Page 2: Important Safety Notice
Consequently, Chevrolet has not undertaken any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Chevrolet must first satisfy himself thoroughly that neither his safety nor vehicle safety will be...
Page 4 ENGINE FOREWORD This manual includes procedures involved in disassembly and assembly o f major components of 1973 Chevrolet, Chevelle, Monte Carlo, Nova, Camaro, Corvette and Light Duty Trucks. Information on theory of operation, diag nosis, maintenance and adjustments, minor service opera...
Page 6: Table Of Contents
AIR C O N D IT IO N IN G COM PRESSOR SECTION 1 AIR CONDITIONING COMPRESSOR INDEX Compressor Rear Head and Internal Mechanism Minor Repair Procedures ..1-1 Hub and Drive Plate............1-1 Pressure Relief Valve............1-7 Pulley and Bearing Assembly........1-2 Superheat Switch..............1-8 Coil Housing Assembly...........1-3 Rear Head, Oil Pump and Valve Assemblies..1-8...
Page 7: Pulley And Bearing Assembly
1-2 AIR C O N D IT IO N IN G COMPRESSOR Rear Head Pulley and Bearing Assembly Th ru st Bearing Rear Head to Shell " 0 " Ring Pulley Bearing Th ru st Race Rear Discharge Valve Plate Pulley Bearing R etainer Ring Compressor Shell Rear Suction Reed Plate...
Page 8: Coil Housing Assembly
AIR C O N D IT IO N IN G COM PR ESSOR Fig. 3-R em oving Hub and Drive Plate Assem bly Fig. 2--Removing Shaft Locknut signs of excessive grooving due to slippage, both the pulley and the clutch hub and drive plate assembly should be replaced.
Page 9: Major Repair Procedures
1-4 AIR C O N D IT IO N IN G COMPRESSOR Fig. 6--Removing Pulley and Bearing Assembly R etainer Ring Fig. 5 -Installing Hub and Drive Plate Assembly MAJOR REPAIR PROCEDURES The following service procedures are considered major since the refrigeration system must be completely purged of refrigerant before proceeding and/or because major internal operating and sealing components of the compressor are being disassembled and serviced.
Page 10: Shaft Seal Assembly
AIR C O N D IT IO N IN G COM PRESSOR 22. Valve and head locator (dowel) pins. 23. Service discharge crossover tube kit. Fig. 9— In sta llin g Coil Housing (a)To be used each time a compressor is rebuilt. 4.
Page 11 1-6 AIR C O N D IT IO N IN G COMPRESSOR Drive Key Discharge Crossover Shaft Seal Seat Shaft N u t Tube Rear " 0 " Ring Retainer Ring Discharge Crossover Clutch Hub Retainer and Spacer Tube Shaft Seal Seat Ring Rear Suction Reed Piston Ring...
Page 12: Compressor Rear Head And Internal Mechanism Pressure Relief Valve
AIR C O N D IT IO N IN G COM PRESSOR STRAIGHT EDGE WIRE G A U G E .029" SHOULD " G O " .072" SHOULD "N O T G O " OR SHOULD "JUST G O " ABSORBENT SLEEVE SLEEVE RETAINER SEAL SEAT...
Page 13: Superheat Switch
1-8 AIR C O N D IT IO N IN G COMPRESSOR Superheat Switch The superheat switch is used on passenger cars and "G " model trucks. If it becomes necessary to replace the superheat switch, located in the rear head casting, the switch assembly should be removed only after purging the system.
Page 14: Major Internal Mechanism
AIR C O N D IT IO N IN G COM PRESSOR gears, valve reeds and the area where the head casting web sealing surface will contact the valve plate. 5. Install the head-to-shell "O " ring. 6. Be sure that the suction screen is properly positioned in the rear head, then assemble the rear head to the compressor shell being careful not to damage the sealing surface of the head casting...
Page 15 1 -1 0 AIR C O N D IT IO N IN G COMPRESSOR Fig. 1 9 -S eparating C ylinder Halves not to move wobble plate on the shaft. This is factory set. 12. Examine the front and rear cylinder halves and replace if cylinder bores are deeply scored or damaged.
Page 16 AIR C O N D IT IO N IN G COM PRESSOR 1-11 W o b b le Plate No. 1 Piston Front Cylinder H alf y Front Thrust Races 3 and Bearing M B H olding Fixture J-9396 H P | Com pressing | Fixture J-9397 Fig.
Page 17 1 -12 AIR C O N D IT IO N IN G COMPRESSOR actual force required to pull the feeler gauge compartment corresponding to the rear ball position of the No. 1 piston. free is measured. Rotate the shaft approximately 120 degrees and 13.
Page 18 AIR C O N D IT IO N IN G COM PRESSOR 1-13 10. When all parts are in proper alignment, tap with a 3. Apply a light smear of petroleum jelly to the fiber block and mallet to seat the rear half of the numbered ball seats chosen in the gauging cylinder over the locating dowel pins.
Page 19: Leak Testing The Compressor
1 -1 4 AIR C O N D IT IO N IN G COMPRESSOR 10. Locate the oil intake tube hole in the rear discharge plate. Line up the oil sump with this hole location and slide the shell down over the mechanism while supporting the mechanism on Fixture J-21352 (fig.
Page 20 AIR C O N D IT IO N IN G COM PRESSOR 1-15 SPECIAL TOOLS Pulley and Bearing J-9481 No. 21 Snap Ring Pliers J-5403 Charging Station J 8393 Installer No. 26 Snap Ring Pliers J-6453 O il Inducer J-24095 J-8092 Handle Compressor Holding...
Page 22 Relieve pressure on spreader tool and remove tool. Oil Seal Replacement Fig. 1—Spreading Case w ith J-5231-01 The axle shaft inner oil seals are located just outboard of CHEVROLET OVERHAUL MANUAL...
Page 23: Front Axle Differential
3-2 FRONT AXLE DIFFERENTIAL N u t D iffe re n tia l Bearing Cone 2 0 . D iffe re n tia l Case 2 9 . T h ru s t Washer Washer D iffe re n tia l Bearing C up 2 1 .
Page 24 Bolt (D ifferential 11. Shims (Inner Pinion Cover and Plug Bearing Cap) Bearing) Lock Pin (Pinion 2. Washer Bolt (Ring Gear) Cup (Inner Pinion Shaft) 3. Companion Flange Pinion Shaft Differential Case Bearing) Pinion Oil Seal 27. Thrust Washer Shims (Differential Cone and Roller 5.
Page 25: Drive Pinion
6. Check fit of side gears and axle shaft splines. 7. Inspect differential pinion shaft and spacer for scoring or evidence of excessive wear. Fig. 4 —Removing Side Bearings J-8614-1 Fig. 6- Removing Inner Pinion B earing Cone and Fig. 5- Removing Pinion Flange Roller CHEVROLET OVERHAUL MANUAL...
Page 26: Drive Pinion
For example: If the old pinion reads ( + 2) and the new pinion is (—2), add .004" shims to the original shim pack. 1. Determine proper inner shim pack (for setting pinion Fig. 7 -Checking Runout depth) by using chart (fig. 8). CHEVROLET OVERHAUL MANUAL...
Page 27 Increase the outer shim pack to reduce rotation torque. Decrease shim pack to increase rotating torque. 11. Remove nut, washer and flange from pinion shaft. 12. Install oil slinger, gasket and using Tool J-22804 Fig. 9—Installing Inner Pinion Cone and Roller install oil seal. CHEVROLET OVERHAUL MANUAL...
Page 28 Install cap screws finger tight. Rotate differential assembly and rap on case with a soft- faced hammer to ensure proper seating of case in carrier. 4. Remove spreader and torque cap bolts to Fig. 11—Gear Tooth N om enclature specifications. CHEVROLET OVERHAUL MANUAL...
