Cylinder Block; Oil Pan; Oil Pumps - Ford 1961 TRUCK 100 SERIES Shop Manual

the gear, then knock it off the
fly-
wheel. Do not hit the flywheel when
removing the ring gear.
Heat the new ring gear even ly
until the gear expands enough to
slip onto the flywheel. Make sure
the gear is seated properly against
the shoulder. Do not heat any por-
tion of the gear to a temperatufe
higher than 500 °F. If this limit is
exceeded, the temper will be removed
from the ring gear teeth.
CYLINDER BLOCK
CLEANING
Thoroughly clean the block in
solvent. Remove old gasket material
from all machined surfaces. Remove
all pipe plugs which seal oil pas-
sages, then clean out all the pas-
sages. Blow out all passages, bolt
holes, etc. with compressed air.
Make sure the threads in the cyl-
in der head bolt holes arc clean. Dirt
in the threads may cause binding
and result in a false torque reading.
Use a tap to true-up threads and to
remove any deposits.
INSPECTION
After the block h as been
thoroughly cleaned, make a check
for cracks. Minute cracks not visible
to the naked eye may be detected
by coating the suspected are a with
a mixture of 25 % kerosene and 75 %
light motor o il. Wipe th e part dry
and immediately app ly a coating of
zinc oxide dissolved in wood al-
cohoL If cracks
are present, the coat-
ing will become discolored at the de-
fective area. Replace the block if it
is cracked.
Check all machined gasket sur-
faces for burrs, nicks, scratches,
and scores. Remove minor imperfec-
tions with an oil stone. Check the
flatness of the cy lind er block gasket
surface following the procedure and
specifications recommended for the
cylinder head.
Replace all expansion-type plugs
that show ev id ence of leakage.
l'nspect the cy lind er walls for
scor ing, roughness, or other signs
of wear. Check the cylinder bore for
out-of-round and taper. t\'feasure
the bore with an accurate gauge fol-
lowing the instructions of the manu-
facturer . Measure the diameter of
each cylinder bore at the top, middle,
and bottom with the gauge placed at
right angles and parallel to the cen-
terline o f the engine (F ig. 46).
Refinish cylinders that are deeply
scored and / or when out-of-round
PART 1 -1- GENERAL ENGINE SERVICE
.....- CENTER LINE OF ENGINE_
A
~
AT
RIGHT
• ANGLE
1
TO
CENTER
LINE OF
ENGINE
" - j
B
PARALLEL
TO
CENTER
LINE OF
ENGINE
1. OUT·OF·ROUND
=
DIFFERENCE BETWEEN
A
AND B
2. TAPER
=
DIFFERENCE BETWEEN THE A
M EASUREMENT AT TOP OF
CYLINDER BORE AND THE A
MEASUREMENT AT BOITOM OF
CYLINDER BORE A 1 025-A
FIG,
46-(ylinder Bore
Out-aI-Round and Toper
and/ or taper exceed the wear lim its.
If the cy lind er walls have minor
surface imperfections, but the out-
of-round and taper are within lim its,
it may be possible
to
remove the
imperfections by honing the
cyl~
inder wal!s and installing new serv~
ice piston rin gs providing th e piston
clearance is within limits. Use the
finest grade of honing stone for this
operation.
REPAIRS
Refinishing Cylindcr Walls. Hon-
ing is recommended for refinishing
cylinder walls only when th e wall s
have minor imperfections, suc h as
light scuffs, scratc hes, etc. Th e grade
of hone to be lIsed is determin ed by
the amount of metal to be removed.
Follow the instructions of the hone
manufacturer.
If
coarse stones are
used to start the honing operation,
leave enough material so that all
hone marks can be removed with the
finishing hone which is used to obtain
the proper piston clearance.
Cylinder walls that are severely
marred and / or worn beyond th e
specified li mit s should be refinished.
Before any cy lin der is refinished, all
main bearing caps must be in place
and tight ened to th e proper torque
so that the c rankshaft bearing bores
will not become distorted from the
refinishing operation.
Refinish only the cylinder or cyl-
inders that require it. All pistons arc
the same weight, both standard and
oversizc; therefore, various sized pis-
tons
can
be intermixed without up-
setting engine balance.
Refinish the cyl inder with the
most wear first to determine the
maximum oversize. If the cylinder
1-25
will not clean up when refinished
for the maxim um oversize piston rec ~
om mended, replace the block.
Refinish the cylinder to within ap-
proximately 0 .00 15 inch of the re-
quired oversize diameter. This wi ll
allow enough stock for the final step
of honin g so the correct surface
finish and pattern are obtained. Use
clean sharp hones of No. 220-280
grit for this operat ion.
For the proper use of the re-
finishin g equipment follow the in-
structions of th e manufacturer. Only
experienced personnel should be al-
low ed to perform this work.
After the final operation in either
of the two refinishing methods de-
scribed and prior to checking the
piston fit, thoroughly wash the cyl-
inder walls with so lvent to remove
a ll abrasive particles, the n
thoroughly dry the walls. Check the
piston fit. Mark the pistons to co rre-
spond to the cylinders in which they
are to be installed. When the refinish-
ing of all cylinders that require it has
been completed and all pist o ns fitted,
thoroughly clean th e entire block to
remove all particles from the bear-
ing bores, oi l passages, cylinder head
bolt ho les, etc. Coat the cylinder walls
with oi l.
OIL PAN AND OIL PUMPS
OIL PAN
Scrape any dirt
or
metal partic les
from th e inside of the pan. Scrape
all old gaske t material from the gas-
ket sllrface. Wash the pa n in
a
so l-
vent and dry it thoroughly. Be sure
all foreign matter is removed from
below the baflle plate.
C heck the pan for cracks, holes,
damaged drain plug th reads, and a
loose balTIc or a damaged gasket
surface.
Repa ir any damage, or replace
the pan jf repairs can not be made.
OIL PUMPS
Cleaning. Wash all parts in a so l-
vent and dry them thoroughly. Use
a brush to clean the insid e of the
pump hOllsing and the pressure relief
valve chamber. Be sure
all
clirt and
chips are removed.
On the gear-type oi l pump, remove
old gasket material from the pump
body and cover.
Inspection - Rotor-Type. C heck
the insid e of the pump housing and
the outer race and rotor for damage
or excessive wear.
Check the mating surface of the