volt system replace the regulator and check the field winding 4 If the voltage is below 15 5 volts on a 12 volt system connect the carbon pile as shown 5 Operate the generator at moderate speed as reguired and adjust the ...

Страница 624: ...d frame 17 SI Series Figures 7 and 9 16 Two ground screws from the rectifier bridge 17 17 BAT terminal stud nut 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 a tube slightly smaller than the bearing shell Press out the bearing from the outside towa...

Страница 625: ...r 16 R egulator 35 Rear C ollar 17 R e ctifie r Bridge 36 Insulator 18 C apacitor 37 R etainer 19 Nut 38 B rushes 20 BAT Term inal Nut 39 Drive End Frame 22 Pulley Nut 40 S lip Ring End Frame 23 W asher 41 S tator 24 B olt 42 R otor 29 G rounded Screw 43 Pulley 30 Insulated Screw 44 Fan F 04199 Figure 8 12 SI Series 100 Components ...

Страница 626: ...ifie r B ridge Term inal Nut 31 Rear Bearing 22 Pulley Nut 32 Front Bearing 23 Wave W asher 33 S lip Ring 39 Drive End Frame 24 B olt 34 Front C ollar 40 S lip Ring End Frame 25 S hort B olt 35 Rear C ollar 41 S tator 26 Long B olt 36 Insulator 42 R otor 27 Through B olt 37 R etainer 43 Pulley 28 R e ctifie r B ridge Retainer B olt 38 Brushes 44 Fan F 04200 Figure 9 17 SI Series 100 Components ...

Страница 627: ...ator if either looks burned Burned insulation appears as a very dark or blackened wiring A strong acrid odor will be apparent 9 Terminal connectors for corrosion or breaks _ B 45 O hm m eter A C heck fo r G rounds B C heck fo r O pens F 04201 Figure 10 Checking Rotor Field Windings 10 Windings on the stator for chipped insulation If the chipped area is small and the rest of the stator is OK repair...

Страница 628: ... regulator Refer to figure 12 Figure 12 Rectifier Bridge Check Observe the ohmmeter reading and reverse the lead connectors to the grounded heat sink and the same flat metal connector or stud If both readings are the same replace the rectifier bridge A good rectifier bridge will give one high and one low reading Repeat this same test between the grounded heat sink and the other two terminals or co...

Страница 629: ... battery polarity 3 Test lamp should be on 4 Turn on the fast charger and slowly increase the charge rate Observe the voltmeter The lamp should go out at the voltage regulator setting The voltage regulator setting should be a minimum of 13 5 volts and a maximum of 16 0 volts The test lamp is connected into the circuit exactly as the rotor is when the regulator is inside the generator The regulator...

Страница 630: ...Grounded screw is located on the resistor mount Stator 41 to the end frame aligning the three stator leads to the three rectifier bridge terminals Three terminal nuts Tighten the nuts securely Press the bearing into the bore using a metal tube against the bearing outer race Fill the cavity between the retainer plate and the bearing with specified lubricant Refer to Lubrication later in this sectio...

Страница 631: ...cator 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 position switch terminal Close the switch and compare the rpm current and voltage readings with the specifications at the end of this section It is not necessary to obtain the exact voltage specified as a good reading can be made by understanding...

Страница 632: ...re 18 10MT Starting Motor 1 S hift Lever 12 O verrunning C lutch 13 Bronze G raphite B ushing 14 Grease R eservoir 15 Sealing G rom m et 16 Sealing W ashers 17 17 C adm ium C opper C o ntact Disc 18 G asket 19 C enter Bearing 20 C enter Bearing R etaining Screw 21 C o n d ucto r B anding F 04209 Figure 19 27MT Starting Motor ...

Страница 633: ...ssembly can be removed from the drive housing LEVER HOUSING Disassemble 1 Drive assembly 32 from the armature shaft 9 as follows Remove the pinion stop washer 34 or thrust collar 39 from the armature shaft Drive the stop collar 39 away from the pinion stop retainer ring 37 by sliding a metal cylinder onto the armature shaft and with a hammer striking the metal cylinder against the stop collar figu...

Страница 634: ...tor cannot be cleaned replace the armature 5 Armature for short circuits figure 31 Rotate the armature in a growler with a steel strip such as a 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 comm utator bars are sometimes produced by brush dust or copper dust 6 Armature for opens Look for loose co n n e c t...

Страница 635: ...by poor m otor performance after everything else has been checked out On the 5MT starter motor the coils cannot be replaced separately because of the integral frame construction The frame and field assembly must be replaced To replace the field coils on the 10MT or 27MT a pole shoe spreader and pole shoe screwdriver should be used Care should be exercised in replacing the field coils to prevent gr...

Страница 636: ...Models Spring Coil Arm ature Grommett Housing Drive Brush Washer Bolt Screw Ring Collar Pin Frame Shaft Nut Lead Grounded Brush Holder Insulated Brush Holder Field Coil Connection Support Center Bearing Retaining Screw Shoe Pole F 04213 Figure 23 27MT Components ...

Страница 637: ...ng do not leave the w inding energized more than 15 seconds The current draw w ill decrease as the w inding tem perature increases Turn the switch on and adjust the carbon pile 1 Shift Lever Finger 9 Armature 31 Drive Housing 39 Drive Collar F 04215 Figure 25 Disengaging the Drive Collar from the Shift Lever Fingers Figure 27 Driving the Stop Collar Off the Retaining Ring ...

Страница 638: ...that can measure tenths of an ohm The coil resistance can be determined by dividing the voltage by the current am peres values liste d in S p e cifica tio n s at the end of this section ASSEMBLY SOLENOID Assemble Figure 30 1 New solenoid disc assembly if needed 2 End cover to the solenoid body 3 Screws attaching the end cover 4 Nuts from the S terminal and the motor terminal Figure 29 Replacing Br...

Страница 639: ...the holders 38 2 Screws into the brush holders 3 Brush holders into the brush supports 62 3 Solenoid 22 Battery 23 S Terminal 24 M Terminal 25 BAT Terminal 26 Voltmeter 27 Am m eter 29 Switch 30 Carbon Pile A Checking Solenoid Pull in W inding B Checking Solenoid Hold in W inding F 04222 Figure 33 Solenoid Test Connections Figure 32 Testing the Armature for Grounds ...

Страница 640: ...sembly on the shaft with the pinion gear toward the shaft end 4 Stop collar 39 on the shaft with the cupped end away from the pinion gear 5 Retainer ring 37 on the shaft figure 34 Place the ring on the end of the shaft With a wood block on the top of the ring force the ring onto the shaft with a light hammer blow Slide the ring down and into the shaft groove Do not distort the retainer ring when i...

Страница 641: ...ntains pull in and hold in windings and the motor external wiring is the 1 Disconnect the motor field connector from the solenoid motor terminal and insulate it carefully 2 Connect a battery of the same voltage as the solenoid from the solenoid switch terminal to the solenoid frame 3 Momentarily flash a jumper lead from the solenoid motor terminal to the solenoid frame This will shift the pinion i...

Страница 642: ... made by understanding that if the voltage is slightly higher the rpm will be slightly higher with the current remaining basically unchanged However if the exact voltage is desired a carbon pile connected across the battery can be used to reduce the voltage to the specified value Compare the test results as follows 1 Rated current draw and no load speed indicates normal condition of the starting m...

Страница 643: ...recaution it is suggested that safety glasses be worn when disassembling or assembling the starting motor Remove or Disconnect Figures 40 through 43 Tool Required J 28509 A Bearing Puller Clean the outside of the starter housing removing grease oil mud etc Make scribe marks to show the relationship of the lever housing field frame and end plate to aid in assembly 1 Nut 44 and lead at solenoid term...

Страница 644: ...y cloth Do not use grease dissolving solvents on the field frame armature bearings or drive assembly Inspect Figure 43 Drive End Bearing Brushes and brush holders Make sure they are clean and the brushes are not worn Check by hand that the brush springs are giving firm contact between the brushes and commutator If the springs are discolored or distorted or the brushes worn replace the brush assemb...

Страница 645: ... and a low reading indicates excessive resistance 8 Solenoid pull in winding With all the leads disconnected from the solenoid make the test connections as shown in figure 47 NOTICE To prevent overheating the pull in w inding do n o t leave the w inding energized more than 15 seconds The current draw w ill decrease as the w inding tem perature increases Turn the switch on and adjust the carbon pil...

Страница 646: ...e commutator 3 Gear bearing into the gear by pressing until it is 0 28 to 0 38 mm 0 011 to 0 014 inch below the casting surface figure 48 Lubricate the bearing with lubricant PN 10497186 or equivalent if needed T his grease m aintains lubricating qualities even at temperature extremes 4 Drive end bearing into the drive housing assembly figure 49 Press the bearing until it is 0 25 to 0 45 mm 0 009 ...

Страница 647: ...Nut 44 and lead to the solenoid terminal PINION CLEARANCE CHECK The pinion clearance cannot be adjusted but should be checked afte r reassem bly of the motor Im proper clearance is an indication of worn parts To check pinion clearance perform the follow steps figures 53 and 54 1 Disconnect the motor lead connector from the solenoid motor terminal 2 Connect a 12 volt battery from the solenoid switc...

Страница 648: ...stributor with an integral coil is used on engines without TBI Throttle Body Injection A distributor with a separate coil is used on engines with TBI and the ignition system is then controlled by the computer This EST Electronic Spark Tim ing system may include ESC E le c tro n ic S park C o n tro l R efer to EN G IN E ELECTRICAL SEC 6D in the applicable truck service manual for a description of t...

Страница 649: ...kup coil and magnet which are located between the pole piece and a bottom plate CENTRIFUGAL AND VACUUM ADVANCE Figures 59 and 60 Distributors without EST systems have centrifugal advance weights and springs Some also have vacuum advance units Centrifugal advance is achieved through the rotation of the timer core in relation to the distributor shaft Vacuum advance is achieved by attaching the picku...

Страница 650: ...imer core shaft 26 from the housing 30 Distributors for non EST ignition systems have centrifugal advance w eights and springs These are part of the shaft assembly and are not serviceable Module Components 16 Four wire connector from the pickup coil connector on distributors with ESC figure 65 Pickup coil connector from the module figure 66 Check the vacuum advance unit if equipped and the pickup ...

Страница 651: ...m source fig u re 70 C om pare to Specifications at the end of this section The unit must function with no leak down that is it must hold a vacuum until the vacuum source is released 2 Voltage of the Hall Effect switch if eguipped Connect a 12 volt battery and voltmeter as shown in figure 71 With a knife blade inserted and held against the magnet the voltmeter should read within 0 5 volts of the b...

Страница 652: ...6D 32 ENGINE ELECTRICAL Figure 63 Distributor with Hall Effect Switch Figure 65 Module and Connectors ...

Страница 653: ... and 3 Use the high scale Replace the coil only if both readings are infinite 14 M odule 36 C apacitor 40 W iring Harness C onnector Figure 67 Removing the Module Figure 69 Cap and Seal Electrical performance of the module The module can only be checked with an approved module tester such as J 24642 F or eguivalent Follow the directions exactly that come with the tester 41 C ontact B utton and Spr...

Страница 654: ...tton 41 and seal 42 into the cap figure 69 2 Coil 21 and wiring into the cap figure 62 3 Four bolts holding the coil to the cap 45 43 M agnet 44 B attery 45 V oltm eter A Insert a knife blade straig ht down and against the m agnet F 04240 Figure 72 Checking the Pickup Coil Figure 71 Testing the Hall Effect Switch ...

Страница 655: ...t Pickup coil connector to the module ESC connector if eguipped to the pickup coil connector Wiring harness and capacitor to the other end of the module 11 Module w iring harness and capacitor to the housing with three bolts 12 Shaft assembly into the housing Rotate the shaft to check for even clearance all around between the pickup coil assembly and the teeth on the d is trib u to r sh a ft assem...

Страница 656: ... from the module 14 Lift the locking tab with a screwdriver Pickup coil 11 11 Two screws holding the module to the housing 12 Module 14 5 6 8 9 10 D IS T R IB U T O R S W IT H O U T SEA LED M O DULE CONNECTORS Remove or Disconnect Figure 80 1 Cap Unlatch the spring latches holding the cap to the housing Place a mark on the rotor and on the shaft assembly to help line up the rotor during reassembly...

Страница 657: ...amage Measure Tools Reguired J 24642 F Module Tester 1 Voltage of the Hall Effect switch if eguipped Connect a 12 volt battery and voltmeter as shown in figure 71 With a knife blade inserted and held against the magnet the voltmeter should read within 0 5 volts of the battery voltage If not replace the switch Remove the knife blade The voltmeter should read less than 0 5 volts If not replace the s...

Страница 658: ...ng with silicone grease or an equivalent heat transfer substance NOTICE Be sure to thoroughly coat the bottom of the m odule Failure to do so could result in heat damage to the m odule 1 Module 14 to the housing 30 with two screws 2 Pickup coil 11 Fit the tab on the bottom of the coil into the anchor hole in the housing 3 Pickup coil wiring connector to the module Make sure the locking tab is in p...

Страница 659: ... Thin C washer into the coil 8 Shaft 26 into the housing 9 Tang washer 33 spring retainer 52 spring 51 and driven gear 29 onto the shaft Align the marks on the driven gear housing and shaft assembly 10 Roll pin into the driven gear After assembly turn the shaft by hand to check tooth clearance between the shaft and pickup coil assembly If the clearance needs adjustment loosen and retighten the thr...

Страница 660: ... 5 7 7 1 50 1600 120 6500 120 1105628 12 SI c w 2 4 2 7 4 5 5 0 30 1600 81 6500 78 1105632 12 SI c w 2 4 2 7 4 5 5 0 23 1600 70 6500 66 STARTER SPECIFICATIONS No Load Test 1 0 Volts Starter AMPS RPM Solenoid Part No Series Type Minimum Maximum Minimum Maximum Part No 1113589 27MT 136 120 210 9000 13400 1114247 1113590 27MT 136 120 210 9000 13400 1114558 1998530 5MT 101 50 75 6000 11900 1114530 199...

Страница 661: ...tributor RPM Degree Vacuum Model 1103717 650 0 3 1200 6 6 2050 11113 1973682 1103719 700 0 2 1000 2 5 3000 4 8 1973682 VACUUM ADVANCE SPECIFICATIONS Start Maximum Max Dist Vacuum Model Inches Hg kPa Inches Hg kPa Deg 1973682 7 9 24 32 13 14 42 46 5 LUBRICATION For generator bearing lubrication use only Delco Remy Lubricant No 1948791 or equivalent This lubricant is a pre mium type lithium soap min...

Страница 662: ...6D 42 ENGINE ELECTRICAL SPECIAL TOOLS ...

Страница 663: ...1 18 Lo And Reverse Clutch Assem bly 7A1 18 Lo And Reverse Clutch Backing Plate Selection 7A1 19 Parking P a w l 7A1 18 Reaction Internal Gear And Carrier Assem bly 7A1 18 Reaction Internal Gear And S upport 7A1 19 Lo And Reverse Support Assembly 7A1 20 Reaction Sun Gear And Shell 7A1 21 Input Interal Gear And Output S h a ft 7A1 22 Input Carrier And Sun G e a r 7A1 24 Input Clutch A ssem b ly 7A1...

Страница 664: ...7A1 2 700 R4 AUTOMATIC TRANSMISSION JH0053 700R4 Figure 67 Case and External Parts ...

Страница 665: ...OR 49 SEAL O RING SOLENOID 50 SOLENOID ASSEMBLY 51 BOLT HEX WASHER HEAD SOLENOID 52 PISTON 3 4 ACCUM ULATOR 53 RING OIL SEAL 3 4 ACCUM ULATO R PISTON 54 SPRING 3 4 ACCUM ULATOR 55 BALL 25 DIAMETER 56 PLATE VALVE BODY SPACER ILL NO DESCRIPTION 59 SPRING 1 2 ACCUM ULATOR 60 RING OIL SEAL 1 2 ACCUM ULATO R PISTON 61 PISTON 1 2 ACCUMULATOR 62 COVER PIN ASSEMBLY 1 2 ACC UM 63 BOLT ACCUM ULATOR COVER 64...

Страница 666: ...gth should now be checked If th e pin length is too short or too long be certain to inspect the 2 4 band and reverse input drum for dam age or w e a r w h en disassem bled 1 2 3 4 5 6 7 l 2 3 4 Remove or Disconnect Figures 70 71 72 73 TOOLS REQUIRED J 22269 01 Piston Compressor 4th apply piston 16 Servo return spring 31 Servo pin retainer ring 18 washer 19 and apply pin spring 20 2nd apply piston ...

Страница 667: ... 62 1 2 accumulator piston 61 and seal 60 Spring 59 1 2 Remove or Disconnect Figures 78 79 80 and 81 1 Bolt 75 and manual detent spring assembly 709 2 Electrical wire clips 66 and tube clamps 97 3 Auxiliary valve tube 96 4 Wiring harness retaining washer A and the filter retainer clips 87 5 Bolts 69 and T V lever and bracket assembly 65 6 T V link 64 E3Remove or Disconnect Figures 78 80 81 and 82 ...

Страница 668: ...Retaining Ring Removal Figure 74 Servo Pin Length Transmission End Play 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 misassembled parts during disassembly Tighten Figures 84 and 85 TOOLS REQUIRED J 24773 A Oil Pump Remover J 25022 A End Play Adaptor 245 mm J ...

Страница 669: ...r set to zero pull up on J 24773 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 88 and 89 TOOLS REQUIRED J 24773 A Oil Pump Remover O ring seal 618 All oil pump bolts 5 and washers 6 Oil pump assembly 7 with J 24773 A Oil pump to case seal 8 and gasket 9 Reverse input clutch to oil pump thrust washer 601 ILL NO DESCRIPTION 10 CASE TRANSMISSION...

Страница 670: ...DUIT SOLENOID WIRE 374 BOLT SPEC HEX WASHER HEAD M6 X 1 X 18 375 BOLT HEX HEAD M6 X 1 X 35 376 BOLT HEX HEAD M6 X 1 X 45 JH0064 700 R4 Figure 78 Valve Body Bolt Locations Figure 79 T V Lever and Bracket M I I V 340 MANUAL VALVE 703 INNER DETENT LEVER 705 MANUAL VALVE LINK 709 MANUAL DETENT SPRING ASSEMBLY JH0066 700R4 Figure 80 Manual Valve Link 2 4 Band Reverse Input Clutch Input Clutch and Input...