Page 29 D E C R E A S E B A C K L A S H HIGH FACE CONTACT IN C R E A S E P IN IO N S H IM Fig. 12—Gear Tooth Contact Pattern CHEVROLET OVERHAUL MANUAL...
Page 30 Driver Handle (use w ith J-6368) (1)-58 w ith 1 " m icrom eter J-9276-2 Installer - Pinion inner bearing J-8001 Dial Indicator Set J-22912 Press Plate Pinion bearing J-23494 Installer - Pinion oil seal use w ith J-23476 Fig. 13—Special Tools CHEVROLET OVERHAUL MANUAL...
Page 32: Service Information
Limited Slip Units................4-38 Truck—Chevrolet 10 1/2" Ring G ea r........4-47 Truck—Dana 10 1/2" Ring G ear..........4-55 Truck—Chevrolet 12 1/4" Ring G e a r........4-63 SERVICE INFORMATION For example, if an axle had this axle number: HKP 218 DW,...
Page 33 4 -2 REAR AXLE DIFFERENTIAL CARRIER ALTERNATE PINION DEPTH SETTING 8 - 7 /8 " Ring Gear—Passenger Car 1. Set up the tools as shown in figure 0-3. PROCEDURE 2. Preload the dial indicator one half revolution, with A new pinion depth coding system facilitates the use of the plunger off the gauge plate, and tighten in this Pinion Setting Gauge J-21777-01, as outlined in later position.
Page 34 REAR AXLE DIFFER EN TIA L CARRIER OVERHAUL MANUAL...
Page 35 4 - 4 REAR AXLE DIFFERENTIAL CARRIER PASSENGER CAR DIFFERENTIAL 8 - 1 / 2 " RING GEAR INDEX D i f f e r e n t i a l Case Drive P in io n C h e c k s a n d A d j u s t m e n t s R e m o v a l a n d D i sa ss e m b ly ....
Page 36 REAR AXLE DIFFER EN TIA L CARRIER DIFFERENTIAL CASE Inspection 1. Clean all parts in cleaning solvent; inspect all Removal and Disassembly bearing cups, races and rollers for scoring, chipping NOTE: Before proceeding with following or evidence of excessive wear. steps, it is advisable to check the existing ring gear to pinion backlash as described under 2.
Page 37 4 -6 REAR AXLE DIFFERENTIAL CARRIER original parts are being reused, replace in original positions. 2. Position pinions and thrust washers through loading hole in case 180° apart so that they engage side gears. J—8092 3. Rotate gears until the differentia] pinion bores and the case shaft holes are aligned.
Page 38 REAR AXLE D IFFERENTIAL CARRIER EXAMPLE RING GEAR SIDE OPPOSITE SIDE Thickness of Tool J-22779 Combined total of required force ring Service Spacer (A ) .250” .265” gear into contact with Service Shim (B ) pinion Feeler Gauge (C ) TO M AIN TAIN PROPER BACKLASH (.005”...
Page 39 4 -8 REAR AXLE DIFFERENTIAL CARRIER 8. Now measure the above dimensions as shown in Fig. 7A. a. Using a micrometer as in Figure 8A, measure the thickness of J-22779 in a minimum of three places and average these readings. Record the result.
Page 40 REAR AXLE DIFFER EN TIA L CARRIER 4 -9 Fig. 12A—Drive Pinion N u t Removal .003" change in shim dimensions. If backlash exceeds .008", increase the shim thickness on ring NOTE: Care must be taken not to damage gear side, while decreasing shim thickness on pinion bearings while removing pinion from opposite side If backlash is less...
Page 41 4 - 1 0 REAR AXLE DIFFERENTIA L CARRIER Fig. 16A—In sta llin g Pinion Rear Bearing Cup bore shoulder, using Installer J-7137 as shown in 3. Remove rear pinion bearing from pinion shaft figure 17A. using Press Plate J-22912. See Figure 15A. 8.
Page 42 REAR AXLE D IFFERENTIAL CARRIER 4-11 machining the parts. When a pinion is found having a plus or minus reading recorded in thousandths on the rear face of the pinion, this indicates that the pinion during testing was found to have best tooth contact at a position varying from design or nominal depth.
Page 43 4 - 1 2 REAR AXLE DIFFERENTIAL CARRIER 13. Once the zero reading is obtained, swing the plunger until it is removed from the gauging plate button. The dial indicator will now read the required pinion shim thickness for a "nominal" pinion. Record this size.
Page 44 REAR AXLE D IFFERENTIAL CARRIER 4 -1 3 pinion through front bearing and companion CHECKS AND ADJUSTM ENTS flange. Tighten only until end play is removed from Four adjustments are essential for proper operation of drive pinion then remove Tool J-9458. the differential and its related parts.
Page 45 4 - 1 4 REAR AXLE DIFFERENTIAL CARRIER all ring gear teeth using a medium stiff brush. position of drive pinion in carrier. The effects of bearing When properly used, the area of pinion tooth preloads are not readily apparent on hand loaded teeth contact will be visible when hand load is applied.
Page 46 REAR AXLE D IFFERENTIAL CARRIER 4 -1 5 The important thing to note is that the contact pattern is (The adjusting shims are also used to set side bearing centrally located up and down on the face of the ring preload).
Page 47 4 - 1 6 REAR AXLE DIFFERENTIA L CARRIER PASSENGER CAR AND SERIES 10 TRUCK DIFFERENTIAL 8— 7 / 8 RING GEAR INDEX D i f f e r e n t i a l Case D rive P i n i o n C h e c k s a n d A d j u s t m e n t s R e m o v a l a n d D i s a s s e m b l y .
Page 48 REAR AXLE D IFFERENTIAL CARRIER 4 -1 7 DIFFERENTIAL CASE Inspection 1. Clean all parts in cleaning solvent; inspect all Removal and Disassembly bearing cups, races and rollers for scoring, chipping NOTE: Before proceeding with following or evidence of excessive wear. steps, it is advisable to check the existing ring gear to pinion backlash as described under 2.
Page 49 4 -1 8 REAR AXLE DIFFERENTIA L CARRIER 2. Position pinions and thrust washers through loading hole in case 180° apart so they engage side gears. 3. Rotate gears until the differential pinion bores and the case shaft holes are aligned. 4.
Page 50 REAR AXLE DIFFERENTIA L CARRIER 4 -1 9 EXAM PLE RING GEAR SIDE OPPOSITE SIDE Thickness of Tool J-22779 Combined total of: Service Spacer (A ) required force ring .265” .250" gear into contact w ith Service Shim (B ) Feeler Gauge (C ) pinion...
Page 51 4 - 2 0 REAR AXLE DIFFERENTIAL CARRIER places and average these readings. Record the result. b. Add together the dimensions of the Service Shim, Service Spacer and Feeler Gauge. Record the result. 9. Use the sample procedure in Figure 7B to determine the proper thickness for each shim pack.
Page 52 REAR AXLE DIFFERENTIAL CARRIER 4-21 Fig. 1 IB —Checking Ring Gear Runout Fig. 12B—Drive Pinion N u t Removal If backlash exceeds .008", increase the shim NOTE: Care must be taken not to damage thickness on the ring gear side, while decreasing the pinion bearings while removing pinion from shim thickness on the opposite side carrier.
Page 53 4 - 2 2 REAR AXLE DIFFERENTIA L CARRIER DRIFT Fig. 16B—In sta llin g Pinion Rear Bearing Cup Fig. 14B—Removing Drive Pinion 7. Install the front cup, with the large end against the 3. Remove rear pinion bearing from pinion shaft bore shoulder, using Installer J-7137 as shown in using Press Plate J-22912, as shown in figure 15B.
Page 54 REAR AXLE DIFFERENTIA L CARRIER 4 -2 3 "nom inal" setting due to allowable variation in machining the parts. When a pinion is found having a plus or minus reading recorded in thousandths on the rear face of the pinion, this indicates that the pinion during testing was found to have best tooth contact at a position varying from design or nominal depth.
Page 55 4 - 2 4 REAR AXLE DIFFERENTIAL CARRIER indicator reading. For example, if indicator reading is .019, and pinion is marked ( + 2), the j _ 2 1777-45 DIAL correct depth shim for installation will be .019 (LARGE STEP) INDICATOR + .002 = .021 inch.
Page 56 REAR AXLE D IFFERENTIAL CARRIER 4 -2 5 Fig. 26B —In sta llin g Pinion Oil Seal—Truck pinion nut and tighten sufficiently to draw pinion Fig. 24B —In sta llin g Rear B earing—Truck through the front bearing far enough to leave carrier shoulder and seal flange.
Page 57 4 - 2 6 REAR AXLE DIFFERENTIAL CARRIER or 10-15 inch pounds on reused bearings. Use an Contact Pattern Check is necessary to verify the correct inch-pound torque wrench such as J-5853, as shown relationship between ring gear and drive pinion. Gear in figure 28B, to measure the rotating torque.
Page 58 REAR AXLE D IFFERENTIAL CARRIER 4 -2 7 Adjustments Affecting Tooth Contact tolerances. Increasing shim thickness will move the Two adjustments can be made which will affect tooth pinion closer to centerline of the ring gear. Decreasing contact pattern. These are backlash and position of drive shim thickness will move pinion farther away from pinion in carrier.
Page 59 4 - 2 8 REAR AXLE DIFFERENTIA L CARRIER CORVETTE DIFFERENTIAL INDEX C over Bolt Differential Pinion S id e B e a rin g C a p S id e G e a r Y o k e Carrier Cover Pin Retainer Bo lt B e a rin g S e a l...
Page 60 REAR AXLE DIFFERENTIA L CARRIER 4 -2 9 DIFFERENTIAL CASE J 2 2 8 8 8 Removal and Disassembly 1. Clamp carrier in Holding Fixture J-3289. 2. Remove snap rings securing side gear yokes and pull yokes out of carrier. See Figure 1C. 3.
Page 61 4 - 3 0 REAR AXLE DIFFERENTIAL CARRIER Fig. 5C—Ring Gear Guide Pins Installed 4. Install every other ring gear bolt and draw ring gear up evenly until gear is seated against flange. Fig. 7C— In sta llin g Side Gear Yoke Seal 5.
Page 62 REAR AXLE D IFFERENTIAL CARRIER 4-31 Shim Identification Shim Notches Thickness I.D. O.D. .040 .042 .044 .046 .048 .050 .052 .054 .056 .058 .060 .062 .064 .066 .068 .070 Fig. 9C—M easuring D iffe re n tia l Shim R equirem ent .072 10.
Page 63 4 - 3 2 REAR AXLE DIFFERENTIAL CARRIER Fig. 11C—In sta llin g D iffe re n tia l Shim Fig. 13C—Checking Ring Gear Runout EXAMPLE: .008" preferred. Check reading at four equally spaced positions around the ring gear. Variation in Gauge thickness (higher reading)....226"...
Page 64 REAR AXLE D IFFERENTIA L CARRIER 4 -3 3 Inspection 1. Clean all gears and bearings in cleaning solvent and blow dry. NOTE: Do not spin bearings during drying process. The extremely fast spinning and lack of lubrication may quickly result in the failure of an otherwise reusable bearing.
Page 65 4 - 3 4 REAR AXLE DIFFERENTIAL CARRIER In order to compensate for all of the allowable machining variables, a procedure of gaging the carrier and shimming the pinion has been developed. After gaging a carrier, the assembler must install the appropriate shim between the drive pinion shoulder and the rear bearing so that pinion depth can be adjusted to the required position for best tooth contact in each axle...
Page 66 REAR AXLE D IFFERENTIA L CARRIER 4 -3 5 Fig. 22C—Pinion Depth Gauging Tools Installed 14. Check the rear face of the pinion being installed for a pinion code number. This number indicates 9. Preload the dial indicator one half revolution, and the necessary alteration of the pinion shim tighten in this position.
Page 67 4 - 3 6 REAR AXLE DIFFERENTIA L CARRIER Fig. 25C—M easuring R o ta tin g Torque are a) Pinion Bearing Preload, b) Side Bearing Preload, c) Pinion Depth and d) Ring gear-to-Pinion Backlash. with a hammer and drift, until oil seal flange seats Pinion Bearing Preload is set to specifications in step 8 against the carrier.
Page 68 REAR AXLE D IFFERENTIA L CARRIER 4 -3 7 Adjustments Affecting Tooth Contact Two adjustments can be made which will affect tooth contact pattern. These are backlash and position of drive pinion in carrier. The effects of bearing preloads are not readily apparent on hand loaded teeth pattern tests: however, these adjustments should be within specifica...
Page 69 4 - 3 8 REAR AXLE DIFFERENTIA L CARRIER Fig. 27C—Gear Tooth Contact Pattern LIMITED SLIP DIFFERENTIAL UNITS INDEX General Description................4-39 Eaton Positraction................4-39 Disassembly..................4-40 Inspection...................4-41 Reassembly..................4-41 Chevrolet Positraction.................4-43 Disassembly..................4-43 Inspection....................4-43 Reassembly..................4-43 Power-Lok Differential................4-45 Disasassembly..................4-45 Inspection....................4-45 Assembly....................446 Testing Procedure................4-46...
Page 70: General Description
Chevrolet or an Eaton Positraction differential unit, if service is necessary. See figure ID. All truck 10 1/2" ring gear axles produced by Chevrolet use an optional Eaton Positive Locking differential that is serviced as an assembly only. Truck 10 1/2" ring gear axles produced by Dana use only the optional Dana Power-Lok, shown in figure 17D.
Page 71: Eaton Positraction
4 -4 0 REAR AXLE DIFFERENTIAL CARRIER EATON PO SITR ACTIO N—FIGURE 2D Disassembly 1. Remove ring gear and side bearings following the procedures established for the conventional differ ential unit. remove the preload For all models except Corvette, spring retainer and springs by tapping on the spring retainer through the observation hole in the case.
Page 72: Inspection
REAR AXLE DIFFER EN TIA L CARRIER 4-41 Fig. 7D —Removing Preload Springs from Pack Fig. 9 D —Removing Side Gear 8. Separate clutch pack assembly from side gear. roll out the differential pinions For Truck Models Retain clutch pack assembly with original side gear. and thrust washers.
Page 73 4 -4 2 REAR AXLE DIFFERENTIAL CARRIER Fig. 10D—Assem bling Clutch Pack 7. Position pinion gears and thrust washers on side gears. Install pinion shaft through case and gears. 8. Install dial indicator in case so that contact button rests against pinion gear as shown in Figure 1 ID. Fig.
Page 74: Chevrolet Positraction
REAR AXLE D IFFERENTIA L CARRIER 4 -4 3 CHEVROLET P O S IT R A C T IO N -F IG U R E 16D A Chevrolet produced Positraction differential unit is used optionally in 8 1/2 inch ring gear axles. Individual components of this positraction unit are not interchange...
Page 75 SHIM BOLT (PINION SHAFT) SPLINED DISC (3) PINION FIXED SHAFT DISC (4) THRUST WASHER BOLT PINION (RING GEAR) GEAR RELOAD SIDE SPRING BEARING Fig. 16D—Chevrolet P ositraction—Exploded OVERHAUL MANUAL...