Страница 671: ...lve Body Assembly COPPER 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 JH0068 700R4 Figure 82 Valve Body Checkballs NOTE 9 CHECKBALL DETENT LO HAS BEEN REMOVED ON 1988 MODELS ILL NO DESCRIPTION 47A GOVERNOR FILTER LOCATION 47B CONVERTER CLUTCH FILTER LOCATION 55E 4 CHECK BALL 3 4 CLUTCH 3 2 EX 55F ...

Страница 672: ...27 Clutch Spring Compressor Bolts 715 and parking lock bracket 710 Important Due to interference the parking pawl may have to be removed before removing or installing the low and reverse piston 2 Parking pawl shaft plug 713 with a 4 screw extractor 3 Parking pawl pivot shaft 712 with a magnet 4 Parking pawl 711 and return spring 714 5 Install tool J 23327 6 Lo and reverse clutch retainer ring 693 ...

Страница 673: ...TOMATIC TRANSMISSION 7A1 11 670 671 672673674 675 676 677 678 679 688 689 690 691 __________________________________________________________________________ JH0071 700R4 R1 Figure 86 Transmission Internal Parts ...

Страница 674: ... SEL 651 RING FORWARD CLUTCH BACKING PLATE RETAINER 652 PLATE 3RD 4TH CLUTCH RING RETAINER 653 PLATE 3RD 4TH CLUTCH APPLY STEPPED 654 PLATE ASSEMBLY 3RD 4TH CLUTCH 655 PLATE 3RD 4TH CLUTCH BACKING SEL ILL NO DESCRIPTION 656 RING 3RD 4TH CLUTCH BACKING PLATE RETAINER 657 BUSHING INPUT SUN GEAR FRONT 658 GEAR INPUT SUN 659 BUSHING INPUT SUN GEAR REAR 661 RET OUTPUT SHAFT TO INPUT CARRIER 662 CARRIER...

Страница 675: ... bore for debris or damage Third accumulator bore for 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 for damage proper torque 38 N m 28 ft lbs Case interior for damaged ring grooves or casting flash clutch plate lugs worn or damaged bushing 76 score...

Страница 676: ...ION SHELL 675 RACE LO REVERSE ROLLER CLUTCH 676 RING LO REVERSE SUPPORT TO CASE RETAINER 678 CLUTCH ASM LO REVERSE ROLLER 679 SUPPORT ASM LO REVERSE CLUTCH 680 SPRING TRANSMISSION LO REVERSE CLUTCH SUPPORT RETAINER 681 CARRIER ASSEMBLY REACTION 682 PLATE ASSEMBLY LO REVERSE CLUTCH 682A PLATE LO REVERSE CLUTCH WAVED 682B PLATE LO REVERSE CL SELECTIVE 683 BEARING ASSEMBLY THRUST REACTION CARRIER SUP...

Страница 677: ...ace the third accumulator retainer and ball assembly Replacement Procedure Third Accumulator Retainer and Ball Assembly Remove or Disconnect Figure 99 and 100 TOOLS REQUIRED 6 3 mm 4 Screw Extractor Third accumulator retainer and ball assembly 80 use 6 3 4 screw extractor 4 Install or Connect Figure 99 and 100 TOOLS REQUIRED 9 5 mm 3 8 in Diameter Metal Rod 705 715 710 ILL NO DESCRIPTION 701 ACTUA...

Страница 678: ...TAINER BALL ASSEMBLY 3RD ACCUM 86 PLUG CASE SERVO JH0049 700R4 Figure 96 Servo Bore Figure 99 Leak Check 3rd Accumulator A C D 80 3RD ACCUMULATOR BORE CASE INTERIOR 2 4 SERVO BORE RETAINER BALL ASSEMBLY 3RD ACCUMULATOR JH0084 700R4 Figure 100 Third Accumulator Retainer and Ball Asm Installation DRIVE UNTIL SCRIBE MARK IS FLUSH WITH CASE JH0085 700R4 Figure 97 Third Accumulator Bore ...

Страница 679: ...tainer 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 accumulator and ball assembly as shown When the scribed line is flush with the case face installation depth is correct ...

Страница 680: ...ng pawl pivot shaft 712 for damage and freeness of fit with the parking pawl Install or Connect Figure 102 Parking pawl 711 and parking pawl return spring 714 into the case Parking pawl pivot shaft 712 into the parking pawl 711 and the case CHECK FOR PROPER OPERATION Retaining plug 713 into the case coat the plug with loc tite sealant or equivalent and install it with a hammer and punch Reaction I...

Страница 681: ... assembly on a flat surface in the following order 1 waved plate 682B 690 662 662 CARRIER ASSEMBLY INPUT COMPLETE 690 SLEEVE OUTPUT SHAFT JH0090 700R4 2 3 4 6 4 Figure 104 Captured Bearing Check 5 fiber and 4 steal plates 682 starting with one fiber plate and alternating with a steal plate Lo and Reverse Clutch Support 679 Apply an evenly distributed load to the top of the Lo and Reverse Support A...

Страница 682: ...RIER ASSEMBLY REACTION 683 BEARING ASSEMBLY THRUST REACTION CARRIER SUPPORT 685 SUPPORT INTERNAL REACTION GEAR 692 BRG REACTION GEAR SUPPORT TO CASE 697 DEFLECTOR OIL HIGH OUTPUT MODELS ONLY JH0092 700R4 Figure 106 Reaction Internal Gear and Carrier Bearing Locations Lo and Reverse Support Assembly l 1 Remove or Disconnect Figure 111 Inner race 675 from the support assembly One retainer ring 677 R...

Страница 683: ...1 3 6 28 1 29m m 1 1 0 7 4 2 38 6m m 0 9 4 2 5 5 7 m m 101 28 1 29m m 1 1 0 7 2 7 4 1 4m m 1 0 7 9 5 3 101 mm 1 2 2 3 2 7 2 m m 1 2 9 JH01 90 700R4 Figure 108 Lo and Reverse Backing Plate Selection Chart 2 Support and roller assembly into the case with the hub down 3 Inner race 675 into the roller assembly 4 Turn inner race 675 while inserting push down for full engagement bottom tangs will be flu...

Страница 684: ...o the reaction carrier index the teeth with the pinion gears 3 Thrust washer 674 onto the lo and reverse support inner race index the four locating ears into the inner race 4 Reaction gear shell 670 onto the reaction sun gear 5 Bronze thrust washer 669 onto the reaction sun shell index tangs into the shell 677 680 679 677 A LOCKED UP B FREEWHEELS 675 RACE LO REVERSE ROLLER CLUTCH 677 RING LO REVER...

Страница 685: ... Shaft 666 for 664 GEAR INPUT INTERNAL 666 SHAFT REACTION CARRIER 668 RING REACTION SHAFT INTERNAL GEAR RETAINER JH0100 700R4 Figure 1 16 Input Internal Gear and Reaction Shaft scored damaged or worn bushings see Bushing Replacement cracked shaft damaged spline or gear teeth under cut around the shaft from interference with the sun gear Input internal gear 664 for Figure 1 15 Input Carrier and Rea...

Страница 686: ...he output shaft 2 3 4 Input Carrier and Sun Gear Install or Connect Figures 116 and 118 Reaction shaft 666 into the input internal gear 664 Retainer ring 668 into the input internal gear Input internal gear and shaft assembly into the sun gear shell index the shaft spline into the reaction carrier Thrust Bearing 663 onto the reaction carrier shaft 2 3 4 Inspect Figures 119 and 120 Input carrier as...

Страница 687: ...0R4 Figure 121 Reverse Input and Input Clutches 3 4 5 6 7 1 2 3 4 5 Disassemble Figures 123 and 124 TOOLS REQUIRED J 23456 Clutch Spring Compressor Press J 25018 Clutch Spring Compressor Place the input clutch assembly 621 on the bench with the turbine shaft through the bench hole The 3 4 clutch plate retainer ring 656 and the backing plate 655 The 3 4 clutch plates 654 The 3 4 clutch apply plate ...

Страница 688: ...utch housing 628 The 3 4 clutch spring assembly 626 The 3 4 clutch apply ring 625 and piston 623 inner and outer lip seals 624 from piston Forward clutch to input housing O ring seal 622 Four turbine shaft oil seal rings 619 Remove or Disconnect Figure 125 TOOLS REQUIRED 4 Screw extractor Straighten the tangs of the retainer and remove the ball Check valve retainer use 4 Screw Extractor Install or...

Страница 689: ...PLATE ASSEMBLY OVERRUN CLUTCH A FORWARD CLUTCH SPRAG ASSEMBLY 637 BEARING ASSEMBLY INPUT SUN GEAR SNAP RING OVERRUN CL HUB RET HUB OVERRUN CLUTCH RETAINER RACE ASSEMBLY SPRAG FORWARD SPRAG ASSEMBLY RETAINER RINGS SPRAG ASSEMBLY RACE FORWARD CLUTCH OUTER 646 PLATE FORWARD CLUTCH APPLY 648 PLATE FORWARD CLUTCH WAVED 649 PLATE ASSEMBLY FORWARD CLUTCH 650 PLATE FORWARD CLUTCH BACKING SEL 651 RING FORW...

Страница 690: ...8 1 Position the input housing and shaft assembly on the bench with the turbine shaft through a bench hole 2 Inner and outer 3 4 clutch lip seals 624 on the 3 4 clutch piston seal lips must face away from the piston hub lubricate the seals with transmission fluid 3 The 3 4 clutch piston 623 into the input housing as shown Figure 126 Input Housing Check Valve Ball USED WITH USED WITH 298 MM CONVERT...

Страница 691: ... 4 clutch apply ring Forward clutch assembly onto the 3 4 clutch spring assembly the forward clutch piston apply legs must be indexed with the 3 4 clutch apply ring legs 6 J 29883 on the input housing as shown 7 Apply ring and forward clutch assembly into the input housing as shown hold the assembly by the apply ring legs during installation do not let the forward clutch piston separate from the h...

Страница 692: ...of plates in the input housing index the plate as shown Thrust bearing assembly 637 onto the input clutch hub the inside race must face the input housing hub retain with petrolatum 3 Align the tangs on the two composition overru clutch plates Forward Clutch Sprag Assembly 1 2 3 L Disassemble Figure 135 Forward sprag outer race 644 Overrun clutch hub retaining snap ring 638 and clutch hub 639 Forwa...

Страница 693: ...nd retainer assembly into the sprag assembly to assemble hold the outer race in your left hand with your fingers supporting the sprag at the recessed side of the outer race insert the race and retainer assembly by pushing in and turning to the left The remaining retainer ring onto the sprag assembly Overrun clutch hub 639 onto the wear plate Overrun clutch hub retaining snap ring 638 into the snap...

Страница 694: ... ring retainer plate 652 for bent tangs flatness Assemble Figures 1 3 9 1 4 0 1 4 1 and 142 Forward clutch apply plate 646 into the input clutch housing index as shown Waved steel forward clutch plate 648 into the input clutch housing index as shown The remaining forward clutch plates 649 into the input clutch housing start with steel plate and alternate with a composition Forward clutch selective...

Страница 695: ...crew to obtain proper height Use J 36418 2A to size the seals after installation Reverse Input Clutch Assembly Disassemble Figure 148 and 149 1 2 3 TOOLS REQUIRED J 23327 Clutch Spring Compressor J 25018 Clutch Spring Compressor Adaptor Retaining ring 614 from reverse input housing Backing plate 613 Clutch plates 612 and belleville steel plate 611 ILL NO 621 646 64 8 649 6 5 0 651 6 5 2 653 6 5 4 ...

Страница 696: ...r seals 608 on the piston lips must face away from the hub as shown lubricate with transmission fluid 2 Piston 607 into the housing and drum assembly use an 8 mm feeler gage to position the lip seals FORWARD CLUTCH BACKING PLATE SELECTION ALL MODELS BACKING PLATE TRAVEL 75m m 1 60m m 0 3 0 0 6 3 PLATE THICKNESS 6 9 2m m 7 07m m 2 7 2 2 7 8 6 3 3m m 6 48m m 2 4 9 2 5 5 5 74m m 5 89m m 2 2 5 2 3 2 5...

Страница 697: ...put clutch assembly 605 onto the input clutch assembly index the reverse input clutch plates with the input clutch hub make certain all clutches are fully engaged 2 3 Assemble Figure 156 Reverse input and input clutch assembly into the transmission case index the 3 4 clutch plates with the input internal gear MODEL BACKING PLATE TRAVEL BACKING PLATE Use Backing Plate Which Gives Correct Travel DIM...

Страница 698: ...assemble Figure 160 Converter clutch apply valve train compress converter clutch apply spring 228 with a screwdriver remove retaining ring 225 slowly release the spring tension stop valve 226 converter clutch apply valve 227 and two converter clutch valve springs Pressure relief ball 231 ball is under strong spring pressure cover the ball with a cloth when removed Pressure regulator assembly 218 2...

Страница 699: ...E FORWARD CLUTCH BACKING SEL 651 RING FORWARD CLUTCH BACKING PLATE RETAINER 652 PLATE 3RD 4TH CLUTCH RING RETAINER 65 3 PLATE 3RD 4TH CL APPLY STEPPED 6 5 4 PLATE ASSEMBLY 3RD 4TH CLUTCH 655 PLATE 3RD 4TH CLUTCH BACKING SEL 656 RING 3RD 4TH CLUTCH BACKING PLATE RETAINER JH01 29 700R4 Figure 147 Input Clutch Assembly Oil seal assembly for damage or wear Pump Body J rji Clean Wash and air dry all pa...

Страница 700: ...ring 212 10 Pump slide spring 209 11 Oil seal assembly 2 retainer 94 use J 25016 Oil Pump Cover Assemble Figures 160 and 163 1 2 3 4 5 6 9 Pressure relief ball 231 spring 232 and rivet 230 Inner 229 and outer 228 converter clutch valve springs into the converter clutch valve bore Converter clutch valve 227 Stop valve 226 Retaining ring 225 Pressure regulator valve 218 into the pressure regulator b...

Страница 701: ...VEL 1 02m m 1 94m m 0 4 0 0 7 6 PLATE THICKNESS IDENTIFICATION 7 6 0m m 7 45m m 2 9 9 2 9 3 5 6 9 4 m m 6 7 9m m 2 7 3 2 6 7 6 6 2 8 m m 6 1 3m m 2 4 7 2 4 1 7 5 6 2m m 5 47m m 2 2 1 2 1 5 8 JH019 1 700R4 Figure 152A Reverse Input Backing Plate Selection Chart 605 607 611 612 605 HOUSING DRUM ASSEMBLY REVERSE INPUT CLUTCH 607 PISTON A S M REVERSE INPUT CLUTCH 609 SPRING A S M REVERSE INPUT CLUTCH ...

Страница 702: ...re 155 Reverse Input and Input Clutches 605 A BAND ANCHOR PIN LOCATION 10 CASE TRANSMISSION 48 PIN BAND ANCHOR 605 HOUSING DRUM ASSEMBLY REVERSE INPUT CLUTCH 621 HOUSING SHAFT ASSEMBLY INPUT JH01 37 700R4 Figure 156 Installing Input Clutch 10 CASE TRANSMISSION 602 BAND ASSEMBLY 2 4 605 HOUSING DRUM ASSEMBLY REVERSE INPUT CLUTCH JH01 38 700R4 Figure 157 2 4 Band Assembly Installed do not twist the ...

Страница 703: ...ws no end play the selective washer and thrust bearing have been misassembled Assemble Figure 172 O ring seal 618 into the groove in the end of the turbine shaft Important Figure 173 There should be clearance between the reverse input clutch and the reaction sun gear shell This clearance can be observed at the point shown in 700 R4 Figure 173 D o n o t try to shim the internal parts because of thi...

Страница 704: ... BOOST 221 SLEEVE REVERSE BOOST VALVE 222 VALVE T V BOOST 223 BUSHING T V BOOST 2 2 4 RING OIL PUMP REVERSE BOOST VALVE RETAINING 2 2 5 RING OIL PUMP CONVERTER CLUTCH VALVE RETAINING 2 2 6 VALVE STOP 227 VALVE CONVERTER CLUTCH 2 2 8 SPRING CONVERTER CLUTCH VALVE OUTER 229 SPRING CONVERTER CLUTCH VALVE INNER 2 3 0 RIVET PRESSURE RELIEF BOLT 231 BALL PRESSURE RELIEF 232 SPRING PRESSURE RELIEF 233 RI...

Страница 705: ... connectors cut or damaged O ring 49 n ILL NO DESCRIPTION 218 VALVE PRESSURE REGULATOR 219 SPRING PRESSURE REGULATOR VALVE 220 VALVE REVERSE BOOST 221 SLEEVE REVERSE BOOST VALVE 222 VALVE T V BOOST 223 BUSHING T V BOOST 224 RING OIL PUMP REVERSE BOOST VALVE RETAINING 225 RING OIL PUMP CONVERTER CLUTCH VALVE RETAINING 226 STOP VALVE 227 VALVE CONVERTER CLUTCH 228 SPRING CONVERTER CLUTCH VALVE OUTER...

Страница 706: ...ASSEMBLY JH0147 700R4 1 DIAL INDICATOR 2 278mm 11 BOLT 3 LOCK NUT J 24773 A JH0073 700R4 Figure 169 J 25022 A Installed Valve Body and Associated Parts 1 The 3 4 accumulator pin 77 into the case 2 The 3 4 accumulator piston seal 53 onto the 3 4 accumulator piston 3 The 3 4 accumulator piston 52 onto the pin the end with three legs must face the valve body 4 The 3 4 accumulator piston spring 54 Ins...

Страница 707: ...e body to spacer plate gasket 89 gasket indentified by a V 298 A SHAFT TURBINE 618 SEAL 0 RING TURBINE SHAFT SELECTIVE WASHER 621 HOUSING SHAFT ASSEMBLY INPUT JH0109 700R4 Figure 172 Turbine Shaft 0 Ring Seal A AS INSTALLED THESE TWO PARTS HAVE A NORMAL END CLEARANCE OF APPROX 3 8 MM 150 IN 10 CASE TRANSMISSION 605 HOUSING DRUM ASSEMBLY REVERSE INPUT CLUTCH 670 SHELL REACTION SUN JH0149 700R4 Figu...

Страница 708: ... M RED RED TA M TBM RED DK GREEN YAM DK GREEN YELLOW YDM DK GREEN DK GREEN YXM DK GREEN RED YMM YELLOW YELLOW YZM YELLOW VIOLET JH01 51 700R4 Figure 176 1 2 and 3 4 Accumulator Spring Chart Remove pressure switches Clean 13 1 L9 2 All valves springs bushings and control valve body in clean solvent Dry using compressed air Inspect All Valves and Bushings For Porosity Scoring Nicks Scratches Springs...

Страница 709: ...Screw Extractor Orifice cup plug 359 Use modified 3 screw extractor Install or Connect Tools Required 3 8 Rod Orifice cup plug 359 Use 3 8 rod seat flush 2 3 4 4 Assemble Figure 181 Auxiliary accumulator valve train exactly as shown Notice the valve lands Assemble Figure 181 Piston oil seal ring 369 onto piston 367 lubricate with petrolatum Piston 367 Accumulator spring 370 Cover 371 and 3 bolts 3...

Страница 710: ...7A1 48 700 R4 AUTOMATIC TRANSMISSION ...

Страница 711: ...A S M PRESSURE T C C SIGNAL 3 5 0 BODY CONTROL VALVE 351 PLUG T V LIMIT 35 2 PLUG VALVE BORE 12 5 O D 35 4 PLUG CONVERTER CLUTCH SHIFT VALVE BORE ECM CONTROLLED VEHICLES 35 5 PLUG CONVERTER CLUTCH T V BUSHING BORE ECM CONTROLLED VEHICLES JH0153 700R4 Figure 179 Control Valve Assembly Legend COPPER FLASH 91 AU X VALVE BODY 359 55B 1 2 55A 2 CHECKBALL 3RD CLUTCH ACC UM 55B 12 CHECKBALL FORWARD CLUTC...

Страница 712: ...TENT LEVER 705 MANUAL VALVE LINK 709 MANUAL DETENT SPRING ASSEMBLY Figure 182 Manual Valve Link torque to 22 N m 18 ft lbs Install or Connect Figure 186 2 The 1 2 accumulator piston seal 60 onto the 1 2 1 filter seal 70 onto the oil filter accumulator piston 61 3 The 1 2 accumulator piston 61 into the 1 2 lubricate with transmission fluid accumulator cover and pin assembly 62 2 Oil filter 71 the t...

Страница 713: ...ING LOCK 715 BOLT PARKING LOCK BRACKET JH0067 700R4 Figure 185 Outside Electrical Connector 10 70 71 72 73 74 93 2 4 Servo Assembly Measure Figure 187 1 TOOLS REQUIRED J 33037 Band Apply Pin Tool 1 Install J 33037 as shown with apply pin 29 2 Apply 11 0 N m 100 in lbs torque 3 If white line A appears in the gage slot B pin length is correct 4 Use pin selection chart to determine the correct pin le...

Страница 714: ... 23 and outer 24 seals on the 2nd apply piston retain with petrolatum O ring seal 21 on servo piston housing 2ND APPLY PISTON HOUSING APPLICATION MODEL YAM YDM YMM FAM FMM MAM MCM MDM MFM MKM MLM MRM MTM MXM PRM TAM TBM THM TJM TKM TLM YNM YPM YTM YXM FJM MHM MPM MWM MZM PAM PBM PCM TNM TUM TXM YKM YWM YZM PISTON DIMENSION A 44 64 mm 1 78 57 85 mm 2 28 63 10 mm 2 48 HOUSING DIMENSION B 45 54 mm 1 ...

Страница 715: ... 84 3 Weights 4 Valve 5 Driven gear 83 Drive out the retainer pin 82 with a small punch Support the governor assembly sleeve on plates installed in the exhaust slots Push out the gear with an arbor press and a long punch a Clean Wash all parts in solvent Air dry and blow out passages Assemble 1 Install a new governor drive gear support the governor or plates through the exhaust slots press gear 83...

Страница 716: ... 31 SPRING SERVO RETURN JH0057 700R4 85 84 A B C D E 82 83 A GOVERNOR ASSEMBLY A VALVE B SECONDARY WEIGHT C PRIMARY WEIGHT D WEIGHT SPRING E SLEEVE AND CARRIER 82 DRIVEN GEAR RETAINING PIN 83 DRIVEN GEAR 84 WEIGHT PINS 85 THRUST CAP JH01 57 700R4 Figure 193 Governor Assembly Install or Connect Figures 193 194 1 Governor assembly 45 into the governor bore 2 Governor Cover 46 apply sealant such as l...

Страница 717: ... sleeve past the machined surface on the output shaft Seal ring 35 on the case extension Case extension 36 and bolts 37 or stud 100 and nut 98 position extension so the speedometer bore is on the governor side of the case torque to 35 N m 26 ft lbs Remove case extension oil seal 89 pry out with a screwdriver install new seal with J 21426 Speedometer driven gear 44 and assembly 43 or speed sensor 9...

Страница 718: ... CASE EXTENSION OIL 40 RETAINER SPEEDO DRIVEN GEAR FITTING 41 BOLT WASHER ASSEMBLY 42 SEAL 0 RING SPEEDO FITTING TO CASE EXTENSION 4 3 FITTING ASSEMBLY SPEEDO DRIVEN GEAR 44 GEAR SPEEDO DRIVEN 45 GOVERNOR ASSEMBLY 46 COVER GOVERNOR 99 SPEED SENSOR INTERNAL TRANSM ISSION 100 BOLT SPEEDO SENSOR RETAINING 6 8 7 SHAFT OUTPUT 6 8 8 CLIP SPEEDO DRIVE GEAR 6 8 9 GEAR SPEEDO DRIVE 6 9 0 SLEEVE OUTPUT SHAF...

Страница 719: ... 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 Refer to Section 7A The converter bolt hole threads are damaged Correct with thread insert Refer to Section 6A Flushing the torque converter is not recommended 0Install or Connect 1 Torque converter 1 2 J 21366 converter holding strap 3 Remove transmissio...

Страница 720: ...UTER 629 SEAL FORWARD CLUTCH INNER OUTER 631 SEAL OVERRUN CLUTCH INNER OUTER 637 BEARING ASSEMBLY INPUT SUN GEAR ILL NO DESCRIPTION 6 6 3 BEARING ASSEMBLY THRUST INPUT CARRIER TO REACTION SHAFT 6 6 9 WASHER THRUST REACTION SHAFT SHELL 6 7 4 WASHER THRUST RACE REACTION SHELL 683 BEARING ASSEMBLY THRUST REACTION CARRIER SUPPORT 692 BRG REACTION GEAR SUPPORT TO CASE 69 6 SEAL TRANSM ISSION LO REVERSE...

Страница 721: ... LB PUMP ASSY TO CASE 7 M8 1 2 5 x 6 0 0 22 N m 18 FT LB VALVE BODY TO CASE 15 M6 1 0 x 5 0 0 11 N m 8 FT LB CASE EXTENSION TO CASE 4 M 10 1 5 0 x 3 0 0 34 N m 26 FT LB OIL PASSAGE COVER TO CASE 3 M6 1 0 x 1 6 0 11 N m 8 FT LB M A N U A L SHAFT TO INSIDE DET LEVER 1 M 10 1 50 NUT 31 N m 23 FT LB SOLENOID ASSY TO PUMP 2 M 6 1 0 x 1 2 0 11 N m 8 FT LB PRESSURE PLUGS 1 4 V e 27 11 N m 8 FT LB TRANSM ...

Страница 722: ... BUSHING REVERSE INPUT CLUTCH FRONT 605 HOUSING DRUM ASSEMBLY REVERSE INPUT CLUTCH 606 BUSHING REVERSE INPUT CLUTCH REAR JH0169 700R4 3 203 BUSHING OIL PUMP BODY BODY PUMP J 8092 3 BUSHING OIL PUMP BODY 203 BODY PUMP 94 BUSHING REVERSE INPUT CLUTCH FRONT HOUSING DRUM ASSEMBLY REVERSE INPUT CLUTCH BUSHING REVERSE INPUT CLUTCH REAR J 3 4 1 96 1 2 4 BUSHING STATOR SHAFT FRONT 90 BUSHING STATOR SHAFT ...

Страница 723: ...CTION CARRIER SHAFT 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 SUN GEAR REACTION SUN 672 BUSHING REACTION SUN 673 GEAR REACTION SUN JH01 70 700R4 Figure 207 Bushing Replacement Procedure BUSHING REPLAC EM ENT PROCEDURE PROTECT PARTS WITH WOOD BL...

Страница 724: ...7A1 62 700 R4 AUTOMATIC TRANSMISSION ...

Страница 725: ...e the reamer and dip in transmission fluid to clean After the reamer reaches the end of the bore and bottoms on the governor support pin rotate the reamer ten additional revolutions Remove the reamer Be certain to rotate during removal to prevent scoring the bore Remove the tools and thoroughly clean the case Install holding fixture J 8763 and mount in vise Remove file any excess material from the...

Страница 726: ...7A1 64 700 R4 AUTOMATIC TRANSMISSION Figure 210 Special Tools ...

Страница 727: ...d Gear Unit A ssem b ly 7A2 24 Intermediate Clutch Assembly 7A2 24 Direct Clutch Assembly and Front B a n d 7A2 25 Forward Clutch A ssem b ly 7A2 25 Turbine Shaft R em oval 7A 2 26 Oil Pump Assem bly 7A 2 29 Pump B ody 7A2 29 Gear Clearance 7A2 29 Pump C o v e r 7A 2 30 Rear Unit End Play Check 7A2 31 Front Unit End Play C h eck 7A2 32 Governor Assembly 7A2 32 Driven Gear Replacem ent 7A2 32 Rear ...

Страница 728: ...7A2 2 400 475 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts HH0021 400 R1 ...

Страница 729: ...N ASSEMBLY GOVERNOR 53 SCREW HEX HD WASHER 54 SOLENOID ASSEMBLY 55 GASKET SOLENOID 56 GASKET VALVE BODY TO SPACER PLATE 57 PLATE VALVE BODY SPACER 58 GASKET SPACER PLATE TO CASE 59 BALL 2 5 DIA 60 PISTON FRONT SERVO 61 WASHER FRONT SERVO 62 PIN FRONT SERVO PISTON 63 RETAINER FRONT SERVO SPRING 64 SPRING FRONT SERVO PISTON 65 BOLT HEX HD 5 1 6 1 8 X 62 SERVO COVER TO CASE 66 COVER REAR SERVO 67 GAS...

Страница 730: ...or electrical connector 2 Screws 53 and solenoid 54 Be careful not to press against solenoid cover 3 Valve body to spacer plate gasket 56 spacer plate 57 and spacer plate to case gasket 58 37 SCREW CONICAL WASHER ASSEMBLY 38 PAN TRANSMISSION 39 GASKET TRANSMISSION OIL PAN 40 MAGNET CHIP COLLECTOR 41 BOLT SHOULDER FILTER TO VALVE BODY 42 FILTER ASSEMBLY TRANSMISSION OIL 43 SPACER VALVE BODY TO FILT...

Страница 731: ...igure 11 Governor Assembly 4 Remove or Disconnect Figure 12 1 Bolts 19 cover 20 and gasket 21 2 Governor assembly 22 Internal Transmission Speed Sensor I T S S Models 3 Retaining bolt 83 4 Speed sensor 81 with o ring 82 Front End Play Check 2 3 4 5 Measure Figures 13 and 14 Tools Required J 6125 Slide Hammer Bolt J 8001 Dial Indicator Remove oil pump bolt 4 and washer 5 at the 10 o clock position ...

Страница 732: ...o Pin Gage J 2 1 3 7 0 1 0 U GAGING STEPS LOCATED ON THREE SIDES OF TOOL Figure 10 Gage Pin JH01 60 400 6 7 Select correct washer from chart Remove tools 9 Important During reassembly Front End Play Check must be repeated to verify accuracy of selective thrust washer 207 Figure 19 Case Extension Assembly Remove or Disconnect Figure 15 1 Bolts 23 and or nuts 24 extension 27 2 Rear seal 26 bearings ...

Страница 733: ...sconnect Figures 18 and 19 Tool Required J 24773 1 Oil Pump Remover 1 Bolts 4 and washers 5 2 Oil pump assembly 6 3 Pump seal 7 and gasket 8 Figure 13 Front Unit End Play Check Parking Lock Pawl and Actuator Assembly 1 4 1 Remove or Disconnect Figure 20 and 21 1 Nut 703 and pin 704 2 Detent lever 707 and actuator 708 3 Bolts 701 and parking pawl bracket 702 4 Spring 710 and retainer 711 5 Shaft 71...

Страница 734: ... TO CASE 33 BUSHING 34 GASKET CASE TO EXTENSION 80 STUD CASE TO CASE EXTENSION HH0034 400 Figure 15 Removing Case Extension Assembly Forward Clutch Assembly Remove or Disconnect Figure 22 Forward clutch assembly 602 618 Grasp turbine shaft and lift THICKNESS INCH IDENTIFICATION NOTCH AND OR NUMERAL 0 7 4 078 None 1 082 086 ON SIDE OF 1 TAB 2 09 0 094 ON SIDE OF 2 TABS 3 09 8 102 ONE END OF 1 TAB 4...

Страница 735: ... DETENT 70 8 ACTUATOR ASSEMBLY PARKING LOCK 709 PLUG PARKING PAWL SHAFT 710 SPRING PARKING PAWL RETURN 71 1 RETAINER PARKING PAWL SHAFT 712 SHAFT PARKING PAWL LOCK 713 PAWL PARKING LOCK HH0102 400 Figure 21 Removing Parking Lock and Actuator Assembly 71 701 BOLT HEX HD 5 1 6 1 8 X 62 702 BRACKET PARKING LOCK 70 3 NUT HEX 3 8 24 704 PIN INSIDE DETENT LEVER 705 SHAFT M ANUAL 706 SEAL ASSEMBLY M ANUA...

Страница 736: ...assembly Center Support and Gear Unit Assembly 1 2 3 4 5 6 Remove or Disconnect Figures 25 26 and 27 Tool Required J 6116 Gear Unit Holding Fixture J 21795 Main Shaft Tool Center support bolt 79 Snap ring 645 Center support assembly 646 654 Sun gear shaft 664 Gear unit assembly 656 697 place in J 6116 fixture Rear band 672 thrust washer 695 selective thrust washer 696 Figure 23 Removing Direct Clu...

Страница 737: ...8 400 R1 Inspect Figure 30 Case 10 for cracks porosity and connected passages Case extension 27 for cracks porosity scored bushing 30 All threaded holes for damage 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 torque 26 30 lbs ft 35 41 N m Intermediat...

Страница 738: ...TE 23 BOLT HEX HD 3 8 1 6 X 1 CASE EXTENSION TO CASE 24 NUT HEX 3 8 24 STUD 25 WASHER FLAT 26 SEAL CASE EXTENSION 27 CASE EXTENSION ASSEMBLY 28 BEARING 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 Figure 28 Transmission Case And Extension Assembly ...

Страница 739: ...400 475 AUTOMATIC TRANSMISSION 7A2 13 Figure 29 Internal Parts H H 0043 400 R2 ...

Страница 740: ... 9 GUIDE INTERMEDIATE CLUTCH 6 5 0 PISTON INTERMEDIATE CLUTCH 651 SEAL INTERMEDIATE CLUTCH INNER 652 SEAL INTERMEDIATE CLUTCH OUTER 65 3 RING OIL SEAL PUMP COVER 65 4 SUPPORT CENTER 6 5 5 BUSHING 6 5 6 WASHER THRUST SUPPORT REACTION DRUM 657 RING SNAP CENTER SUPPORT CASE 6 5 8 ROLLER ASSEMBLY LOW CLUTCH 65 9 RING REACTION DRUM SPACER 6 6 0 RACE THRUST BEARING TO CENTER SUPPORT 661 BEARING NEEDLE T...

Страница 741: ...704 11 Parking lock bracket 702 with bolts 701 ILL NO DESCRIPTION 703 NUT HEX 3 8 2 4 704 PIN INSIDE DETENT LEVER 705 SHAFT M ANUAL 706 SEAL ASSEMBLY M ANUAL SHAFT 707 LEVER INSIDE DETENT 708 ACTUATOR ASSEMBLY PARKING LOCK 709 PLUG PARKING PAWL SHAFT 710 SPRING PARKING PAWL RETURN 71 1 RETAINER PARKING PAWL SHAFT 712 SHAFT PARKING PAWL LOCK 713 PAWL PARKING LOCK HH0102 400 Figure 32 Installing Par...

Страница 742: ...r 693 for wear or cracks Main shaft 681 for scored damaged or worn bushings see Bushing Replacement Procedure SPEEDOMETER DRIVE GEAR SPEED SENSOR ROTOR REPLACEMENT FIGURE 36 Tools Required J 21427 01 Speedometer Gear Puller Adapter J 8433 Speedometer Gear Puller J 5590 Speedometer Gear Installer J 36352 3 Rotor Installer Mechanical Press J 36352 5 Rotor Installer Mechanical Press Do not remove rot...

Страница 743: ...E THRUST BEARING TO SUN GEAR 68 3 BEARING NEEDLE THRUST 68 4 RACE THRUST BEARING TO REAR INTERNAL GEAR 68 5 GEAR REAR INTERNAL 686 RACE THRUST BEARING TO SUN GEAR 68 7 BEARING NEEDLE THRUST 688 RACE THRUST BEARING TO OUTPUT SHAFT 68 9 RING SNAP 69 0 BUSHING OUTPUT SHAFT 691 SHAFT OUTPUT 692 CLIP SPEEDOMETER DRIVE GEAR 69 3 GEAR SPEEDOMETER DRIVE 6 9 4 RING SNAP OUTPUT FRONT INT GEAR 6 9 5 WASHER T...

Страница 744: ...play should be 009 024 228 610 mm cracks or damage to band apply surface Roller clutch assembly for damage to rollers springs cage Sun gear 665 and sun gear shaft 664 for nicked scored or worn bushings 663 see Bushing Replacement Procedure damaged splines or teeth cracks Pinion Gear Replacement Procedure Reaction Carrier Assembly 1 Remove or Disconnect Figures 42 43 and 44 Stake marks from pinion ...

Страница 745: ...roller needle bearings 668 1 Inspect Pinion pocket thrust surfaces for burrs Reaction carrier 666 for cracks damage or wear Assemble 1 Needle bearings 668 in pinion gears 669 2 Bronze washers 670 and steel washers 667 as shown 3 Pinion gear assemblies into carrier 666 4 Pinion pins 671 headed end of pins must be flush with carrier face 5 Stake pins at three points with blunt chisel 666 A 1 2 DRILL...