Page 76: Power-Lok Differential
REAR AXLE DIFFERENTIA L CARRIER 4 -4 5 7. Remove five plates and discs from side gear ring. POWER-LOK DIFFERENTIAL NOTE: A series of clutch plates and dished The Power-Lok differential shown in Figure 17D is a (Belleville) friction plates on each side of unit which is installed as optional equipment in place of differential side gears transmits drive from the standard differential.
Page 77: Assembly
4 - 4 6 REAR AXLE DIFFERENTIA L CARRIER 2. Inspect clutch discs and plates for wear, cracked, or 8. Before tightening bolts, use axle shafts and align distorted condition. Refer to "Specifications" splines of the side gear and side gear ring, on each section.
Page 78 7. Collapsible Spacer Side Bearing Adjusting Nut 8. Pinion Rear Bearing Adjusting N ut Retainer 9. Drive Pinion Fig. IE —Cross Section of Chevrolet Truck D iffe re n tia l w ith 10 1 / 2 " Ring Gear OVERHAUL MANUAL...
Page 79 4 - 4 8 REAR AXLE DIFFERENTIAL CARRIER DIFFERENTIAL CASE Removal 1. Mount axle assembly in a bench vise or holding J -2 4 4 2 9 fixture. 2. Remove cover bolts and cover, as seen in figure 2E, and allow lubricant to drain into pan. 3.
Page 80 REAR AXLE D IFFERENTIA L CARRIER 4 -4 9 2. Loosen the right side adjusting nut and tighten the left side nut, using J-24429 as shown in figure 3E, until the ring gear contacts the drive pinion. Do not force the gears into contact so as to bind them. At this point, zero lash is obtained.
Page 81 4 -5 0 REAR AXLE DIFFERENTIAL CARRIER DRIVE PINIO N ASSEMBLY Removal 1. Remove differential as previously outlined. 2. Check pinion bearing preload as described under "Drive Pinion - Reassembly". Record the result. If there is no preload reading, check for looseness of pinion assembly by shaking the companion flange.
Page 82 REAR AXLE DIFFERENTIAL CARRIER 4-51 Fig. 11E—Removing Pinion Rear Bearing Fig. 10E—Pressing Drive Pinion from Bearing R etainer 4. Inspect the bearing retainer for cracks, imperfec tions, corrosion, pits and grooves. 5. Replace parts as required. Reassembly 1. Lubricate all parts with hypoid lubricant. 2.
Page 83 4 -5 2 REAR AXLE DIFFERENTIAL CARRIER the drive pinion. Install a new collapsible spacer into position. CODE NUMBER ON O R IG IN A L PINIO N 6. Press front bearing onto drive pinion. 7. Lubricate the oil seal lips with a lithium-base extreme pressure lubricant, and install the seal in ADD .001 A D D .002 A D D .003 A D D .004 the retainer bore.
Page 84 REAR AXLE DIFFERENTIA L CARRIER 4 -5 3 teeth. When properly applied, the area of tooth contact will be clearly visible after load is applied. 3. Tighten bearing cap bolts to specifications. 4. Apply load to gears by expanding brake shoes or by wrapping a heavy rag around the companion flange to resist rotation.
Page 85 4 - 5 4 REAR AXLE DIFFERENTIAL CARRIER OVERHAUL MANUAL...
Page 86 REAR AXLE D IFFERENTIA L CARRIER 4 -5 5 DAIMA DIFFERENTIAL 1 0 - 1 / 2 / RING GEAR INDEX Differential Case—Removal and Disassembly......4-56 Drive Pinion—Removal and Disassembly........4-57 Differential Case—Reassembly............4-57 Shim Requirements—Gauging Procedures.........4-58 Drive Pinion—Assembly and Installation........4-59 Differential Case—Installation and Adjustment....... 4-60 Checks and Adjustments..............
Page 87 4 -5 6 REAR AXLE DIFFERENTIAL CARRIER the ring gear with a soft-faced hammer to free it DIFFERENTIAL CASE from the case. Removal 3. Scribe both case halves for reassembly in same 1. Place vehicle on hoist with rear axle hanging free. position.
Page 88 REAR AXLE D IFFERENTIAL CARRIER 4 -5 7 DRIVE PINIO N Removal and Disassembly 1. Remove differential as previously outlined. 2. Check pinion bearing preload as described under "Drive Pinion - Installation and Adjustment." If there is no preload reading, check for looseness of pinion assembly by shaking the companion flange.
Page 89 4 -5 8 REAR AXLE DIFFERENTIAL CARRIER tools J-8092 and bearing installer J-24383 as shown in figure 7F. 9. Install bearing on opposite side in the same manner. Be sure to support differential case on pilot plug J-8107-3. SHIM REQUIREMENTS—GAUGING PROCEDURES Side Bearing Shims 1.
Page 90 REAR AXLE DIFFER EN TIA L CARRIER 4 -5 9 New Pinion Marking Old Pinion Marking + 0.001 + 0.004 + 0.003 + 0.002 + 0.008 + 0.007 + 0.006 + 0.005 + 0.001 - 0.001 + 0.004 + 0.003 + 0.002 + 0.006 + 0.005...
Page 91 4 - 6 0 REAR AXLE DIFFERENTIAL CARRIER Bearing Shims". From that figure, subtract the size of the shim installed in step 9 above; then add .006 inch for preload and backlash. For example, if the reading in step 18 was .329 inch, and the shim just installed on the ring gear side of the case was .172 inch, the correct shim dimension would be .329 -.172 = .157 + .006 = .163 inch.
Page 92 REAR AXLE D IFFERENTIA L CARRIER 4-61 When properly used, the area of pinion tooth contact will be visible when hand load is applied. 3. Tighten bearing cap bolts to specifications. 4. Apply load to gears by expanding brake shoes or by wrapping a heavy rag around the companion flange to resist rotation.
Page 93 4 -6 2 REAR AXLE DIFFERENTIAL CARRIER OVERHAUL MANUAL...
Page 94 REAR AXLE DIFFERENTIAL CARRIER 4 -6 3 CHEVROLET TRUCK DIFFERENTIAL 1 2 - 1 / 4 RING GEAR INDEX Differential Inspection..........4-65 Case and Drive Pinion...........4-64 Ring Gear Replacement......... 4-65 Removal................4-64 Differential Bearing Replacement....... 4-66 Disassembly..............4-64 Differential Reassembly........... 4-66 Repairs.................. 4-64 Reassembly..............4-66...
Page 95 4 - 6 4 REAR AXLE DIFFERENTIAL CARRIER bearing from pinion, using Tool J-1453, as shown CASE AND DRIVE PINIO N in figure 2G. Removal 6. Position drive pinion in an arbor press so that the 1. Drain lubricant from differential, remove axle shaft bearing is supported by two pieces of flat steel stock as outlined in Truck Service Manual.
Page 96 REAR AXLE DIFFERENTIAL CARRIER 4 -6 5 exercise care to prevent damage to ground Pinion Reassembly surface o f pilot. 1. Pack the cavity between the pinion oil seal lips with a lithium-base EP lubricant to provide initial 5. Slide oil seal retainer on pinion shaft, then tap lubrication and to aid in inserting pinion flange.
Page 97 4 - 6 6 REAR AXLE DIFFERENTIAL CARRIER and has pilot to assure proper installation 2. Inspect ring gear pilot case flange and back of ring and seating of bearing. gear for dirt or burrs. 3. Install two guide pins (made from cap screws with Differential Reassembly heads cut off and ends slotted) to new gear 1.