Страница 746: ...gures 46 and 47 Roller clutch race inside center support 654 for scratches wear or damage Center support 654 for cracks damaged lugs Oil rings 653 and ring grooves for damage burrs or cuts Air check oil passages Figure 49 Intermediate clutch piston 650 for cracks or damage Sealing surfaces and seal grooves for scratches or other damage Springs 648 for collapsed coils or distortion Constant bleed o...

Страница 747: ...tationary Center support 654 should turn counter clockwise only 65 4 65 6 65 8 659 666 67 5 ILL NO DESCRIPTION 6 5 4 SUPPORT CENTER 6 5 6 WASHER THRUST SUPPORT REACTION DRUM 65 8 ROLLER ASSEMBLY LOW CLUTCH 6 5 9 RING REACTION DRUM SPACER 6 6 6 CARRIER ASSEMBLY REACTION 6 7 5 CARRIER ASSEMBLY OUTPUT HH0058 400 R1 Installing Spacer Ring and Roller Clutch Assembly Figure 50 Direct Clutch and Intermed...

Страница 748: ...er 630 and outer 631 clutch piston seals and grooves with transmission fluid 2 Inner seal 630 and outer seal 631 with lips facing away from spring pockets 3 Center seal 632 Direct Clutch Piston Install or Connect Figure 54 and 55 4 1 2 3 4 5 6 Tools Required J 21362 Seal Protector J 21409 Piston Installer J 21664 Adapter J 21362 on housing 633 hub Piston 629 inside J 21409 J 21409 and piston into ...

Страница 749: ... 3 HOUSING DIRECT CLUTCH _______________________________________________________ H H 0 0 6 3 4 0 0 R 1 Figure 54 Installing Direct Clutch Piston ILL NO DESCRIPTION 62 5 RING SNAP DIRECT CLUTCH 62 6 RETAINER RELEASE SPRING 63 3 HOUSING DIRECT CLUTCH H H 0 0 6 0 4 0 0 R 1 Figure 53 Direct Clutch and Intermediate Roller Figure 55 Installing Piston Release Spring Retainer Assembly 1988 THM 4 0 0 CLUTC...

Страница 750: ...o case Locate J 23093 into the center support 654 direct clutch passage through case 10 Apply pressure on J 23093 in direction ofarrow Figure 60 seating the center support splines against the case splines Case to center support bolt 79 torque to 20 25 lbs ft 27 34 N m Snap ring 645 L Intermediate Clutch Assembly Inspect Figure 61 Clutch plates 642 for wear pitting flaking or cracks in lining Clutc...

Страница 751: ...Unit Assembly 1 Direct clutch assembly 619 638 onto the intermediate clutch 2 Front band 639 Forward Clutch Assembly Disassemble Figure 64 and 65 Tools Required J 21795 1 wear pitting flaking or cracks in lining hJi Assemble Figure 61 and 62 1 Waved plate 644 if used 2 Steel plates 643 and composition plates 642 alternately refer to chart 3 Intermediate clutch backing plate 641 4 Snap ring 640 64 ...

Страница 752: ...tes 613 and 614 5 Waved clutch plate 611 or dished plate 612 6 Snap ring 609 and release spring retainer 608 with J 4670 01 and J 21364 7 Piston release springs 607 piston 606 Important 9 Unless forward clutch housing 602 and turbine shaft 601 are damaged disassembly is not necessary Turbine Shaft Removal 1 Place housing 602 in mechanical press with turbine shaft 601 down 2 Remove turbine shaft 60...

Страница 753: ...tch housing 602 approximately 1 8 Continue installing in small steps checking frequently to make sure connection is straight Assemble Figure 64 65 and 6 6 Tools Required J 21409 Seal Protector J 21362 Piston Installer Lubricate new inner seal 605 and outer seal 604 with transmission fluid Lubricate seal grooves with petrolatum Seals 604 and 605 on piston 606 with lips facing away from spring pocke...

Страница 754: ...age in pump Install forward clutch assembly 602 618 with turbine shaft 601 into transmission J9 Inspect Figure 69 Figure 69 Air Checking Forward Clutch 601 SHAFT TURBINE 60 2 HOUSING FORWARD CLUTCH 61 8 HUB DIRECT CLUTCH DRIVING HH0075 400 Figure 70 Installing Forward Clutch Housing 1988 THM 4 0 0 CLUTCH PLATE APPLICATION CHART FORWARD CLUTCH MODELS NO OF FLAT STEEL PLATES NO OF WAVED STEEL PLATES...

Страница 755: ...400 Figure 71 Oil Pump Assembly Oil Pump Assembly Disassemble Figure 71 1 2 3 4 5 6 N O T IC E Regulator spring 214 is tightly compressed Use care when removing bushing 212 Retaining ring 211 Pressure regulator and boost valve assemblies 212 217 Bolts 203 204 and 205 Important 9 Before removing gears 209 and 210 from pump body mark gear faces to ensure reassembly to same position Pump drive gear 2...

Страница 756: ...COVER TO BODY 205 BOLT 5 1 6 1 8 X 1 75 COVER TO BODY HH0010 400 Figure 73 Pump Cover Attaching Screws 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 215 and spring 214 in pressure regulator bore 5 Regulator boost valve 213 into boost valve bushing 212 ...

Страница 757: ...aft 691 set indicator to 0 2 Move output shaft 691 in and out proper end play is 007 019 178 mm 483 mm 3 Remove tools and correct if necessary 203 BOLT 5 1 6 1 8 X 1 00 COVER TO BODY 204 BOLT 5 1 6 1 8 X 1 50 COVER TO BODY HH0078 400 205 BOLT 5 16 18 X 1 75 COVER TO BODY J 2 1 3 6 8 HH01 31 400 Figure 77 Rear Unit End Play Check THICKNESS INCH IDENTIFICATION NOTCH AND OR NUMERAL 07 4 078 None 1 08...

Страница 758: ... solvent and air dry Inspect Sleeve 407 for nicks burrs or galling and free operation in case bore Valve 402 for damage and operation in bore of sleeve 407 Driven gear 409 for damage Springs 403 for distortion damage Weights 404 and 405 for operation in retainers free or free i j Measure Figure 82 Valve opening at entry with weights minimum clearance is 020 51 mm Valve opening at exhaust with weig...

Страница 759: ...Transmission Speed Sensor I T S S models 4 Inspect Sensor 81 for porosity cracks or damage o ring 82 and o ring groove for nicks or damage Speed sensor bore in case for porosity scoring or damage Install or Connect Figure 85 1 Governor 22 into case 10 2 Governor cover 20 and gasket 21 with bolts 19 Figure 83 Installing Driven Gear 3 Lubricate speed sensor bore in case with petroleum jelly 4 Speed ...

Страница 760: ...re with the hex nut facing the parking pawl linkage Fasten with two 5 16 18 x 1 screws and torque to 18 lbs ft 24 N m 1 2 3 4 Make sure J 21370 10 moves freely in the tool and pin bore 5 To determine correct pin length apply 25 lbs ft Torque to the nut on the gage 6 For pin selection see Figure 88 Rear Servo Accumulator Inspect Figure 89 Remove retaining ring 68 from rear band apply pin 77 and ins...

Страница 761: ...etaining ring 68 Install or Connect Figure 89 1 Assembly in bore 2 Cover 66 gasket 67 and bolts 65 Front Servo Assembly Inspect Figure 90 Servo piston 60 for porosity or damage ring groove damage 65 BOLT HEX HD 5 1 6 1 8 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 SERVO PISTON 71 RING OIL SE...

Страница 762: ...g Solenoid and Spacer Plate 4 5 6 7 9 Six check balls 59 in case Spacer plate to case gasket 58 Valve body spacer plate 57 Valve body to spacer plate gasket 56 Gasket 55 and solenoid assembly 54 with screw 53 finger tight Wire connector to case connector Control Valve Assembly 1 2 3 4 5 Disassemble Figures 93 94 and 95 J 21885 Piston Installer Install J 21885 on front accumulator piston Retainer 3...

Страница 763: ...400 475 AUTOMATIC TRANSMISSION 7A2 37 Figure 93 Control Valve Assembly ...

Страница 764: ...PIN 3 2 VALVE VALVE 3 2 HH0096 400 Figure 94 Control Valve Assembly Legend Remove valve trains beginning with the upper left hand corner N O T E Some valves are under pressure cover the bores while removing the roll pins Remove blind hole roll pins with a modified drill bit Valves springs and bushings must be laid out on a clean surface in the exact sequence they are removed Remove pressure switch...

Страница 765: ...Spacer 43 and bolt 41 Gasket 39 to oil pan 38 Oil pan 38 with screw and conical washer assembly 37 torque to 6 10 lbs ft 8 14 N m Case Extension Assembly Inspect Figure 99 L 9 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 2 Extension to case seal 32 3 Gaske...

Страница 766: ...80 STUD CASE TO CASE EXTENSION HH0100 400 Figure 98 Installing Filter Oil Pan Figure 99 Installing Case Extension 3 Modulator valve bore in the case for burrs porosity or scoring 1 2 3 4 Install or Connect Figure 101 Modulator valve 15 into case small end first New o ring seal 14 into case Modulator assembly 13 into case Retainer 12 and bolt 11 torque to 15 20 lbs ft 10 27 N m TORQUE CONVERTER ASS...

Страница 767: ...nd measure end play 000 024 00 mm 61 mm The Torque Converter Should 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 Refer to Section 7A The converter bolt hole threads are damaged Correct with thread insert Refer to Section 6A Flushing the torque converte...

Страница 768: ...SCREW 2 0 2 7 1 5 2 0 2 0 2 7 1 5 2 0 SPEEDOMETER DRIVEN GEAR RETAINER TO CASE S C R E W 5 8 4 6 5 8 4 6 OIL PAN TO CASE S C R E W 8 1 4 6 1 0 4 2 2 3 1 6 EXTENSION HOUSING TO CASE SCREW 2 7 3 4 2 0 2 5 20 MIN 1 5 MIN M A N U AL SHAFT TO DETENT LEVER N U T 2 0 2 7 1 5 2 0 2 0 2 7 15 2 0 M A N U AL YOKE TO M A N U AL SHAFT N U T 1 8 2 4 1 3 1 8 1 8 2 4 1 3 1 8 CASE TO CENTER SUPPORT SCREW 2 7 3 4 2...

Страница 769: ...auge Used w ith J 2 1 3 7 0 6 Oil Pum p R em over End Play C heckin g F ixtu re J 8001 J 21370 10 D river Handle 3 4 1 0 Thread Band to A p p ly Pin A sse m b ly J 8092 J 21370 6 Speedo Gear Rem over Use w ith J 2 1 4 2 7 0 1 Forw ard and D ire ct C lu tch O uter Seal P ro te cto r j t IF J 8433 J 21409 E xtension H ousing Oil Seal Installer Speed S ensor R otor Installer Q J 36352 5 J 36352 3 J 2...

Страница 770: ... 3 BUSHING PUMP BODY 220 BUSHING STATOR SHAFT FRONT 30 BUSHING CASE EXTENSION 65 5 BUSHING 33 BUSHING 66 3 BUSHING STATOR SHAFT M AIN SHAFT 206 BUSHING STATOR SHAFT REAR 69 0 BUSHING OUTPUT SHAFT 33 HH0106 400 Figure 105 Bushing Locations ...

Страница 771: ...400 475 AUTOMATIC TRANSMISSION 7A2 45 ...

Страница 772: ... INSTALL AS SHOWN J 8 0 9 2 J 2 1465 6 65 4 6 5 4 SUPPORT CENTER 655 BUSHING J 8 092 654 J 2 619 J 261 9 4 J 2 1 4 6 5 16 J 8 092 J 2 1 465 1 6 9 0 BUSHING OUTPUT SHAFT 691 SHAFT OUTPUT ______________I_____________ J 8 0 9 2 J 2 1465 8 10 CASE TRANSMISSION 33 BUSHING J 2 1465 1 3 J 8092 HH0104 400 Figure 107 Bushing Replacement Procedure ...

Страница 773: ...400 475 AUTOMATIC TRANSMISSION 7A2 47 ...

Страница 774: ...7A2 48 400 475 AUTOMATIC TRANSMISSION ...

Страница 775: ...rust 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 rings when removing or installing EXTERNAL PARTS a y Clean Thoroughly transmission clean the exterior of the Remove or Disconnect Torque converter Install or Connect Tools Required J 3289 20 Base J 8763 01 Holding F...

Страница 776: ... PIPE H 180C 91 Figure 2 Hookup of Solenoid Pipes and Electrical Wires 3 Servo piston snap ring 4 Slowly release servo piston 1 SERVO PISTON TO CASE SNAP RING 2 OFFSET OF TOOL TO REAR OF CASE H 180C 14 Figure 3 Compressing the Servo Piston 2 T Figure 4 Check Balls and Servo Piston Selector Lever and Electrical Connector Removal 1 Remove or Disconnect Figures 5 and 6 1 Inner selector hex nut Inside...

Страница 777: ...nect Figures 9 1 0 and 11 Tools 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 necessary 1 MODULATOR 2 MODULATOR PLUNGER 3 O RING SEAL 4 MODULATOR VALVE 5 MODULATOR VALVE SLEEVE 6 RETAINING PIN 7 0 RING SEAL 8 DETENT VALVE SLEEVE 9 DETENT VALVE 1...

Страница 778: ...s 2 Separate the second clutch and the third clutch assemblies NOTICE Ifthe reverse clutch plates are not being replaced they must be installed in their original position 1 PARKING LOCK ACTUATOR ROD 2 GOVERNOR GASKET 3 GOVERNOR ASSEMBLY 4 SPEEDOMETER DRIVE GEAR 5 RETAINING CLIP 6 GOVERNOR HUB H 180C 20 Figure 1 1 Speedometer Drive Gear and Governor 3 Reverse clutch plates and aluminum pressure pla...

Страница 779: ...g Bolts and O Ring Seal Inspect Low band for cracks flaking heat damage Reaction sun gear and drum for chipped teeth worn bushing scored drum 1 REV CL WAVED PLATE 2 REVERSE CLUTCH PLATE 3 REV CL COMPOSITION PLATE 4 PRESSURE PLATE 5 2ND CLUTCH ASM 6 3RD CLUTCH ASM 7 BEARING ASSEMBLY 8 THRUST WASHER 9 PLANETARY CARRIER ASM 10 THRUST WASHER 11 BEARING ASSEMBLY 12 SUN GEAR DRUM 13 LOW BAND 14 BEARING ...

Страница 780: ...7 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 actuator assembly Inside selector lever Electrical connector with a new O ring if necessary Install or Connect Figure 15 Thrust washer and bearing The case bushing acts as a guide for the thrust washer and...

Страница 781: ...hird Clutch Ring Compressor late 1979 to current Mount the third clutch assembly in a soft jaw vise as shown Position the five pins of J 28456 in the elongated slot DO NOT PUT A PIN INTO A SLOT IF THE INTERIOR SNAP RING IS NOT VISIBLE Slide compression ring of J 28456 J 29351 over the pin cage Pull on the input sun gear until the internal snap ring clears the ring groove Remove J 28456 J 29351 Spr...

Страница 782: ...sten for check ball movement Replace the piston ifcheck ball is missing or falls out Clutch piston lip seal for nicks cuts or damage Input shaft lip seal for nicks cuts or damage Inspect Figure 26 Clutch plates composite plates for damaged tangs delamination or excessive wear steel plates for damaged lugs or heat damage Third clutch drum for damage or worn clutch splines Thrust washer and bearing ...

Страница 783: ...the thrust washer and bearing in place 1 2 3 4 SPRAG ASSEMBLY THIRD CLUTCH PLATES BEARING AND THRUST WASHER TOGETHER THIRD CLUTCH HOUSING STAKED H 180C 36 the 1 PROPERLY INSTALLED LIP SEAL 2 THIRD CLUTCH HOUSING H 180C 33 5 6 I l 2 Figure 27 Input Shaft Lip Seal Compress the piston return springs using J 23075 Spring seat snap ring Remove J 23075 Assemble Figure 28 Third clutch plates into the clu...

Страница 784: ...gm xaxe M i l fcsnn S J 29351 1 THIRD CLUTCH HOUSING 2 SNAP RING COMPRESSED BY TOOL FINGERS 3 SNAP RING GROOVE H 180C 37 Figure 31 Installing Retaining Ring in Third Clutch 3 Second speed clutch plates 4 Thrust washer 1 2 3 4 5 6 7 1 Disassemble Figures 32 33 and 34 Tools Required J 23327 Clutch Spring Compressor J 29838 Clutch Spring Compressor Adapter Install J 23327 and J 29838 Compress the pis...

Страница 785: ...fluid 3 Second clutch piston into the clutch drum Lubricate the lip seals with liberal amounts of transmission fluid Use J 23080 to protect the outer piston lip seal 4 Remove J 23080 Assemble Figure 33 Tools Required J 23327 Clutch Spring Compressor J 29838 Clutch Ring Compressor Adapter J 23080 Second Speed Piston Seal Installer 1 Piston return springs and spring seat on the second clutch piston ...

Страница 786: ...d Clutch Assemblies Into Case Determining Selective Washer Thickness Figure 36 Installing Third Clutch Assembly Into Second Clutch Assembly Measure Figures 38 and 39 Tools Required J 23085 Selective Washer Gaging Tool 1 Install J 23085 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...

Страница 787: ...NG SEAT 3 RETURN SPRINGS 24 REQUIRED 4 REVERSE PISTON INNER SEAL 5 REVERSE PISTON 6 REVERSE PISTON OUTER SEAL 7 OIL PUMP TO CASE GASKET 8 SELECTIVE WASHER 9 OIL PUMP 10 OIL PUMP OUTER OIL SEAL 11 WEAR PLATE 12 CONVERTER HOUSING H 180C 46 3 Five oil pump to converter bolts 4 Separate the oil pump from the converter housing 5 Oil pump wear plate 6 Oil pump gears H 180C 48 H 180C 45 WHEN MEASURED GAP...

Страница 788: ...6 Tools Required J 23327 Clutch Spring Compressor Inner and outer piston oil seals Reverse clutch piston onto the rear face of the oil pump Clutch return springs Spring seat and snap ring Install J 23327 Compress clutch piston return springs Snap ring Remove J 23327 Assemble Oil pump gears with tangs on the driven gear facing up Measure Figure 47 Use a straight edge and a feeler gage to measure be...