Page 98 REAR AXLE D IFFERENTIAL CARRIER 4 -6 7 Ring Gear Thrust Pad Adjustment 1. Inspect bronze tip of thrust pad and if worn install a new one. 2. Install thrust pad and tighten screw until bronze tip engages back face of ring gear while rotating gear. 3.
Page 99 4 -6 8 REAR AXLE DIFFERENTIA L CARRIER SPECIAL TOOLS Dial Indicator J-8001 Differential Side Bearing Remover J-22888 In. Lbs. Torque Wrench J-5853 Adapter Plug J-8107-2 Differential Side Bearing Installer Com panion Flange Remover J-22761 J-8614 Side Bearing Shim Gauge J-22779 J-8614-11 Holder...
Page 100 REAR AXLE D IFFERENTIAL CARRIER 4 -6 9 P in io n S e ttin g G a u g e J -6 2 6 6 P o sitra c tio n T o r q u e M e a su rin g A d a p te r J -5748 J -6 266-28 Barrel A d a p te r...
Page 101 4 - 7 0 REAR AXLE DIFFERENTIA L CARRIER ® J-6266 Pinion Setting Gauge J-22175 Differential Bearing Installer J-6266-28 Barrel Gauge J-22888 Differential Bearing Remover (Used with J-6266-31 Sleeves J-8107-4) J-9774 Differential Y oke Bearing Seal Installer J-6266-53 Gauge Plate J-5780 Com panion Flange Installer J-0358-1...
Page 102 REAR AXLE DIFFERENTIAL CARRIER 4-71 © -4P5L J-22912 Press Plate J-8001 Dial Indicator Set J-1453 Pinion Bearing Press Plate J-0972 Differential Nut Wrench J-8107 Differential Bearing Puller Set J-24381 Pinion Rear Bearing C up Installer J-8107-3 Adapter Plug J-24383 Side Bearing Installer J-22888 Differential Side Bearing Remover J-24384...
Page 104: Special Tools
BRAKES SECTION 5 BRAKES The following caution applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Caution on page 1 of this section."...
Page 105 5-2 BRAKES 1. F ront Housing 10. Rear Housing 19. Boot 2. Power Piston Return Spring 11. Power Piston 20. Push Rod 3. Reaction Retainer 12. Reaction Levers 21. Silencer 4. Master Cylinder Piston Rod 13. A ir Valve Spring(s) 22.
Page 106: Remove Tool
BRAKES separate the two housings. If the rear housing cannot be readily loosened, tap the rear housing lightly with a plastic hammer. 5. Remove Tools J-9504 and J-22893 from rear housing (tilted mounting bracket type); Tool J-9504 on regular type. CAUTION: Care must be exercised not to damage or loosen studs in housing.
Page 107 5 -4 BRAKES 5. Remove the power piston seal from the rear plate and grip the steel support plate by hand, press housing. down and rotate counterclockwise to separate the plate from the power piston (fig. 7A). 6. Remove the diaphragm from the support plate and Power Piston Group (Fig.
Page 108 BRAKES cuts, nicks and distortion. These rubber parts are the key to control of air flow and should account for the majority of troubles traceable to leakage. If there is any question whatever as to serviceability of any part, replace it. Refer to "Inspection Chart"...
Page 109 5-6 BRAKES IN S P E C T IO N C H A R T C orrective A ctio n Inspect For Part 1. Cracks, distortion, 1. Clean up or replace. Power Piston and Support chipping, damaged lever Plate and Reaction seats, pitted or rough Retainer holes.
Page 110 BRAKES 7. Install a new floating control valve retainer over the push rod, (flat side toward the floating control valve). 8. Start the floating control valve and retainer into the power piston tube. 9. Seat retainer in the power piston tube by pressing it in place with Tool J-21601;...
Page 111 5-8 BRAKES Fig. 1 3 A -In sta llin g R etainer Lock Ring Fig. 12A~lnstalling Reaction Retainer on Power Piston Rear Housing Group two housings so they will match when in locked 1. Install a NEW seal in the center of the rear housing position.
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BRAKES 5-9 DELCO MORAINE POWER BRAKE CYLINDER DUAL DIAPHRAGM TYPE INDEX Disassembly...................5-9 Cleaning....................5-12 Inspection....................5-12 Assembly....................5-13 G auging....................5-18 OVERHAUL OPERATIONS damage or loosen studs in housing. Also, take care that no pressure is brought to bear on plastic power piston. Disassembly (Fig.
Page 113 5 -1 0 BRAKES primary power piston from the secondary power piston. NOTE: It is possible that the primary support plate will unlock from the primary piston before the primary piston unscrews from the secondary piston. If this happens, continue to turn the primary support plate counterclock...
Page 114 BRAKES 5-11 Fig. 3B--Power Piston Group Fig. 4B--Positioning Secondary Power Piston in Tool Fig. 5B~Locking or U n locking P rim ary and J-23101 (Large Dia. End Up) Secondary Power Pistons clockwise to unlock the secondary support plate 7. Remove the secondary diaphragm from the from the secondary power piston (fig.
Page 115 5 -1 2 BRAKES 8. Remove the reaction piston and reaction disc from the center of the secondary power piston by pushing down on the end of the reaction piston with a small object, such as a pencil, wooden dowel or metal rod (fig.
Page 116 BRAKES 5 -1 3 PR IM A R Y P O W E R P IS T O N J-23101 Fig. 9B -L o ckin g or U nlocking P rim ary Support Plate Fig. 8B--Positioning P rim ary Power Piston in Tool From P rim ary Power Piston J-23101 (Sm all Dia.
Page 117 5 -1 4 BRAKES IN S P E C T IO N C H A R T Corrective A ctio n Inspect For Part 1. Replace 1. Damaged threads. Power Pistons and Support Plates 2. Clean up or replace. 2. Cracks, distortion, chip ping, pitted or rough holes, worn seal surfaces (tubes).
Page 118 BRAKES 5-15 Since the floating control valve is a compo nent part of this assembly and cannot be disassembled from the push rod. 3. Place the air valve end of the air valve push rod assembly into the tube of the primary power piston. Manually press the air valve push rod assembly so that the floating control valve bottoms on the tube section of the primary power piston.
Page 119 5 -1 6 BRAKES POWER PISTON GAUGING REMOVE RUBBER REACTION DISC, PISTON ROD RETAINER & AIR VALVE SPRING FOR GAUGING REACTION PISTON J23337 “ NOSE” SECONDARY POWER CORRECT PISTON REACTION PISTON PRIMARY POWER PISTON INCORRECT (REACTION PISTON TOO SHORT) (REACTION PISTON TOO LONG) AIR V A L V E -P U S H ROD ASSEMBLY Fig.
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BRAKES 5-17 primary power piston so that the holes at the base protrusions on the middle of the divider are facing up. Press the divider down over the tool and onto of the tube are covered. the secondary power piston tube where it will rest 17.
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5 -1 8 BRAKES 36. Wipe a thin film of Delco Silicone Lube #5459912 housing clockwise in relation to front housing (or equivalent) on the O.D. of the piston rod until fully locked. retainer. Insert the master cylinder piston rod NOTE: If unit is not easily locked, hold retainer into the cavity in the secondary power housings together and apply vacuum to check...
Page 122: Remove Tool
BRAKES 5 -1 9 never contact the shorter section (higher level) of (or equivalent) on the I.D. of the front housing seal and position seal in the depression in the housing. the gauge. Move gauge from side to side to check piston rod height.
Page 123 5 -2 0 BRAKES Master C ylinder A ir Valve Valve Return Spring Vacuum Check Valve F ro n t Housing Seal M ou n tin g Stud G rom m et Poppet Valve A ir Valve Lock Plate Diaphragm Poppet Valve Spring Diaphragm L ip Diaphragm Plate...
Page 124 BRAKES 5-21 b. Hold the diaphragm plate so that the push rod is in its normal (horizontal) installed position, depress the push rod slightly (approximately 1/16 inch), and rotate piston so the air valve lock will fall from its location in the diaphragm A ir V alve L o c k Rear H ou sin g M o u n tin g plate hub.
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5 22 BRAKES The use o f gasoline, kerosene, air valve and push rod assembly in extension of CAUTION: antifreeze, alcohol or any other cleaner, with diaphragm plate. even a trace o f mineral oil, will damage rubber NOTE: The air valve, poppet valve and push parts.
Page 126 BRAKES 5 -2 3 IN S P E C T IO N T A B L E Inspect For Part Corrective A ctio n Diaphragm Support Plate 1. Cracks, d istortion, 1. Clean up or replace. chipping, damaged seats, pitted or rough holes.
Page 127 5 -2 4 BRAKES - Install locknut and push rod Clevis Type Push Rod clevis. 8. Install mounting bracket to the rear shell, if so equipped. See " Caution" on Page 1 o f this CAUTION: section. 9. Remove power cylinder from vise and remove Holding Fixture J-22805.
Page 128 BRAKES 5 -2 5 FRONT HOUSING VACUUM CHECK VALVE REAR HOUSING REACTION DISC AIR VALVE RETURN SPRING AIR VALVE CHECK POPPET VALVE VALVE GROMMET POPPET VALVE SPRING PUSH ROD FRONT HOUSING SEAL PISTON ROD FILTERS—SILENCERS DUST BOOT DIAPHRAGM RETURN SPRING REAR DIAPHRAGM FRONT DIAPHRAGM PLATE...
Page 129 5 -2 6 BRAKES REAR DIAPHRAGM PLATE SEAL REAR DIAPHRAGM VALVE RETURN SPRING DIAPHRAGM RETAINER AIR VALVE REAR HOUSING VACUUM CHECK VALVE CHECK VALVE GROMMET FRONT HOUSING SEAL DUST BOOT FRONT HOUSING DIAPHRAGM RETURN SPRING PISTON ROD REACTION DISC FRONT DIAPHRAGM PLATE FRONT DIAPHRAGM CENTER PLATE Fig.
Page 130 BRAKES 5-27 Fig. 4 D -R em oving Valve O perating Rod, Retainer, Filters and Poppet 28. Remove the diaphragms from the plates. 29. If rear housing seal requires replacement, use a blunt punch or 1-1/4" socket to drive seal from housing.
Page 131 5 -2 8 BRAKES aligned between lances in rear housing for reassembly. Work outer rim of front diaphragm into rear housing with screwdriver blade so that it is under lances in housing. 11. Attach base of Holding Fixture J-22805 to front housing with nuts and washers and draw down tight to eliminate bending or damage to studs.
Page 132 BRAKES 5 -2 9 IN S P E C T IO N C H A R T Part Inspect Corrective A ctio n Diaphragm Support Plates 1. Cracks, distortion, 1. Clean up or replace. chipping, damaged lever seats, pitted or rough holes.
Page 133 5 -3 0 BRAKES AIR VALVE PLUNGER Fig. 7D -Installing Rear Housing Seal w ith Installer Fig. 9 D -In s ta llin g A ir Valve Assembly J-22677 The piston rod is designed with a - Assemble locknut and clevis CAUTION: Clevis Type Push Rod self-locking adjustment screw to provide the...
Page 134 BRAKES 5-31 # 1 5 OR * * I6 U.S.S. GAUGE SH E E T STEEL io|^- Fig. 12D- Piston Rod Gauge serrated end and turn adjusting screw either in or out as is not available, the required dimensions for fabrication are given in Figure 12D for required.
Page 135: Description And Operation
5-32 BRAKES BENDIX SINGLE DIAPHRAGM TYPE HYDROVAC INDEX Disassembly..................5-32 Cleaning....................5-34 Inspection....................5-34 Assembly....................5-34 DESCRIPTION AND OPERATION shell and a mounting pad boss on the side of the The Single Diaphragm Hydrovac is a self contained hydraulic cylinder or by studs protruding from the rear vacuum hydraulic power brake unit for use on a vehicle shell.
Page 136 BRAKES 5 -33 H ydraulic C ylinder Return Spring Snap Ring Washer Gasket Diaphragm Plate Front Shell 1 1. Diaphragm Capscrews W asher Push Rod Hydraulic Cylinder Rear Shell Control Tube Seal Control Tube Nut Clamp Band Fig. 3E--Removal of D iaphragm , Spring, Front Shell Vacuum Hose Clamp Bolt and Gasket...
Page 137 5 -3 4 BRAKES any occasion to doubt cleanliness - such as parts dropped or left exposed for eight hours or longer. I f there is any suspicion o f contamination or any evidence o f corrosion, completely flush the car hydraulic brake system in accordance with the Chassis Service Manual.
Page 138 BRAKES 5-35 IN S P E C T IO N C H A R T Part Inspect For Corrective A ctio n Diaphragm Support Plate Clean up or replace. 1. Cracks, distortion, chipping, damaged lever seats, pitted or rough holes. 2.
Page 139 5 -3 6 BRAKES 8. Carefully insert hydraulic piston assembly, retainer, groove and, while holding spring compressed, dip piston and cup(s) in clean brake fluid. seal and bearing in cylinder bore. Press against diaphragm and plate to compress return spring and 6.
Page 140 BRAKES 5-37 Special Tools P jP l S2E5 bibmih 1. J -4 8 8 0 S n a p R in g Pliers 9. J -2 2 8 0 5 P o w e r C y lin d e r H o ld in g F ix tu r e 2.
Page 142 EN G IN E SECTION 6 ENGINE INDEX Connecting Rod and Piston Assemblies....... 6-22 Introduction................6-1 Removal.................6-22 General Description............. 6-2 In-Line Engines..............6-2 Disassembly................. 6-22 V8 Engines................6-2 Cleaning and Inspection..........6-23 Repair Procedures..............6-6 Connecting Rods............6-23 Engine Assemblies............6-6 Pistons................6-24 Disassembly..............6-6 Piston Pins...............6-24 Assembly................6-6 Assembly................6-24...
Page 143 6 2 ENGINE GENERAL DESCRIPTION V8 ENGINES IN-LINE ENGINES Cylinders are numbered front to rear, 1-3-5-7 on the left Cylinders are numbered front to rear. Firing order is bank and 2-4-6-8 on the right bank. Firing order is, 1-8- 1-5-3-6-2- 4 for the L6 engines. Crankshaft rotation as 4-3-6-5-7-2.
Page 144 E N G IN E OIL PRESSURE SENDING UNIT Fig. 1—In-Line Engine Lubrication OVERHAUL MANUAL...
Page 145 6-4 ENGINE FUEL PUMP PUSH ROD OILING OIL FILTER AND BY-PASS VALVE Fig. 2 — "S m a ll V 8 " Engine Lubrication OVERHAUL MANUAL...
Page 146 EN G IN E TO OIL COOLER (HI-PERFORMANCE ONLY) OIL COOLER BY-PASS V A L V E ,^ (HI-PERFORMANCE ONLY) OIL FILTER BY-PASS VALVE CYLINDER WALLS ARE OILED BY OIL THROW N OFF PRESSURE FED CON NEC TING ROD BEARINGS OIL FILTER AND DISTRIBUTOR OILING CYLINDER WALL AND CAMSHAFT LOBE OILING FUEL PUMP PUSH ROD OILING...