Страница 789: ...ER SEAL 3 REVERSE CLUTCH PISTON OUTER SEAL J 8059 1 REVERSE CLUTCH PISTON 2 OIL PUMP 3 CONVERTER HOUSING H 180C 49 Figure 44 Reverse Clutch Piston Governor Hub J 9 Inspect Figures 52 and 53 Seal rings for nicks burrs or damage Governor hub oil screen Governor hub splines for cracks chipped teeth Figure 45 Compressing Reverse Clutch Piston Retainer 2 Seal rings if necessary 3 Governor hub 4 Snap ri...

Страница 790: ...ns H 180C 66 1 GUIDE PINS 1 inspect Primary and secondary valves for nicks burrs Oil passages and valve bores for nicks burrs varnish Inspect Figure 54 1 Primary valve small end first 2 Secondary valve small end first 3 Secondary spring and retainer 4 Governor body gasket bolts Tighten Torque bolts to 8 N m 6 lbs ft Valve should move freely Assemble Speedometer drive gear and retaining clip ...

Страница 791: ... Exploded View Extension Housing and Speedometer Drive Gear Inspect Figure 55 Extension housing for cracks or porosity Parking pawl and spring ijh Assemble Figures 56 and 57 Tools Required J 21426 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 bolts t...

Страница 792: ... small end first TAB MUST ENGAGE SLOT MODULATOR BORE 3 Modulator valve and plunger 4 O ring onto the modulator assembly IN N O T IC E Use of another tool to install the vacuum modulator may result in internal damage to the modulator 5 Modulator assembly Tighten Torque modulator to 52 N m 38 lbs ft Jbn Q 1 MODULATOR 2 MODULATOR PLUNGER 3 O RING SEAL 4 MODULATOR VALVE 5 MODULATOR VALVE SLEEVE 6 RETA...

Страница 793: ...PPLY ROD 11 RETURN SPRING H 180C 77 Figure 60 Servo Piston Exploded View Install or Connect Figures 61 62 and 63 Tools Required J 23075 Servo and Clutch Compressor Piston 1 2 3 4 5 Servo apply rod return spring and piston Install J 23075 with tool offset toward the rear of the case Compress the servo piston return spring using J 23075 Tap servo piston with a rubber mallet while compressing the ret...

Страница 794: ...lve 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 Remove blind hole roll pins with a modified drill bit Valves springs and sleeves must be laid out on a clean surface in the exact sequence they are removed Clean All valves springs sleeves and control valve body Dr...

Страница 795: ...SHIFT TIMING VALVE SPRING 7 16 x 1 3 8 MANUAL LOW CONTROL VALVE SPRING 7 16 x 1 5 16 MANUAL LOW CONTROL VALVE REVERSE CONTROL VALVE 1 2 SHIFT VALVE 1 2 SHIFT CONTROL VALVE SPRING 3 4 x 2 7 16 1 2 SHIFT CONTROL VALVE 1 2 SHIFT CONTROL VALVE SPRING 1 2 SHIFT CONTROL VALVE SLEEVE 2 3 SHIFT VALVE 2 3 SHIFT CONTROL VALVE SPRING SEAT 2 3 SHIFT CONTROL VALVE SPRING 11 16 x 1 3 4 2 3 SHIFT CONTROL VALVE 2...

Страница 796: ...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 m 14 lbs ft make sure tubing does not interfere with manual valve operation 5 Electrical connections Install or Connect Figures 69 and 70 1 Servo cover gasket and bolts torque to 24 4 N m 18 lbs ft 1 SOLENOID TO GOVER NOR PRESSURE SWITCH WIRE 2 SOLENOID TO...

Страница 797: ...verter 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 11 SOLENOID VALVE 12 TRANSFER PLATE Figure 70 Proper Converter Installation Figure 69 External Parts ...

Страница 798: ...R FITTINGS 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 TRANSFER PLATE TO VALVE BODY 9 7 REINFORCEMENT PLATE TO CASE 19 14 VALVE BODY TO CASE 19 14 SERVO COVER TO CASE 24 18 CONVERTER HOUSING TO OI L PUMP 19 14 CONVERTER HOUSING TO CASE 33 25 SELECTOR...

Страница 799: ...BE STAKED TOGETHER 6 TORRINGTON BEARING SUN GEAR TO OUTPUT SHAFT 7 THRUST WASHER 8 THRUST WASHER OUTPUT SHAFT TO REACTION SUN GEAR 9 10 11 12 13 14 15 16 17 18 19 TORRINGTON BEARING TORRINGTON BEARING REACTION SUN GEAR TO CASE THRUST WASHER OIL PUMP HUB BUSHING FRONT CONVERTER HOUSING BUSHING OIL PUMP BODY BUSHING REAR SECOND CLUTCH HUB BUSHING REACTION SUN GEAR DRUM BUSHING REACTION SUN GEAR DRUM...

Страница 800: ... 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 Driven In Until Tool Bottoms On Bench Figure 77 Installing Oil Pump Bushing Rear Inner ...

Страница 801: ...ISSION 7A3 27 Figure 80 Installing Sun Gear Drum Bushing H 180C 106 Figure 82 Removing or Installing Case Bushing J 8092 J 21424 9 H 180C 103 Figure 81 Removing or Installing Extension Housing Bushing Sleeve Bushing Sleeve ...

Страница 802: ...UTCH 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 REMOVER INSTALLER J 7004 SLIDE HAMMER J 21465 17 CONVERTER HOUSING BUSHING REMOVER INSTALLER J 23080 A 2ND CLUTCH PISTON SEAL INSTALLER J 29369 1 BUSHING REMOVER J 23130 2 REACTION SUN GEAR DRUM BUSHI...

Страница 803: ...ISSION CONTENTS SUBJECT PAGE Disassembly of the HM 117 Transm ission 7B1 3 Disassembly and Assembly of Sub Assem bly 7B1 7 Main Drive G e a r 7B1 7 M a in sh aft 7B1 8 7B1 11 7B1 13 7B1 13 C ountergear Rear Bearing Retainer Main Drive Gear Bearing R etain er Shift C o v e r 7B1 14 7B1 17 7B1 19 7B1 19 Transmission Assembly Installation of Sub Assemblies Specifications Fastener Torque Lubrication 7...

Страница 804: ... Disassembly and Assembly of Front Housing Assembly 7B1 53 Disassembly and Assembly of Rear Housing A ssem bly 7B1 61 Shift Shaft Rail and Fork Assemblies Inspection 7B1 63 Shift Lever Housing Assembly Inspection 7B1 64 Input Shaft Bearing Retainer Assembly 7B1 64 Countershaft Endplay Adjustm ent 7B1 65 Input Shaft Bearing Retainer Selective Shim Procedure 7B1 68 Output Shaft Bearing Selective Shi...

Страница 805: ... nut 256 and the washer using J 35907 4WD models only 5 Rear bearing retainer 223 and the gasket 6 Speedometer gear 219 7 Front bearing retainer 202 and the gasket 8 Cover 238 and the gasket 9 Bearing 237 using J 28509 A figure 23 10 Snap rings 225 and 226 11 Bearing 228 using J 22832 01 and J 8433 figure 24 J 22832 01 must be seated in the groove n m pletely 12 Main drive gear 201 Remove the bear...

Страница 806: ...dometer Drive Gear 220 Output Yoke 221 Flange Nut 222 Rear Bearing Retainer Oil Seal 223 Rear Bearing Retainer 224 Main Shaft Rear Bearing 225 Snap Ring Bearing to Case 226 Snap Ring Bearing to Gear 227 Counter Gear 228 Counter Gear Rear Bearing 229 Snap Ring 230 Reverse Idler Gear 231 Reverse Idler Shaft 232 Case Magnet 233 Spacer 234 Driven Gear Thrust Washer Snap Ring Front Counter Gear Bearing...

Страница 807: ...ring to Shaft 264 Screw 219 Speedometer Drive Gear 250 Main Shaft 265 Gasket 220 O utput Yoke 251 Gasket 266 Oil Seal 2 2 1 Flange Nut 252 Dowel Pin 267 Screw 2 2 2 Oil Seal 253 Screw 268 Shift Cover 223 Rear Bearing Retainer 254 Transfer Case Adapter 269 Gasket 224 Main Shaft Rear Bearing 255 Gasket 225 Snap Ring Bearing to Case 256 Rear Lock Nut 226 Snap Ring Bearing to Gear 257 Lock Washer 227 ...

Страница 808: ...7B1 6 HM 117 MANUAL TRANSMISSION Figure 25 Main Drive Gear Cutout ...

Страница 809: ...276 3 Snap ring 241 4 Bearing 278 using J 358 1 and J 22872 figures 28 and 29 5 Slinger 240 Clean All parts in a suitable solvent Important Do not spin the bearings dry y Inspect 1 Parts for damage and wear 2 Oil the bearings and check for roughness Assemble Figures 27 and 30 Tools Required J 358 1 Bearing Remover Holder J 22872 Drive Gear Bearing Remover 1 New slinger 240 The concave side goes to...

Страница 810: ...way from the gear New bearing to shaft small snap ring 241 New bearing to case large snap ring 203 Pilot bearings 239 Use chassis grease to hold the bearings in place MAINSHAFT Disassemble Figure 31 Thrust washer and the 1st speed gear 216 Reverse driven gear 211 the synchronizer keys and springs Do not loose the keys and springs 3 4 synchronizer snap ring 280 Do no let the synchronizer come apart...

Страница 811: ...zer sleeves for a sliding fit 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 teeth for excess wear Bearings and bearing surfaces for nicks burrs and wear Lubricate all roller bearings with light engine oil and check for rough rotation Assemble Figure 31...

Страница 812: ...7B1 10 HM 117 MANUAL TRANSMISSION ANUAL Figure 37 Installing the 1st and 2nd Synchronizer Figure 36 Installing the 2nd Speed Bushing Figure 38 Installing the 1st Speed Gear Bushing ...

Страница 813: ...11 Reverse gear 211 The shift fork groove goes to the rear of the mainshaft 12 1st speed gear 216 13 Thrust washer 217 COUNTERGEAR Disassemble Figure 42 Tools Required J 22832 01 Countergear and Mainshaft Rear Bearing Remover 1 Snap ring and the thrust washer 235 2 Driven gear 234 Install J 22832 01 with the open side to the spacer figure 43 Support the gear and press the countergear through figur...

Страница 814: ...Figure 42 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 required replace the gear s or the shaft or both 1 3rd speed gear 290 figure 45 The gear is marked FRONT in the web area as shown in figure 42 2 Spacer 233 3 Driven gear 234 using J 22873 figure 46 4 Thrust washer 235 5 New ...

Страница 815: ...ar 2 Gasket material from the retainer 223 using a scraper Inspect the retainer for damage 0 Install or Connect Figure 22 Tools Required J 22834 Extension Housing Seal Installer 1 Locking compound on the outside of a new seal 222 2 New seal using J 22834 2 figure 48 Use J 22834 1 if a parking brake is used Fill between the seal lips with chassis grease MAIN DRIVE GEAR BEARING RETAINER SEAL REPLACE...

Страница 816: ...e 51 3 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 shuttles and pin when removing the rods 4 Interlock shuttles 306 and the pin 304 5 Detent balls 213 and the springs 212 6 Retainer 302 from the plunger 299 7 Plunger 299 and spring 300 from the reverse shift fork 3...

Страница 817: ...d 4 Position the 3rd 4th shift fork 206 and push the rod through the yoke but not into the front support bore Place an interlock shuttle 306 in the cross bore of the front support between the reverse and the 3rd 4th shift rods figure 54 Then install the interlock pin 304 in the 3rd 4th shift rod hole Push the 3rd 4th shift rod 306 into the front support bore and install a new retainer pin through ...

Страница 818: ...Detent Spring 213 Detent Ball 214 Reverse S h ift Rod 215 1st and 2nd S h ift Fork 301 Reverse S h ift Fork 303 R etaining Pin 304 Interlock Pin 305 3rd and 4th S h ift Rod 306 Interlock S huttle 307 1st and 2nd S hift Rod 215 F 04633 Figure 53 Shift Rod and Fork Positions ...

Страница 819: ...ransmission Tighten all bolts to specified torque Lubricate all assemblies as they are installed in the transmission case using transmission oil Install or Connect Figure 22 Tools Required J 22874 Mainshaft and Countergear Bearing Installer J 35907 Mainshaft Lock Nut Wrench 4WD models only 1 Countergear 227 into the case Do not install the bearings 2 Reverse idler gear 230 and the shaft The gear t...

Страница 820: ...gear 219 Rear bearing retainer 223 and a new gasket Parking brake assembly 4WD models only Back plate New mainshaft lock nut 256 and a new spring washer using J 35907 10 12 13 14 15 Brake drum and the flange or yoke 220 Lubricate the flange sealing surface with transmission oil 16 Flange nut 221 17 Shift cover 268 and a new gasket Move the transmission gears and shift rods to the neutral position ...

Страница 821: ...3 17 3 4 5 41 30 LUBRICATION Capacity 4 0L 4 2 qts Type Recom m ended API GL5 SAE 80W90 Use SAE 80W GL5 in Canada SPECIAL TOOLS 1 J 22873 Main S haft B ushing Installer 2 J 22875 3rd Gear A ssem bly Tool 3 J 22834 Extension H ousing Seal Installer 4 J 22833 Front H ousing Drive G ear Seal Installer 5 J 22874 M ain Shaft And C ounter Gear Bearing Installer 6 J 35907 Main S haft Lock N ut Tool 7 J 8...

Страница 822: ...7B1 20 HM 117 MANUAL TRANSMISSION BLANK ...

Страница 823: ...ct Figure 1 2 3 and 4 GENERAL SERVICE INFORMATION Lubricant The lubricant may appear to be very dark in color almost black This is a normal condition The silicon imbedded into the shift forks to reduce wear is reacting with the lubricant Clean Thoroughly clean the exterior of the transmission ...

Страница 824: ...7B1 22 HM 290 MANUAL TRANSMISSION Figure 1 Transmission 2WD Gear Components ...

Страница 825: ...GEAR NEEDLE MG5 31 GEAR ASSEMBLY 5TH SPEED MG5 32 SYNCHRONIZER ASSEMBLY REVERSE MCO 33 BEARING ASSEMBLY OUTPUT SHAFT 34 RACE ROLLER BEARING 35 BEARING ROLLER 36 RACE BALL BEARING INNER 37 RACE BEARING ASSEMBLY OUTER 38 RACE BALL BEARING OUTER 39 RING THREADED THRUST OUTER 4 0 BALL 4m m 41 RING THREADED THRUST INNER 42 PIN SPRIL ROLL 4 3 RING SNAP 4 4 WASHER SPEEDO GEAR THRUST 2WD 45 ROTOR SPEED SE...

Страница 826: ...7B1 24 HM 290 MANUAL TRANSMISSION Figure 2 Transmission 2WD Shift Mechanism and Case Components ...

Страница 827: ...GER 125 O RING 243 PLUNGER SHIFT SHAFT DETENT 1 26 BUSHING SHIFT SOCKET 24 4 SPRING SHIFT SHAFT DETENT PLUNGER 127 WASHER SHIFT SOCKET 245 PLUG 128 RING SNAP 24 6 BUSHING 5 REVERSE DETENT PLUNGER 129 O RING 247 PLUNGER ASSEMBLY 5TH REVERSE DETENT 130 BOOT 248 SPRING 5TH REVERSE DETENT 131 O RING 249 PLUG HEX HEAD 132 SEAL SHIFT LEVER HOUSING 2 5 0 PLUG COUNTERSHAFT BEARING 133 NUT HEX JA M MCO 251...

Страница 828: ...7B1 26 HM 290 MANUAL TRANSMISSION Figure 3 Transmission 4WD Gear Components ...

Страница 829: ...NG ASSEMBLY 5TH SPEED GEAR NEEDLE 31 GEAR ASSEMBLY 5TH SPEED 32 SYNCHRONIZER ASSEMBLY REVERSE 33 BEARING ASSEMBLY OUTPUT SHAFT 34 RACE ROLLER BEARING 35 BEARING ROLLER 36 RACE BALL BEARING INNER 37 RACE BEARING ASSEMBLY OUTER 38 RACE BALL BEARING OUTER 39 RING THREADED THRUST OUTER 4 0 BALL 4m m 41 RING THREADED THRUST INNER 42 PIN SPRIL ROLL 4 3 RING SNAP 46 IDLER ASSEMBLY REVERSE 4 7 RING SNAP 4...

Страница 830: ......

Страница 831: ... SHIFT SHAFT 240 SLEEVE DETENT CAM PIVOT 124 SOCKET SHIFT SHAFT 241 WASHER RETAINING 125 O RING 242 BUSHING DETENT PLUNGER 126 BUSHING SHIFT SOCKET 243 PLUNGER SHIFT SHAFT DETENT 127 WASHER SHIFT SOCKET 244 SPRING SHIFT SHAFT DETENT PLUNGER 128 RING SNAP 245 PLUG 129 O RiNG 246 BUSHING 5 REVERSE DETENT PLUNGER 130 BOOT 247 PLUNGER ASSEMBLY 5TH REVERSE DETENT 131 O RING 248 SPRING 5TH REVERSE DETEN...

Страница 832: ...ed J 36824 onto the transmission case J 8763 02 onto J 36824 2 Backup lamp switch assembly 313 Figure 7 Figure 7 Removing External Components 3 Bolt 317 and electronic speed sensor assembly 314 2WD models only 4 Detent plug 245 using J 36509 and J 23907 Spring 244 and plunger 243 5 Two bolts 236 detent spring cover 325 springs 324 and balls 323 Figure 8 It may be necessary to remove sealant from i...

Страница 833: ... OUTER jhqqu hm zm Figure 10 Removing Input Shaft Bearing Retainer Assembly 12 13 Countershaft bearing 203 Ball bearing inner race 217 and roller bearing 218 Degreasing with a liquid cleaner will make it easier to remove Grab on OD edge non machined surface of the inner race 217 and remove with large pliers 9 14 15 16 Important Do not damage bearing cage while removing ball bearing inner race Idle...

Страница 834: ...ft shaft bearing 309 causing increased shift effort 116 SHAFT ASSEMBLY SHIFT 121 FINGER 122 PIN ROLL 123 SOCKET ASSEMBLY SHIFT SHAFT J H 0 0 3 1 H M 2 9 0 Figure 13 Removing Shift Socket Assembly Roll Pin 18 Shift Shaft 116 shift shaft socket assembly 123 and finger 121 19 3rd and 4th shift fork roll pin 107 Figure 14 With a large pair of diagonal cutters pry out 9 Important If roll pin 107 breaks...