Page 147 6-6 ENGINE REPAIR PROCEDURES NOTE: It will be necessary to turn the E N G IN E ASSEM B LIES crankshaft to disconnect and remove some of the connecting rod and piston assemblies. Disassembly NOTE: For partial disassembly of the engine 13.
Page 148 E N G IN E d. Install crankshaft, being careful not to damage and install camshaft, being careful not to bearing surfaces. damage bearings (fig. 5). Remove the two 5/16- 18 bolts. e. Apply a thin coat of brush-on type oil sealing compound to block mating surface and corre...
Page 149 6-8 ENGINE c. Draw camshaft sprocket onto camshaft, using mounting bolts. Torque bolts specifications. d. Lubricate timing chain with engine oil. WITH TIMING GEAR (In Line) a. Lubricate camshaft journals with engine oil, then rotating crankshaft and camshaft so that marks on gears will line up, install camshaft and gear assembly being careful not to damage bearings (fig.
Page 150: Remove Tool
E N G IN E and between connecting rod caps on V8 engines. b. Attach damper Installer Tool J-22197 to Refer to Figures 46 and 47. damper. Tighten fingers of tool to prevent weight from moving (fig. 11). 5. Install oil pump and screen assembly (and extension shaft on V8 engines).
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6 -1 0 ENGINE —Starter d. Remove tool from crankshaft. e. Install damper retaining bolt and torque to —Oil Filter (new) specifications. —Carburetor and Fuel Lines 9. Install cylinder head(s) as follows: —Distributor Cap (with spark plug wires) CAUTION: The gasket surfaces on both the —Fuel Pump (and fuel pump push rod on V8 head and the block must be clean o f any engines)
Page 152 E N G IN E 6-11 indicator so that movement of the valve stem from side to side (crosswise to the head) will cause a direct movement of the indicator stem. The indicator stem must contact the side of the valve stem just above the valve guide.
Page 153 6 -1 2 ENGINE Fig. 18—Rocker Arm Stud and Push Rod Guide Fig. 17—Checking Valve Spring Tension In-Line and Sm all V8 Rocker arm studs that have damaged threads or are loose in cylinder heads should be replaced with new studs available in .003"...
Page 154 EN G IN E 6 -1 3 Fig. 21 —Installing Rocker Arm Stud (In-Line and "S m a ll V 8 ") the head is imperative to insure that the heat in the valve head will be properly carried away. Several different types of equipment are available for Fig.
Page 155 6 -1 4 ENGINE 2 5 0 & 2 9 2 LIQU ID PETROLEUM G A S TRUCK E N G IN ES HAVE ALLOY CAST INLET A N D EXHAUST VALVE SEAT INSERTS PARALLEL INLET & E X H A U S T V A L V E S 2 5 0 & 2 9 2 LPG T R U C K E N G IN E S 3 5 0 LIQ U ID PETROLEUM G A S TRUCK EN G IN ES HAVE...
Page 156 EN G IN E 6-15 L O C K S \^ ^ “ C A P ------- S E A L-------- W SHIELD S P R IN G —► ^ y p * DAM PER * NOT USED ON 250 CU. IN. L6 Fig.
Page 157 6 -1 6 ENGINE the entire lifter assembly should be replaced. If the lifter body wall is scuffed or worn, inspect the cylinder block lifter bore, if the bottom of the lifter is scuffed or worn inspect the camshaft lobe, if the push rod seat is scuffed or worn inspect the push rod.
Page 158: Oil Pump
E N G IN E 6-17 Vs" DRIFT PIN OIL FEED H O LE V \t" DRIFT Fig. 33—Assem bling H ydraulic Lifter 7. Install the metering valve and push rod seat (fig. 30). 8. Install the push rod seat retainer, press down on the push rod seat and remove the 1/16"...
Page 159 6 -1 8 ENGINE S h a f t E x te n s io n P r e s s u r e R e g u la t o r S h a f t C o u p li n g V a lv e P u m p B o d y P r e s s u r e R e g u la t o r...
Page 160 EN G IN E 6 -1 9 their specified torque. In addition, prepara M A IN BEARINGS tory to checking fit of bearings, the surface of Main bearings are of the precision insert type and do the crankshaft journal and bearing should be not utilize shim for adjustment.
Page 161 6 -2 0 ENGINE Fig. 41 —M easuring C ra nksh a ft End Play Fig. 4 0 —M easuring Gauging Plastic .001", interference between the bearing and Replacement journal will result in rapid bearing failure. If NOTE: Main bearings may be replaced with the flattened gauging plastic tapers toward or without removing the crankshaft.
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E N G IN E 6-21 Inspection and Replacem ent 1. With oil pan and oil pump removed, remove the connecting rod cap and bearing. 2. Inspect the bearing for evidence of wear or damage. (Bearings showing the above should not be installed.) 3.
Page 163 6 -2 2 ENGINE d. Remove the bearing cap and using the scale on the gauging plastic envelope, measure the gauging plastic width at the widest point (fig. 44). 6. If the clearance exceeds specifications, select a new, correct size, bearing and remeasure the clearance. 7.
Page 164: So They May Be Reinstalled In Their Original
E N G IN E 6 23 Fig. 4 9 —Piston Support Tool Rework (4-3/32"), and J-22250 (4-1/4") are available for this purpose. 3. Using Tool J-9500 for In-Line and "Small V8" (fig. 50) or Tool J- 6994 for "M ark IV V8" (fig. 51), place connecting rod and piston assembly in an arbor press with piston on Support then using Remover, press piston pin out of connecting rod...
Page 165 6 -2 4 EN G INE Assembly 1. Lubricate piston pin holes in piston and connecting rod to facilitate installation of pin. 2. Using Tool J-9510 for In-Line and "Small V8" (fig. 52) or Tool J- 6994 for "M ark IV V8" (fig. 53) place Support with spring and pilot in place on an arbor press.
Page 166 E N G IN E 6 -2 5 specifications, remove the ring and try another for fit. 5. Fit each compression ring to the cylinder in which it is going to be used. REM O VER A N D INSTALLER 6.
Page 167 6 -2 6 ENGINE PISTON-VIEW ED FROM TOP “ B” SIDE OF PISTON ALIGNED WITH ENGINE PISTON CYLINDER CONNECTING ROD BEARING TANGS 250 CU. IN. ALIGNMENT NOT NECESSARY “B” NOTCH ON PISTON TOWARD 292 CU. IN. FRONT OF ENGINE 307 CU. IN. “...
Page 168: Remove Tool
E N G IN E 6 -2 7 Fig. 55—M easuring Ring Gap Fig. 56—Checking Ring In Groove Tool J-8037 to compress the rings (fig. 61). Guide the connecting rod into place on the crankshaft journal with Tool J-5239 (3/8") or J-6305 (11/32"). Use a hammer handle and light blows to install the piston into the bore.
Page 169 6 -2 8 ENGINE Fig. 60—P isto n s-ln sta lle d Position (In-Line) Fig. 59—C onnecting R o d s-In sta lle d Position V8 6. Install the bearing caps and torque nuts to specification. NOTE: If bearing replacement is required refer to "Connecting Rod Bearings".
Page 170 E N G IN E 6 -2 9 10. Remove main bearing caps and lift crankshaft out 2. Drive new nozzle in place (oil hole in vertical of cylinder block. position) using a suitable light plastic or rubber hammer. 11. Remove rear main bearing oil seal and main bearings from cylinder block and main bearing caps.
Page 171 6 -3 0 ENGINE REM O VA L INSTALLATION IN LINE J-5590 S M A L L V - 8 " \J-5590] M ARK IV V-8 WASHER i J-21058 Fig. 6 2 —Sprocket or Gear Replacement nut. When bearing has been pulled from bore, bearings by driving towards center of cylinder remove remover and installer tool and bearing block (fig.