Страница 835: ...TH SHIFT INTERLOCK 3 2 3 BALL DETENT INTERLOCK J H 0 0 7 8 H M 2 9 0 J 36824 JH 01 6 9 H M 2 9 0 Figure 16 Removing and Installing Special Tools Remove or Disconnect Figure 17 Tools Required J 8105 Gear Puller 2WD models only J 21427 01 Speedometer Gear Puller Adapter 2WD models only J 36516 Output Shaft Spanner Nut Wrench 1 Bolts 304 and 305 2 2WD rear housing assembly 300 Tap upwards on the hous...

Страница 836: ... re 18 L o c k in g U p T ra n s m is s io n DO NOT REUSE ROTOR AFTER REMOVAL 6 Washer 44 and snap ring 43 7 Spiral roll Pin 42 using J 36516 Figure 20 Move the black depth locating tang for the spiral 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 clockwise till it stops 8 Snap ring 43 9 Threaded...

Страница 837: ...ing out 13 Input shaft gear 1 and pilot bearing 3 4WD REAR HOUSING REMOVAL Important Steps 1 through 10 are for 4WD models only Remove or Disconnect Tools Required J 36516 Output Shaft Spanner Nut Wrench Figure 19 Removing Speed Sensor Rotor Lock up the transmission in 2nd and 4th gear by sliding the 1st and 2nd Shift rail assembly 100 and the 3rd and 4th shift fork 108 downward towards J 36515 Fi...

Страница 838: ...ang for the spiral roll pin remover installer out of the way then drive roll pin down Put the black depth locating tang back Turn J 36516 counter clockwise till it stops 2 Snap ring 43 3 Threaded thrust ring inner 41 ball 40 and threaded thrust ring outer 39 Turn J 36516 clockwise till both threaded thrust rings 39 and 41 are completely apart 4 4WD Rear Housing Assembly 301 Figure 24 Tap upwards o...

Страница 839: ...e parts can be installed in the same position Leave the synchronizer rings 2 to prevent the synchronizer detent balls 9 from popping out Third gear bearing 14 Snap ring selective 15 Figure 26 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 assembly 19 to preven...

Страница 840: ... SHIFT 111 RAIL ASSEMBLY 5TH REVERSE SHIFT 20 3 BEARING COUNTERSHAFT 301 HOUSING REAR 4W D J H 0 0 3 4 H M 2 9 0 2 RING SYNCHRONIZER 6 RING SNAP SELECTIVE 7 SYNCHRONIZER ASSEMBLY 3 4 13 GEAR ASSEMBLY 3RD SPEED 14 BEARING ASSEMBLY 3RD SPEED GEAR NEEDLE 23 SHAFT OUTPUT 2WD 24 SHAFT OUTPUT 4W D _________________________________________________________ J H 0 0 2 5 H M 2 9 0 Figure 24 Removing 4WD Rear...

Страница 841: ...EMBLY 2ND SPEED 23 SHAFT OUTPUT 2WD 24 SHAFT OUTPUT 4WD _____________________________ J H 0 0 2 4 H M 2 9 0 2 RING SYNCHRONIZER 17 BEARING ASSEMBLY SPEED GEAR NEEDLE 19 SYNCHRONIZER ASSEMBLY 1 2 22 GEAR 1ST SPEED 23 SHAFT OUTPUT 2WD 24 SHAFT OUTPUT 4WD J H 0 0 2 3 H M 2 9 0 Figure 26 Removing 2nd Gear Components Figure 27 Removing 1st Gear Components ...

Страница 842: ...G ASSEMBLY 5TH SPEED GEAR NEEDLE MG5 31 GEAR ASSEMBLY 5TH SPEED MG5 34 RACE ROLLER BEARING 35 BEARING ROLLER 36 RACE BALL BEARING INNER _______________________________________J H 0 0 2 2 H M 2 9 0 Figure 28 Removing 4 Speed Ball and Roller Races Figure 29 Removing 5th Gear Components ...

Страница 843: ...e synchronizer detent balls 9 from popping out 14 Speed gear bearing assembly 17 15 Place 1 2 3 4 and 5th speed synchronizers in separate shop towels wrap assemblies and press against inner hub 9 Important DO NOT MIX PARTS Clean All parts in a suitable solvent and air dry Important Do not spin dry the ball bearings i 2 RING SYNCHRONIZER 17 BEARING ASSEMBLY SPEED GEAR NEEDLE 23 SHAFT OUTPUT 2WD 24 ...

Страница 844: ...bearing surfaces for nicks burrs bent cages and wear 10 Lubricate all bearings with light engine oil 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 replace the component and inspect mating parts Lubricate all components as assembly progresses Use lubricant 5W 30 GM P N 1052931 or equiv...

Страница 845: ...HM 290 MANUAL TRANSMISSION 7B1 43 BLANK ...

Страница 846: ...7B1 44 HM 290 MANUAL TRANSMISSION Figure 32 2WD Main Shaft Components ...

Страница 847: ... 20 SLEEVE 1 2 SYNCHRONIZER 21 HUB 1 2 SYNCHRONIZER 22 GEAR 1ST SPEED 23 SHAFT OUTPUT 2W D 25 GEAR ASSEMBLY REVERSE SPEED 26 SYNCHRONIZER ASSEMBLY 5TH REVERSE MG5 27 RING SPIRAL LOCK M G5 ONLY 28 HUB 5TH REVERSE SYNCHRONIZER 29 RING SNAP SELECTIVE 30 BEARING ASSEMBLY 5TH SPEED GEAR NEEDLE MG5 31 GEAR ASSEMBLY 5TH SPEED MG5 32 SYNCHRONIZER ASSEMBLY REVERSE MCO 33 BEARING ASSEMBLY OUTPUT SHAFT 3 4 R...

Страница 848: ...Figure 33 4WD Main Shaft Components ...

Страница 849: ... NEEDLE 18 GEAR ASSEMBLY 2ND SPEED 19 SYNCHRONIZER ASSEMBLY 1 2 20 SLEEVE 1 2 SYNCHRONIZER 21 HUB 1 2 SYNCHRONIZER 22 GEAR 1ST SPEED 24 SHAFT OUTPUT 4W D 25 GEAR ASSEMBLY REVERSE SPEED 2 6 SYNCHRONIZER ASSEMBLY 5TH REVERSE 27 RING SPIRAL LOCK 28 HUB 5TH REVERSE SYNCHRONIZER 29 RING SNAP SELECTIVE 30 BEARING ASSEMBLY 5TH SPEED GEAR NEEDLE 31 GEAR ASSEMBLY 5TH SPEED 32 SYNCHRONIZER ASSEMBLY REVERSE ...

Страница 850: ... groove 4 speed in hub 28 towards reverse speed gear 25 NEW selective snap ring 29 Install the thickest snap ring that will fit in the groove Bearing assembly 30 and 5th speed gear 31 5 speed Figure 38 5 speed only Important When pressing the bearing races onto the main shaft 23 or 24 Press until there is no clearance between roller bearing race and stop on main shaft Roller bearing race 34 HEATED...

Страница 851: ...CE SYNCHRONIZER RING 2 HERE VIEW E VIEW F 8 SLEEVE SYNCHRONIZER 9 BALL SYNCHRONIZER DETENT 10 SPRING SYNCHRONIZER DETENT 11 KEY SYNCHRONIZER 27 RING SPIRAL LOCK MG5 ONLY 28 HUB 5TH REVERSE SYNCHRONIZER 5TH REVERSE ASSEMBLY PROCEDURES Install 1 Sleeve 8 onto hub 28 Check scribe marks for correct positions Make sure spiral lock ring 27 is in place RPO MG5 ONLY NOTE The follow ing steps are for RPO M...

Страница 852: ...ng 2 Continue to press until seated Be sure all shavings are removed 11 1 2 synchronizer assembly 19 with both synchronizer rings 2 using J 36183 J 36184 J 22912 01 and hydraulic press Check scribe marks for correct positions 9 Important The groove on the outside of the sleeve MUST GO TOWARDS THE 2ND SPEED GEAR to prevent gear clash during 1st and 2nd gear shifts the teeth on the sleeve have diffe...

Страница 853: ...RONIZER ASSEMBLY 1 2 22 GEAR 1ST SPEED 23 SHAFT OUTPUT 2WD 24 SHAFT OUTPUT 4WD J H 0 0 5 9 H M 2 9 0 23 SHAFT OUTPUT 2WD 24 SHAFT OUTPUT 4WD 30 BEARING ASSEMBLY 5TH SPEED GEAR NEEDLE MG5 31 GEAR ASSEMBLY 5TH SPEED MG5 3 4 RACE ROLLER BEARING 35 BEARING ROLLER 36 RACE BALL BEARING INNER ________________________________________ J H 0 0 5 8 H M 2 9 0 r i e H L J 3 6 1 8 4 3 6 5 1 3 24 NOTE SMALLER DI...

Страница 854: ... ASSEMBLY 2ND SPEED 23 SHAFT OUTPUT 2WD 24 SHAFT OUTPUT 4WD J H 0 0 6 0 H M 2 9 0 Y PART NO D IM 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 80 071 2 RING SYNCHRONIZER 6 RING SNAP SELECTIVE 7 SYNCHRONIZER ASSEMBLY 3 4 13 GEAR ASSEMBLY 3RD SPEED 14 BEARING ASSEMBLY 3RD SPEED GEAR NEEDLE 23 SHAFT OUTPUT 2WD 24 SHAFT O...

Страница 855: ...E O ring 52 1 2 4 5 Ijrji I 2 3 Clean All parts in a suitable solvent and air dry Inspect Gear teeth 49 for scuffed nicked burred or broken teeth Bearing assemblies 50 for roughness of rotation burred or pitted condition and gage damage replace if these conditions exist Shaft 51 for scoring wear or overheating Important If scuffed nicked burred or scoring conditions cannot be removed with a soft s...

Страница 856: ... 231 2 3 0 LEVER SHIFT SHAFT 231 PIN SHIFT SHAFT LEVER 23 2 ROLLER C OVR DETENT 23 3 SLEEVE BIAS SPRING 2 3 4 SPRING BIAS LOAD TORSIONAL 23 5 SEAT BIAS SPRING SLEEVE 23 6 BOLT HEX HEAD M 6 X 16mm 237 SUPPORT 5TH REVERSE DETENT CAM 23 8 CAM 5TH REVERSE DETENT MCO 23 9 CAM 5TH REVERSE DETENT MG5 2 4 0 SLEEVE DETENT CAM PIVOT 241 WASHER RETAINING 24 2 BUSHING DETENT PLUNGER 24 6 BUSHING 5 REVERSE DET...

Страница 857: ...Tap using 3 8 16 bottom tap Screw 3 8 16 adapter into the plug Remove the plug with J 6725 B 6 Snap ring 251 shim s 252 and countershaft bearing race 202 using J 36799 and J 8092 Tap in countershaft bearing race 202 before removing snap ring 251 9 Important If countershaft bearing race 202 is removed refer to COUNTERSHAFT ENDPLAY ADJUSTMENT Measure Figure 48 The countershaft bearing race bore in t...

Страница 858: ... high tension 23 9 5 SPEED 2 0 4 241 2 0 0 HOUSING FRONT 2 0 4 BOLT HEX HEAD M6 X 25m m 2 3 8 CAM 5TH REVERSE DETENT MCO 23 9 CAM 5TH REVERSE DETENT MG5 2 4 0 SLEEVE DETENT CAM PIVOT 241 WASHER RETAINING J H 0 3 1 3 H M 2 9 0 Assembly Figure 50 Removing Detent Cam Components 9 Bolt 236 bias spring and sleeve seat 235 bias load torsional spring 234 bias spring sleeve 233 shift shaft lever assembly ...

Страница 859: ...gs 246 using J 36506 Figure 52 Drive J 36506 till BOTH bushings are removed Figure 53 Removing Detent Plunger Bushings 13 Breather assembly 223 DO NOT REMOVE metal tube from case 14 Oil fill plug 222 and oil drain plug 225 using J 36511 Figure 54 Figure 52 Removing 5th Reverse Detent Bushings 12 Two detent plunger bushings 242 using J 36507 Figure 53 Remove ONE bushing at a time 2 0 0 HOUSING FRON...

Страница 860: ...aller J 36511 Oil Fill Plug Hex Bit 17mm J 36799 Countershaft Bearing Race Shimming Tool Ball bearing outer race 216 using brass driff Put a shop towel over the bearing during installation Three shift rail front housing bearings 228 using J 36798 1 and J 36190 Figure 55 Install flush and stake using J 36798 2 J 36798 1 and J 36190 DO NOT STAKE the tabs on the bushings Clutch fork pivot assembly 21...

Страница 861: ...t bearing plug 250 using J 36799 and J 8092 Apply gasket maker 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 59 Install one at a time Install the first bushing till the second scribe mark on the tool lines up with the housing Install the second bushing till the first scribe mark on the tool l...

Страница 862: ...__________________________J H 0 3 2 4 H M 2 9 0 _________ Figure 61 Bias Spring Components Install NOTICE Take great care not to strip the bore threads while installing hex head plug 14 Breather assembly 223 15 Oil fill plug 222 and oil drain plug 225 using J 36511 torque drain plug to 60 N m 46 Lb Ft Apply pipe sealant with Teflon GM P N 1052080 or equivalent to the threads 16 Shift shaft rails p...

Страница 863: ...shing Remover J 23907 Slide Hammer with pilot bearing puller J 26941 2WD Output Shaft Oil Seal Remover 2WD models only J 2 3 9 0 7 0Remove or Disconnect 2 4 Rear housing shift rail bearings 308 three using J 36800 and J 23907 Figure 65 Screw J 36800 into the bearing then slide hammer out Rear housing shift shaft bearing 309 using J 23907 with pilot bearing puller Figure 66 Position pilot bearing p...

Страница 864: ... replaced Machined mating surfaces for flatness check with a straight edge Important If scratches grooves or scoring cannot be removed with a soft stone or crocus cloth replace the component Clean up damaged threads with correct size tap Assemble 1 2 3 Tools Required J 36190 Drive Handle J 36503 Extension Housing Seal Installer 2WD models only J 36798 1 Shift Rail Bushing Installing Tool J 36798 2...

Страница 865: ... suitable solvent and air dry The parts that compose the 1 2 100 5th reverse 111 shift rail and fork assemblies are serviceable as an assembly only Shafts 101 109 112 and 117 for wear or scoring 309 BEARING REAR HOUSING SHIFT SHAFT J H 0 0 6 9 H M 2 9 0 Figure 69 Shift Shaft Bearing Install _________________________________________________ J H 0Q 7 9 H M 2 9 0 _________ Figure 70 2WD Slip Yoke Oil...

Страница 866: ...ft shaft socket assembly 123 components for wear or distortion Important Wear scoring or distortion requires replacement of assembly and close inspection of mating parts SHIFT LEVER HOUSING ASSEMBLY INSPECTION Clean The gasket material from the machined mating surface with liquid gasket remover Inspect Figure 72 The parts that compose the shift lever housing assembly 4 speed 135 or 5 speed 136 are...

Страница 867: ...ut shaft bearing retainer oil seal 209 Heat oil seal with J 25070 for a minimum of one minute Hold clutch release bearing pilot 207 with heat resisting glove or equivalent then slide hammer out seal 3 Gasket material from the retainer 205 using liquid gasket remover Seal 1 Inspect 1 Clutch release bearing pilot 207 for scoring wear or cracks especially at the flange Retainer for wear or damage Ins...

Страница 868: ...input shaft bearing retainer bolt holes Measure Use a long screwdriver to pry the counter shaft upward noting the dial indicator travel Use the fill plug hole to reach the 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 position noting the dial indicator...

Страница 869: ... 2 4 2 3 0 4 9 6 2 5 2 3 0 4 9 6 2 6 2 3 0 4 9 6 2 7 2 3 0 4 9 6 2 8 2 3 0 4 9 6 2 9 2 3 0 4 9 6 3 0 23049631 2 2 0 0 0 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 Figure 75 Countershaft Endplay Adjustment J 8092 J 3 6 799 53 COUNTERSHAFT ASSEMBLY MG5 54 COUNTERSHAFT MCO 2 0 0 HOUSING FRONT 202 RACE COUNTERSHAFT BEARING 251 RING SNAP 25 2 S...

Страница 870: ...rd this measurement Subtract the bearing race height from the retainer depth and select a shim the same or next smaller size as the difference in measurements C SHIM SPACE ILL D IM C NO PART NO mm IN 2 3 0 4 9 8 2 5 0 3 0 0 012 21 2 2 3 0 4 9 8 2 6 0 4 0 0 016 2 3 0 4 9 8 2 7 0 5 0 0 020 2 0 0 HOUSING FRONT 20 5 RETAINER ASSEMBLY INPUT SHAFT BEARING 212 SHIM SELECTIVE 21 3 RING INPUT SHAFT BEARING...

Страница 871: ...ng width from the housing bore depth Select a shim which is the same or next smaller size as the difference in measurements MEASURE BEARING OUTER RACE WIDTH MEASURE BEARING BORE DEPTH I f 33 300 OR 301 212 CALCULATION A HOUSING DEPTH B BEARING W IDTH C SHIM SPACE 33 BEARING ASSEMBLY OUTPUT SHAFT 212 SHIM SELECTIVE 3 0 0 HOUSING REAR 2WD OR 301 HOUSING REAR 4WD ILL DIM C NO PART NO mm IN 2 3 0 4 9 ...

Страница 872: ...nd ball bearing outer race 38 2WD models only Install on main shaft assembly 4 or 5 3 4 shift fork 108 TAPER ON FORK TOWARDS 3RD GEAR 1 2 shift rail assembly 100 Reverse shift rail assembly 111 and spacer block 115 4 speed ONLY Lock up transmission by sliding the 3 4 shift fork 108 and 1 2 shift rail assembly downward towards J 36515 Figure 81 2WD MODELS ONLY 9 Important Steps 1 through 12 are for...

Страница 873: ...UST RING OUTER 39 Important Screw the rings together completely then back the 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 slide the rod through so the roll pin will be installed to the correct depth MAKE CLEARANCE FOR THE SNAP RING BY FIRST screw...

Страница 874: ...7B1 72 HM 290 MANUAL TRANSMISSION Figure 81 Locking Up Transmission ...

Страница 875: ...HM 290 MANUAL TRANSMISSION 7B1 73 Figure 82 2WD Threaded Thrust Rings Assemble ...

Страница 876: ...ARING RACE Retain with petroleum jelly 9 Make sure the reverse idler shaft is lined up with the hole in the case Rotate back and forth while pulling down Pull up on J 36515 10 while installing rear housing Important Bring housing straight down If resistance is felt at about 1 4 inch then the rollers are 203 cocked Repeat above procedures to install DO NOT FORCE HOUSING DOWN Remove J 36515 10 12 Bo...

Страница 877: ...th while pulling down Important Bring housing straight down If resistance is felt at about 1 4 inch then the rollers 35 or 203 are cocked Repeat above procedures to install DO NOT FORCE HOUSING DOWN Ball bearing outer race 38 Ball 4mm 40 Figure 88 Retain in output shaft with petroleum jelly Threaded thrust inner ring 41 and threaded thrust outer ring 39 MAKE SURE THE OLD SPIRAL ROLL PIN 42 IS REMO...

Страница 878: ...n the seal lips with chassis grease Remove seal protector 2W D AND 4W D Tools Required J 36515 Assembly Pallet J 36515 12 Countershaft Adapter for 1988 and 1989 Models J 3289 20 Base Holding Fixture J 8763 02 Holding Fixture C Clamp J 8763 21 Balance Bracket for C Clamp J 36824 Transmission Adapters Lay the unit down on the workbench and remove J 36515 Install or Connect Figure 90 1 Idler shaft su...

Страница 879: ... 311 BOLT HEX HEAD M 8 X 50m m J H 0 0 7 3 H M 2 9 0 Figure 90 Reverse Idler Support Install 9 Important The 1 2 AND 5th REVERSE SHIFT RAIL MUST BE IN THE NEUTRAL POSITION or the interlock system will not allow the 3 4 rail to engage Roll pin 107 36mm Figure 92 Install to a depth where a MAXIMUM of 12 5mm of the roll pin measured from the NOTE MACHINED EDGE DOWN INTO CASE 301 HOUSING REAR 4W D 3 2...

Страница 880: ...gasket maker GM P N 1052943 or equivalent to the outside of the bolt hole pattern of the detent spring cover Tighten Bolts 236 to 8 5 N m 7 Lb Ft Four rollers 118 Figure 95 Retain with petroleum jelly Countershaft bearing 203 Figure 96 Install in bearing race 202 of the front housing Important SMALLER DIAMETER OF BEARING CAGE INTO BEARING RACE Retain with petroleum jelly and press on each roller t...

Страница 881: ...ly gasket maker GM P N 1052943 or equivalent to the inside cover bolt hole pattern 9 Important DO NOT APPLY too much gasket maker around the oil drain back hole This could clog the hole causing a low fluid flow through the bearing resulting in premature bearing failure Shim 212 into input shaft bearing retainer assembly 205 Make sure input bearing retainer washer 208 is in place Retain with petrol...

Страница 882: ... 0 4 9 9 3 6 2 3 0 4 9 9 3 7 2 3 0 4 9 9 3 8 2 0 0 0 0 7 9 2 1 0 0 0 8 3 2 2 0 0 0 8 7 2 3 0 0 0 9 0 2 0 4 BOLT HEX HEAD M 6 X 25 8 5 N m 205 RETAINER ASSEMBLY INPUT SHAFT BEARING 21 0 RING SNAP SELECTIVE 211 SPACER INPUT SHAFT 21 2 SHIM SELECTIVE 215 RACE BALL BEARING OUTER _______________________________________________________J H 0 0 6 2 H M 2 9 0 20 0 HOUSING FRONT 20 3 BEARING COUNTERSHAFT 21...

Страница 883: ...ENSOR ASSEMBLY ELECTRONIC SPEED 3 1 5 O RING 3 1 6 SENSOR ELECTRONIC SPEED 317 BOLT HEX HEAD M 6 X 16 _________________________________________________________ J H 0 3 1 6 H M 2 9 0 3 1 2 BOLT HEX HEAD M 8 X 50 35 N m _________________________________________________________ J H 0 1 4 1 M H 2 9 0 Figure 99 Bolts Install Figure 98 External Components Install ...

Страница 884: ...il 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 Support Idler Shaft Bolt 22 17 312 Housing Front Rear 35 27 317 Sensor Electronic Speed B olt 9 7 204 Housing Assembly Shift Lever 8 5 7 LUBRICATION Capacity RPO MCO 4 SPEED 2 03L 2 13 qts RPO MG5 5 SPEED 1 98L 2 08 qts Type Rec...

Страница 885: ...HM 290 MANUAL TRANSMISSION 7B1 83 Figure 100 Special Tools ...

Страница 886: ...7B1 84 HM 290 MANUAL TRANSMISSION Figure 101 Special Tools ...

Страница 887: ...shaft 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 in the extension housing Roller bearings support the mainshaft inde pendently in the input shaft The input shaft and mainshaft are engaged by a synchronizer for direct drive in top gear 4 Reverse idler s...

Страница 888: ...ain Drive Gear 417 V ent Plug 429 C ounte rshaft 406 3rd Speed B lo cke r Ring 418 M ain S haft 430 C ounte r Gear 407 3rd and O verdrive S ynchronizer 419 R etainer 431 C o unte rshaft Spacer 408 O verdrive B lo cke r Ring 420 S peedom eter G ear 432 E xpansion Plug 409 O verdrive G ear 421 Rear E xtension Seal 433 Snap Ring 410 2nd Speed G ear 422 Reverse Idler Gear 434 P ilot B earings 411 2nd ...

Страница 889: ...oved 10 11 12 Drive the countershaft to the front until it pushes the plug out of the case Countershaft 429 using J 29793 Drive the countershaft out the rear of the case Extension housing screw 439 Turn the housing to the normal position Bearing retainer 401 and the gasket Main drive gear 405 Drive the gear out the front of the case Extension housing 416 and the mainshaft Slide the 3rd and overdri...

Страница 890: ...on Housing 435 Screw 447 Nut 417 Vent Plug 436 Bearing Retainer Gasket 448 Spring Washer 418 M ainshaft 437 Transmission Case 449 Screw 422 Reverse Idler Gear 438 Spring Washer 450 Side Cover 423 Reverse Idler Gear Bushing 439 Screw 451 Side Cover Gasket 424 Reverse Idler Shaft 440 Extension Housing Gasket 452 3rd and Overdrive Shift Fork 426 W oodruff Key 441 Detent Ball 453 1st and 2nd Shift For...

Страница 891: ...ner 416 Extension Housing 429 Countershaft 432 Plug 437 Case 439 Screw 439 IN CENTER HOLE ON RIGHT SIDE 416 INVERTED 437 UPRIGHT Figure 3 Turning the Extension Housing B 08858 Figure 4 Removing the Mainshaft Figure 5 Removing the Reverse Idler Shaft ...

Страница 892: ...1st speed blocker ring off Remove the snap ring and the 1st and 2nd synchronizer 412 Do not let the synchronizer come apart Remove the 2nd speed blocker ring and the 2nd speed gear 410 Synchronizers 407 and 412 figure 9 The synchronizer hub and sleeve are a select fit do not m ix the p a rts of the two synchronizers Mark the hub and sleeve alignm ent for reassembly Push the hub out of the sleeve w...

Страница 893: ...he sleeve onto the hub aligning the marks made during disassembly Important The long side of the hub center A must be to the front 2 2nd speed gear 410 and the blocker ring Slide the gear on with the cone to the rear Slide the blocker ring onto the gear cone with the clutching teeth to the front 3 Install the 1st and 2nd synchronizer 412 and a new snap ring The hub slots must be engaged with the b...

Страница 894: ...r 431 C ountershaft Spacer 428 C ountershaft 476 Bearing Spacers Bearings 430 C ounter Gear B 08868 4 Figure 11 Countergear and Com ponents COUNTERGEAR D isassem ble F ig u re 11 Tool Required J 29793 Countershaft Alignment Tool 1 Remove tool J 29793 2 Remove the bearings 428 and the spacers 3 Remove the countershaft spacer 431 Clean All parts in suitable solvent and air dry Inspect Countergear fo...

Страница 895: ...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 or damaged Install or Connect Figure 14 Tool Required J 23096 Drive Gear Seal Installer New seal 402 using J 23096 Coat the inside of the seal with transmission oil SIDE COVER Disassemble Figure 15 1 Remove the shift levers 484 and 487 2 Shift shafts 480 and 481 ...

Страница 896: ...t 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 and a new gasket onto the case Turn the extension housing upside down and install one screw to hold it in place figure 3 4 Main drive gear 405 Tap the gear in until the bearing snap ring bot toms a...

Страница 897: ...r 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 in the locating hole A figure 16 Install the remaining screws finger tight Tighten the screws evenly 16 Reverse shift lever 445 Shift the transmission through all gears to check the operation Speedomet...

Страница 898: ...7B2 12 NEW PROCESS TRANSMISSION SPECIAL TOOLS ...

Страница 899: ...ined 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 engaged by a synchronizer for direct drive in top gear Thrust washers limit the play of the mainshaft 4 Reverse idler gear The idler gear drives the mainshaft in reverse The idler gear is supported on it s o...

Страница 900: ...gure 4 3 Extension housing 613 and the offset lever Im portant The offset lever is engaged into the extension housing and cannot be removed when the ex tension housing is mounted to the transmis sion Detent ball and the spring from the offset lever fig ure 5 Countergear rear thrust bearing 612 Plastic funnel 5 speed only figure 6 Front thrust race 5 speed only Shift cover 601 9 Im portant Two of t...

Страница 901: ...BORG WARNER TRANSMISSIONS 7B3 3 Figure 2 77 mm Transmission and Components ...

Страница 902: ...ll 658 Detent Spring 659 Pin y e 655 O ffset Lever v 656 D etent N eutral G uide Plate 657 D etent Ball 658 Detent S pring 656 B 08480 Figure 5 Detent Ball and the Spring Figure 3 Shift Lever Components 615 Funnel 618 5th Speed S h ift Fork 630 5th Speed S ynchronizer Figure 6 Plastic Funnel B 08481 B 08482 Figure 4 Removing the Offset Lever Pin Figure 7 Removing the 5th Speed Shift Fork Pin ...

Страница 903: ...640 to the rear to re move the bearing figure 15 Important Note the direciton the bearing faces 21 Countergear 640 and the rear bearing spacer 636 22 Countergear thrust washer 641 23 Countergear front bearing 642 Press the bearing from the case 644 Main Drive Gear Bearing Race 645 Bearing Shim Pack 646 Main Drive Gear Bearing Retainer B 08472 623 5th Speed and Reverse Shift Lever 624 Pivot Bolt 62...

Страница 904: ... Speed and Reverse Shift Lever 627 Lock Spring 629 5th Speed and Reverse Shift Shaft K B 08577 Figure 13 5th Speed and Reverse Shift Shaft Figure 14 Removing the Reverse Idler Shaft Pin B 08359 Figure 15 Removing the Countergear Rear Bearing ...

Страница 905: ...not let the synchronizer come apart 9 Im portant 3 Do not let the mainshaft fall to the floor Remove the snap ring and the 2nd speed gear thrust washer 666 4 Remove the 2nd speed gear 667 and blocker ring 5 Press the mainshaft through the 5th speed driven gear 679 using J 22912 01 figure 20 5 speed only Im portant Do not let the mainshaft fall to the floor Mainshaft rear bearing 678 It may be nece...

Страница 906: ...haft and Components mj 5 Clean Figure 18 All parts in a suitable solvent and air dry Important Do not spin dry bearings Inspect Figure 18 Gears for cracks chipped gear teeth and other damage that could cause gear noise Thrust washers and bushings for damage and wear Related surfaces on the gears like thrust faces and bearing surface diameters The reverse sliding gear for a sliding fit on the synch...

Страница 907: ...igure 22 Hold the antirattle ball and spring 669 in the hub 5 speed only 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 made during disassembly Slide the 2nd speed blocker ring 668 onto the mainshaft The clutching teeth must be to the front Slide the 2nd speed gear 667 on with the cone into the...

Страница 908: ...ng the Mainshaft Rear Bearing EXTENSION HOUSING Remove or Disconnect Figure 25 Tools Required J 8092 Driver Handle J 23062 14 E xtension H ousing B ushing Remover and Installer 1 Seal 681 2 Sealing compound from the flange of the extension 3 Bushing 680 if it is worn or damaged using J 8092 and J 23062 14 Inspect Figure 25 1 Extension for scoring wear or cracks especially at the flange 2 Snap ring...

Страница 909: ...taining 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 Bearing Retainer Oil Seal I Figure 29 Installing the Bearing Retainer Oil Seal 5 Remove the inserts 686 from the forks Clean Figure 30 All metal parts in solvent and air dry Inspect Figure 30 1 Shift forks For da...

Страница 910: ...st be 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 Drive a new retaining pin 670 into the selector arm and the shift shaft Be sure the arm and shaft pin holes are aligned The retaining pin must be flush with the selector arm 8 Install a new oil sea...

Страница 911: ...ler Be sure the reverse lever fork is engaged in the idler gear slot New reverse shift lever retaining ring 625 Countergear rear bearing spacer 634 and a new snap ring 5 speed only 5th speed drive gear 632 5 speed only 5th speed and reverse shift shaft 629 figure 13 Install the shaft from the rear of the case Turn the shaft to engage it in the reverse lever Hook the lock spring to the front of the...

Страница 912: ...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 clip Do not lose the balls from the gear Extension housing 613 Apply a 3 mm Vs inch diameter bead of RTV 732 or equivalent sealer to the mating sur face Hold the extension housing so the shift shaft j...

Страница 913: ...earing Assem bly 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 Installer 7 J 8092 Driver Handle 8 J 23062 14 Extension Housing Bushing Remover and Installer B 08343 ...

Страница 914: ...7B3 16 BORG WARNER TRANSMISSIONS ...

Страница 915: ... lever for the transfer case is floor mounted in the passenger compartment Depending on the type of transfer case and the shift lever position various combinations of rear wheel drive four wheel drive high 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 avail...

Страница 916: ...79 and washers 80 and 69 4 Yoke 68 5 Shaft assembly 26 from the housing 62 6 Snap ring 46 using Tool J 23432 Discard the snap ring 7 Thrust washer 81 8 Washer pin 45 9 Tanged bronze washer 60 10 Gear roller bearings 32 per row 41 11 Spacer 42 12 Gear roller bearings 32 per row 41 13 Tanged bronze thrust washer 60 14 Pilot rollers 25 15 Retainer ring 23 16 Washer 24 17 Oil seal retainer 65 18 Ball ...

Страница 917: ...hift rails and into the case Clevis 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 14 Bearing 9 15 Shift rail cup plugs and shift fork pins 36 from the case 16 Snap ring 11 in front of the main drive gear bearing 12 17 Main drive shaft 22 Tap the shaft out the rea...

Страница 918: ...7D1 4 NEW PROCESS 205 TRANSFER CASE Figure 3 New Process 205 Transfer Case ...

Страница 919: ...iaft S haft 18 Poppet Ball 60 T hrust W asher 19 Transfer Case 61 Rear O u tput Sh aft 20 Fill Plug R etainer Bearing 2 1 S hift Rail Interlink Plunger 62 Rear O utput Shaft 2 2 Input M ain Drive Gear Bearing Retaine r 23 P ilot R oller R etainer Ring 63 S peedom eter Gear 24 Rear O utput Shaft R oller 64 R etainer Oil Seal Gasket Bearing T hrust W asher 65 Retainer 25 Rear O u tput Shaft P ilot 6...

Страница 920: ...e 5 Front Output Shaft Rear Bearing Removal 36 C oiled S pring Pin F 02034 Figure 6 Shift Fork Pin Removal Figure 7 Shift Rail Removal 39 Tw o Four W heel S h ift S haft 59 H i Lo Range S h ift S haft F 02035 Figure 8 Idler Gear Shaft Removal ...

Страница 921: ... for cracks warpage or damage 6 Shafts for wear corrosion cracks and damage 7 Bolts and threaded holes for wear damage stret ched threads or corrosion ASSEMBLY IDLER GEAR k Install or Connect Figures 3 4 9 10 11 12 and 13 Tools Required J 8092 Driver Handle Tool B Tool A 1 Two bearing cups 50 in the idler gear 51 using Tool B and J 8092 figure 9 2 Two bearing cones 50 spacer 52 shims 53 and idler ...

Страница 922: ...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 12 and shaft 22 into the case 6 Range rail 39 into the case Start the range rail into the case from the front with the poppet notches up 7 Sliding clutch 34 and fork 77 Install the sliding clutch onto the fork Pl...

Страница 923: ...bolts into sealant before installing Tighten Bolts to 40 N m 30 ft lbs 20 Front output yoke 4 21 Washers 2 and 3 22 Lock nut 1 Tighten Bolts to 40 N m 30 ft lbs 12 Washer 32 in the case 13 Front output shaft high gear 33 in the case 14 Shift fork 77 in the sliding clutch hub 34 15 Shift fork 77 and rail 39 in the front wheel drive 4H position with the clutch teeth in mesh with the front output hig...

Страница 924: ... 05 56 mm 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 using Tool C figure 16 Grease the bearing before installing it R etainer housing 62 onto the output shaft assembly 26 Retainer housing and output shaft to the case 19 Retainer bolts 6 a Tighten Bolts to 40...

Страница 925: ...utput Shaft Front Bearing Retainer B o lts 40 30 Front Output Rear Bearing Retainer B o lts 40 30 Front Output Yoke Lock N u t 202 150 Retainer Housing Bolts 40 30 Seal Retainer B olts 40 30 Lubricant Dexron I I 5 2 Pints SPECIAL TOOLS 1 Driver Handle 2 Seal Installer 3 Seal Installer 4 Bearing Installer 5 Snap Ring Pliers J 8092 J 21359 J 22836 J 22875 J 23432 6 Snap Ring Picks 7 Tool A 8 Tool B ...

Страница 926: ...7D1 12 NEW PROCESS 205 TRANSFER CASE ...

Страница 927: ... torque flows from the input gear to the planetary assembly and annulus gear which rotate as a unit Torque is transferred to the mainshaft through the planetary carrier which is splined to the mainshaft Torque flow continues through the mainshaft and rear yoke which is splined to the mainshaft and finally to the rear propeller shaft and axle In 2H range the sliding clutch remains in a neutral posi...

Страница 928: ...7D2 2 NEW PROCESS 207 TRANSFER CASE F 02138 Figure 1 New Process 207 Transfer Case ...

Страница 929: ... Dowel W asher 47 Bolt 19 A lig nm ent Dowel 48 Yoke 20 Front O utput S haft P ilot 49 Yoke N ut Bearing 50 Yoke W asher Rubber 2 1 Front O utput S haft 51 Yoke D eflector 2 2 Planet Gear C arrier 52 Front O utput S haft Seal A ssem bly 53 Bearing R etainer Ring 23 T hrust W asher 54 Front O utput S haft Bearing 24 R etainer Ring 55 S hift S ector S pring Screw 25 A nn u lu s Gear 56 S hift Lever ...

Страница 930: ...range fork figure 7 Rotate the mode fork and shaft 69 and remove the assembly from the transfer case 16 Main drive shaft 1 Figure 6 Rear Housing Removal Pull up on the drive shaft until it separates from the planetary assembly Remove the drive shaft from the transfer case figure 8 17 Planetary assembly with the range shift fork 66 from the transfer case 2 figure 9 18 Main drive gear thrust washer ...

Страница 931: ... 52 34 Input gear seal 46 35 Rear extension seal 15 36 Input drive gear caged roller bearings 45 Use J 33841 with J 8092 Press out the bearings figure 14 37 Front output shaft rear bearing 20 Figure 1_ sh t Sector Removal Figure 10 Input Gear and Bearing Removal 37 Input Main D riveG ear 38 Input Drive G earThrust Bearing F 02148 39 Input Drive G earThrust Bearing W asher 74 S hift S ector o 75 S ...

Страница 932: ...the mainshaft Tap the hub off with a brass hammer 5 Drive sprocket 32 6 Thrust washer 33 7 Caged roller bearings 31 from the drive sprocket 32 using J 33826 and J 8092 figure 18 8 Synchronizer keys 28 from the synchronizer hub 9 Retaining rings 29 from the synchronizer hub 27 PLANETARY GEAR Remove or Disconnect Figures 1 2 and 18 Tools Required J 8092 Driver Handle J 33826 Mainshaft Sprocket Beari...

Страница 933: ...NEW PROCESS 207 TRANSFER CASE 7D2 7 4 Inner thrust ring 23 from the planetary assembly Discard the ring Figure 18 Drive Sprocket Bearing Removal ...

Страница 934: ...0 Drive Sprocket Front Bearing Installation PLANETARY GEAR Install or Connect Figures 1 2 and 19 1 Inner thrust ring 23 on the planetary assembly 22 2 Planetary assembly 22 into the annulus gear 25 3 Outer thrust ring 23 4 Snap ring 24 MAINSHAFT Install or Connect Figures 1 2 20 and 21 Tools Required J 33828 Front Drive Sprocket Bearing Installer J 8092 Driver Handle 1 Front drive sprocket bearing...

Страница 935: ...ound the bolt holes with Locktite 515 or equivalent 2 Lock plate retaining bolts 47 Tighten Bolts to 35 N m 25 ft lbs Input gear roller bearings 45 into the transfer case using J 33830 and J 8092 Press the bearings until the tool bottoms in the bore figure 22 Front output shaft rear bearing 20 using J 33832 and J 8092 Press the bearing until the tool bottoms in the case figure 23 6 9 10 11 12 13 1...

Страница 936: ...ut shaft in the case Magnet into the pocket in the transfer case Rear case 2 on the front case 44 Apply a 3 mm Vs inch bead of Loctite 515 or equivalent to the mating surface of the front case Align the rear case to the front case aligning dowel pins Case bolts 17 Install the two bolts with washers into the dowel pin holes figure 26 Tighten 29 Bolts to 31 N m 23 ft lbs Output bearing 10 into the r...

Страница 937: ...Tighten Nut to 150 N m 110 ft lbs 44 Drain plug 16 and fill plug 16 Tighten Plugs to 47 N m 35 ft lbs SPECIFICATIONS NEW PROCESS 207 TRANSFER CASE Bolt Locking Plate to Transfer Case Nut Front Output Yoke Switch Vacuum Nut Shift Lever Bolt Transfer C a s e Bolt Rear R etainer Bolt Extension H ousing Plug Drain F ill Bolt Adapter to Transfer Case Bolt Shift Bracket Bolt Shift Lever P ivo t Bolt Shi...

Страница 938: ...aft Rear Bearing Remover 11 Front O utput Seal Installer 4 Bearing Cup P uller Bridge 12 Pum p H ousing Seal In sta lle r 5 Front Drive S procket Bearing Installer 13 Rear O utput B ushing Remover 6 P ilot Bearing Installer 14 Input Drive Gear R oller Bearing Rem over 7 Front Input Bearing Installer 15 E xtension H ousing Seal In sta lle r 8 Input Seal Installer F 05810 J 8902 J 29369 1 J 29369 2 ...

Страница 939: ...l C om ponents 7D3 Mainshaft E xten sio n 7D3 Internal Com ponents 7 0 3 Front and Rear Bearings 7 0 3 Cleaning and Inspection 7 0 3 Assembly 7D3 7 Front and Rear Bearings 7D 3 7 Internal Com ponents 7D3 8 Mainshaft E xten sio n 7D 3 9 External C om ponents 7D 3 9 S pecifications 7D3 10 Special T oo ls 7D3 11 ...

Страница 940: ...from the input gear to the planetary assembly and annulus gear whifch rotates as a unit Torque is transferred to the mainshaft through the planetary carrier which is splined to the mainsh ft Torque flow continues through the mainshaft and rear yoke which is splined to the mainshaft and finally to the rear propeller shaft and axle In 2H range the sliding clutch remains in a neutral position and doe...

Страница 941: ...ings may drop out of the drive sprocket 8 Front output shaft 72 and front thrust bearing assembly 69 70 and 71 9 Synchronizer stop ring 30 10 Synchronizer 27 mode fork bushings 43 and 42 mode fork 44 and bracket 38 as an assembly The synchronizer keys may fall free from the hub 11 Shifter fork shaft 41 12 Mainshaft 1 with the synchronizer hub and retainer ring 26 attached 13 Annulus gear snap ring...

Страница 942: ...7D3 4 NEW PROCESS 208 TRANSFER CASE Figure 1 New Process 208 Transfer Case ...

Страница 943: ... Screw 20 Planetary Gears C arrier 61 Front O utput Yoke Nut 21 Planetary Gear T hrust W asher 62 Front O utput Yoke Seal W asher 22 A nnulus Gear 63 Yoke 23 A nnulus Gear T hrust W asher 64 Yoke D efle ctor 24 Range Fork C enter Pad 65 Front O utput S haft Seal 25 A nnulus Gear R etainer Ring 66 Front O utput S haft Bearing 26 S ynchronizer R etainer Ring 67 Range S ector S haft Oil Seal 27 S ync...

Страница 944: ..._ 33 Drive Sprocket 73 Driven Sprocket 75 Drive Chain B 08593 Figure 3 Sprocket and Chain Removal Figure 4 Front Output Shaft Front Bearing Removal B 08592 Figure 6 Input Gear Bearing Removal Figure 5 Front Output Shaft Rear Bearing Removal ...

Страница 945: ...rtion ASSEMBLY FRONT AND REAR BEARINGS Install or Connect Figures 8 through 12 Tools Required J 8092 Driver Handle J 29174 Mainshaft Bearing Installer J 29169 Input Gear Bearing Installer J 29163 Front Output Shaft Rear Bearing Installer J 29167 Front Output Shaft Front Bearing Installer J 29162 Extension Oil Sealer Installer J 7818 Rear Output Bearing Installer 1 Input drive gear pilot bearing 47...

Страница 946: ...nt Figure 12 Rear Output Bearing Installation Tighten Bolts to 41 N m 30 ft lbs 3 Input gear race 51 in the front case Thrust bearing 50 Input gear 49 Mainshaft thrust bearing 46 in the input gear 49 Range sector 52 8 Range sector shaft oil seal 67 9 Range sector shaft retainer 68 10 Operating lever 79 on the range sector shaft 11 Shaft washer 80 12 Lock nut 81 Tighten Nut to 24 N m 18 ft lbs 13 P...

Страница 947: ...sembly 69 70 71 on the front output shaft The sequence is thin race thrust bearing thick race The thick race is next to the housing 35 Oil pump gear 7 on the mainshaft Be sure the recessed side of the pump faces downward toward the case interior 36 Speedometer drive gear 2 on the mainshaft 37 Magnet in the front case 38 Spring 39 on the shift shaft 41 39 Retainer 38 on the shaft shaft 41 40 Loctit...

Страница 948: ...ten Nut to 163 N m 120 ft lbs 10 10 pints of Dexron II into the transfer case 11 Fill plug 15 Tighten Plug to 24 N m 18 ft lbs SPECIFICATIONS NEW PROCESS 208 TRANSFER CASE N m FT LBS Lock Plate Retaining B o lt 41 30 Range Sector Shaft Retaining N ut 24 18 Transfer Case Bolts 31 23 Extension B o lts 31 23 Indicator Switch 24 18 Poppet S c re w 31 23 Drain P lu g 24 18 Front Yoke Nut 163 120 Fill P...

Страница 949: ...dle Front O utput Shaft Rear Bearing Rem over E xtension Oil Seal Installer Front O utput S haft Rear Bearing Installer 7 8 9 10 11 12 J 29174 J 29369 1 Front O utput Shaft Front Bearing In staller Front O utput Shaft Rear Bearing Remover Input Gear Bearing Insta ller Input Gear Front and Rear Bearing Rem over M ainshaft Bearing Installer Input Drive Gear Pilot Bearing Rem over F 05820 ...

Страница 950: ...7D3 12 NEW PROCESS 208 TRANSFER CASE ...

Страница 951: ...or servicing 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 positions input torque is transmitted to the transfer case gear train through the transfer case input gear In 2H range torque flows from the input gear to the range shift hub and main shaft To...

Страница 952: ...7D4 2 NEW PROCESS 241 TRANSFER CASE F 05386 Figure 1 New Process 241 Transfer Case Components ...

Страница 953: ...Gear 21 Front O u tput Shaft 63 S hift Lever Nut Prev Torque 22 Driven S procket 64 W asher 23 Retainer Snap Ring 65 S hift Lever 24 Front O utput Rear Bearing 66 W asher P lastic 25 M agnet 67 O Ring Seal 26 Oil Tube C o nnector 68 Poppet Screw 27 W asher 69 O Ring Seal 28 Main Drive S ynchronizer S top Ring 70 S election P lunger 29 S ynchronizer Sleeve 71 Poppet Spring 30 S trut 72 Front O u tp...

Страница 954: ...nnect 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 Pump retainer housing bolts are shouldered 4 Pump retainer housing 8 from the rear case half 17 5 Retainer snap ring 10 speedometer tone wheel 11 and retainer snap ring 10 from the mainshaft 19 6 Case bolts 3 from the case halves Note ...

Страница 955: ...tput Flange F 05388 Figure 4 Front View 241 Transfer Case 65 63 F 05391 25 45 54 55 81 M agnet Front Case H alf M ode Fork S ector W ith Shaft S ynchronizer A ssem bly F 05389 S h ift Rail Range Fork M ode Fork Spring M ode Fork S ector W ith Shaft S h ift Lever Nut Lever Figure 5 Mode Fork and Shaft Assembly 48 51 52 54 55 63 65 Figure 6 Shift Rail Assembly ...

Страница 956: ... the range fork 51 figure 6 Shift lever nut 63 washer 64 shift lever 65 plastic washer 66 and the O ring seal 67 from the front case half 45 Input bearing retainer bolts 43 and input bearing retainer 44 from the front case half 45 Bearing retainer snap ring 39 Planetary carrier 36 and the input gear 38 from the annulus gear 62 using a soft faced hammer Retainer ring snap ring 41 from the input gea...

Страница 957: ...h oil feed port and channel in order to remove any obstructions or cleaning solvent residue 6 All mating and sealing surfaces Inspect 1 Bearings and thrust washers for wear spalling brin neling or corrosion 2 Gear teeth for excessive wear or damage spalling cracks or corrosion 3 Gear splines for excessive wear spalling cracks twist or corrosion 4 Shaft splines for excessive wear spalling cracks di...

Страница 958: ...earings into the driven sprocket so that it is flush on the synchronizer side 2 Needle bearing 24 to the 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 pump retainer housing 8 using J 36371 figures 13 and 14 6 Bearing 84 to the input gear 38 using ...

Страница 959: ... m 20 ft lbs 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 Synchronizer assembly mode shift fork 54 and rail into the front case half 45 figure 16 9 Front output shaft 21 to the front case half 45 10 Driven sprocket 22 into the chain 58 11 Drive sprocket 20 and mainshaft 19 into the chain 58 Mainshaft 19...

Страница 960: ...ner housing 8 Apply RTV sealer to the mating surfaces A pply Loctite 242 or equivalent on the extension housing bolts Figure 16 Synchronizer Hub Assembly and Mode Fork 4 Tighten Bolts to 31 N m 23 ft lbs EXTERNAL COMPONENTS Install or Connect 1 Selection plunger 70 poppot spring 71 O ring seal 69 and poppet screw 68 to the front case half 45 Tighten Poppet screw to 31 N m 23 ft lbs 2 Speedometer s...

Страница 961: ...NEW PROCESS 241 TRANSFER CASE 7D4 11 Figure 17 Oil Pump Pickup Screen Doweled Case Holes ...

Страница 962: ...7D4 12 NEW PROCESS 241 TRANSFER CASE Figure 18 241 Transfer Case Cut Away ...

Страница 963: ...Snap Ring 16 Bolt 61 Front O utp ut Bearing 17 Rear Case H alf 62 A nnu lus Gear 18 Oil Pump Pick Up Tube 63 S h ift Lever N ut Prev Torque 19 M ainshaft 64 W asher 20 Drive S procket 65 S hift Lever 21 Front O u tput S haft 66 W asher Plastic 22 Driven S procket 67 O Ring Seal 23 R etainer Snap Ring 72 Front O utpu t S haft Seal 24 Front O u tput Rear Bearing 73 D eflecto r 27 W asher 74 Front O ...

Страница 964: ...and Fill P lu g s 47 35 Lubricant Dexron I I 4 6 Pints SPECIAL TOOLS 3 4 J 2619 01 J 2619 5 J 8092 J 22912 1 J 29369 1 J 29369 2 1 S lide H am m er 2 Slide H am m er 3 Driver H andle 4 Bearing Rem over 5 O utput S haft Bearing Remover 6 O utput S haft Bearing Remover 7 8 10 11 12 J 9276 21 J 33832 J 36371 J 36370 J 36372 J 36373 7 S lide H am m er A dapter 8 Bearing Installer R em over 9 Front and...

Страница 965: ...ation 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 positions input torque is transmitted to the transfer case gear train through the transfer case input gear In 2H range torque flows from the input gear to the range shift hub and main shaft Torque flow continues...

Страница 966: ...H D Front Case Half EXTERNAL COMPONENTS Clean The transfer case exterior using a solvent and a stiff brush l Remove or Disconnect Figure 2 3 and 4 1 Front output yoke nut 77 washer 76 rubber sealing washer 75 and front output flange 74 from the front output shaft 2 Indicator lamp switch 46 and O ring seal 47 3 Poppet screw 68 O ring seal 69 poppet spring 71 and poppet plunger 70 MAINSHAFT EXTENSIO...

Страница 967: ...t is 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 the front case half 45 8 Input bearing retainer bolts 43 and input bearing retainer 44 from the front case half 45 9 Bearing retainer snap ring 39 10 Planetary carrier 36 and the input gear 38 from...

Страница 968: ...7D5 4 NEW PROCESS 231 H D TRANSFER CASE Figure 3 New Process 231 H D Transfer Case Components ...

Страница 969: ... Front Case H alf 77 N ut Front O utput Yoke 14 O Ring 46 Indicato r Lamp S w itch 78 C arrier Lock Ring 15 Plug 47 O Ring Seal 79 Oil Pum p Screw 16 Bolt 48 S h ift Rail 80 Id e n tifica tio n Tag 17 Rear Case H alf 49 Pads 81 S ynchro nizer A ssem bly 18 Oil Pump Pick Up Tube 50 Pads Center 82 Drive Sp rocket Bearing 19 M ainshaft 51 Range S h ift Fork 83 M ode S ynchronizer Hub 20 Drive S prock...

Страница 970: ... Oil Pump Pickup Tube and Screen 25 M agnet 45 Front Case H alf 54 M ode Fork 55 S ector W ith Shaft 81 S ynchronizer A ssem bly F 05391 48 S h ift Rail 51 Range Fork 52 M ode Fork Spring 54 M ode Fork 55 S ector W ith S haft 63 S h ift Lever Nut 65 Lever F 05389 Figure 6 Mode Fork and Shaft Assembly Figure 7 Shift Rail Assembly ...

Страница 971: ...palling or excessive wear Synchronizer hub and sleeve for cracks chips spalling or excessive wear Pads on the mode fork and the range fork for wear distortion Oil pump gears and case halves for wear spalling cracks and damage Replace complete assembly if there is wear Input gear planetary carrier and range shift hub tooth chamfers for excessive wear ASSEMBLY OF TRANSFER CASE BEARING AND SEAL REPLA...

Страница 972: ...sleeve 29 3 Main drive synchronizer stop ring 28 to the synchronizer sleeve 29 Install or Connect Drive sprocket 20 to the mainshaft 19 Planetary input gear assembly 38 into the annulus gear 62 using a soft faced hammer Bearing retainer snap ring 39 to the input bearing 40 Input bearing 40 to the front case half 45 Input bearing retainer bolts 43 and input bearing retainer 44 to the front case hal...

Страница 973: ...t 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 28 S ynchronizer Stop Ring 29 S ynchronizer Sleeve 31 S ynchronizer Hub 48 S hift Rail 54 Mode Fork F 05432 Figure 14 Synchronizer Hub Assem bly and Mode Fork The two longer case bolts and washers into doweled case holes 33 figure 16 Tig h ten Bolts to 31 N...

Страница 974: ...lf 45 Poppet 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 3 Front output flange 74 rubber sealing washer 75 washer 76 and flange nut 77 SPECIFICATIONS NEW PROCESS 231 H D TRANSFER CASE N m Ft Lbs Input Shaft Retainer B o lts 19 14 Shift Selector Lever N u t 31 23 Shift Selector Light Switch 24 17 Case Half Bolts 31 23...

Страница 975: ...R em over 2 S lide H am m er 9 Bearing In sta ller 3 Driver Handle 10 Bearing Installe r 4 Bearing Rem over 11 Seal Installe r 5 Bearing Rem over 12 E xtension H ousing Seal In sta lle r 6 O utput S haft Bearing Rem over 13 Bearing In sta ller 7 A dapter 14 Bearing Remover F 05907 Special Tools ...

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