Page 172 E N G IN E 6-31 2. Using Tool Set J-6098, with nut then thrust washer installed to end of threads, index pilot in camshaft front bearing and install puller screw through pilot. 3. Index camshaft bearing in bore (with oil hole aligned as outlined below), then install remover and installer tool on puller screw with shoulder toward bearing.
Page 173 6 -3 2 ENGINE IN LINE Fig. 67—Replacing C am shaft C enter Bearing assembly. Clean valve chamber in cylinder block thoroughly. Torque retaining screws to specifications (fig. Fig. 66—Removing C am shaft Gear 71). down cylinder to determine taper and turn it to different points around cylinder wall to determine Distributor Lower Bearing Replacem ent (In- the out-of-round condition.
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E N G IN E 6 -33 Fig. 68— Replacing Cam shaft Front Bearing 4. Position bushing and driver to block and drive the bushing in position, which is determined by tool bottoming against the block. 5. Remove tool from bushing. It is possible that the bushing with minimum I.D.
Page 175 6 -3 4 ENGINE 3. When finish honing a cylinder bore to fit a piston, the hone should be moved up and down at a sufficient speed to obtain very fine uniform surface NSTALLING finish marks in a cross-hatch pattern of approx BEARING imately 45 to 65 degrees included angle.
Page 176 EN G IN E 6-35 292 TRUCK 307 PASSENGER ----- 307 TRUCK 3 5 0 (2 4 5 & 2 5 0 HP) 3 5 0 (1 4 5 , 170 & 190 HP) ----- 4 0 0 (1 5 0 HP) >o •O «...
Page 177 6 -3 6 ENGINE TORQUE SPECIFICATIONS C Y L I N D E R H E A D T O R Q U E S E Q U E N C E S M A L L V 8 V ' "...
Page 178 E N G IN E 6 -37 SPECIAL TOOLS J -5 7 1 5 (.0 0 3 ” ) R o c k e r A r m S tu d E n g in e L if t K it J -4 5 3 6 R e a m e r (0 -2 0 0 Ft.
Page 180: Introduction
The model MV (Fig. M2, M3, M4 and M5) carburetor used on sion incorporates a hot idle compensator to maintain the Chevrolet, 6 cylinder engine is a single bore, down draft smooth engine idle during periods of extreme hot engine unit using a triple venturi in conjunction with a plain tube nozzle.
Page 181 SHIFT IDENTIFICATION ASSEMBLY PLANT CO D E O F YEAR MODEL NO . __ ■ SHIFT I — IDENTIFICATION SHIFT ASSEMBLY IDENTIFICATION PLANT CO D E _ ASSEMBLY YEAR PLANT CODE YEAR — DAY O F YEAR DAY O F THE YEAR '2 G ’...
Page 182 CARBURETORS 6 M - 3 behind the fuel inlet nut to give maximum filtration of DISASSEMBLY OF CARBURETOR incoming fuel. An electrically operated idle stop solenoid is attached to C.E.C. Valve Assembly and Idle Stop Solenoid the carburetor float bowl casting and replaces the curb idle speed screw.
Page 183 6 M - 4 CARBURETORS TIMED VACUUM TO E.G.R VALVE TIMED VACUUM TO VAPOR CANISTER PURGE TIMED VACUUM TO SPARK ADVANCE VACUUM TUBE TRANSMISSION VACUUM TO AIR CLEANER MODULATOR TUBE Fig. M 3—Model MV ( lb b l.) Passenger Car (A u to m a tic) C arburetor rod-pow er piston drive assemblies, perform following operation: a.
Page 184 CARBURETORS 6 M -5 Fig. M5—Model MV (1 bbl) Passenger Car 1. Thoroughly clean carburetor castings and metal throttle body to bowl attaching screws. Throttle parts in an approved carburetor cleaner. body and insulator gasket may now be removed from float bowl. Any rubber parts, plastic parts, CAUTION: including float, diaphragms, pump plunger,...
Page 185 6 M - 6 CARBURETORS Fig. M6 -M onojet-(See Fig M7 for legend)
Page 186 CARBURETORS 6 M - 7 Air Horn Assembly Choke Rod Compensator C.E.C. Vacuum Tube Screw— A ir Horn—Long Cam—Fast Idle Screw— Cover C.E.C. Valve Nut S crew -A ir Horn-Short Screw-Cam Float Assembly C.E.C. Valve Bracket B racket-A ir Cleaner Attaching Hinge Pin—Float C.E.C.
Page 187 6 M - 8 CARBURETORS GAUGE FROM TOP OF CASTING TO TOP OF INDEX POINT AT TOE BEND HERE SPECIFICATIONS HOLD FLOAT RETAINING PIN FIRMLY IN PLACE - PUSH DOWN ON END OF FLOAT ARM, AGAINST BEND HERE TO TOP OF FLOAT NEEDLE ADJUST FLOAT UP OR DOWN Fig.
Page 188: Rochester 2Gv (Sae
CARBURETORS 6 M - 9 casting until metering rod rests lightly against 3. Install the choke vacuum break diaphragm hose to inside edge of bowl. the nipple on vacuum break diaphragm and tube on air horn. 4. Use specified plug gauge and insert between bowl 4.
Page 189 6 M - 1 0 CARBURETORS Fig.G 2-Hot Idle C om pensator inner lever to remove. I f the retaining tang on the inner lever is bent outward to remove the Fig. G l-R o che ste r 2GV (SAE 1 1 /4 ) C a rburetor pump plunger assembly, throttle sticking can Except Vega result.
Page 190 CARBURETORS 6 M -1 1 Power Piston A ir Horn Pump Rod Diaphragm Link Vacuum Diaphragm Pump Outer Lever A ir Horn to Bowl 2 1. Float Needle and Choke Lever W asher Gasket Seat Fuel Inlet Nut A ccelerator Pump Choke Valve Float Hinge Pin Gaskets...
Page 191 6 M 12 CARBURETORS C luster Assem bly Pump D ischarge M ain Jets Check A ssem bly Gasket A ir Horn G asket A c c e le ra to r Pump Splash S h ie ld -M a in B ow l Assem bly Spring W e ll...
Page 192 CARBURETORS 6 M - 1 3 Fig. G5--Bowl A sse m b ly-P a rts Location screeen into cavity in bottom of float bowl and push downward until seated. Assemble Air Horn (Figure G6) 1. Install choke kick lever on choke shaft with tang on kick lever towards lever on shaft.
Page 193 6 M - 1 4 CARBURETORS the float pontoon. To adjust, bend the float arm at rear, as shown in inset (Fig. G7). 2. With the air horn assembly held upright and float suspended freely, measure dimension from air horn gasket to bottom of float pontoon at toe.
Page 194: General Description
CARBURETORS 6 M - 1 5 G A U G E FROM TOP OF AIR H O R N R IN G TO TOP OF PUMP ROD THROTTLE VALVES FULLY CLOSED Fig. G il- A ir Horn T igh te n in g Sequence Fig.
Page 195: Air H Orn
6 M - 1 6 CARBURETORS NOTE: The paper fuel inlet filter has its own sealing gasket so there is no extra gasket required between the filter element and fuel inlet nut. 5. Remove pump rod retaining clip from throttle lever end of rod, and remove rod from throttle lever, depress pump and rotate the pump rod out of upper pump lever.
Page 196: Throttle Body
CARBURETORS 6 M - 1 7 pump well. Where used. Remove the aluminum allowing spring to snap sharply thus forcing piston inlet check ball from the bottom of the pump well from casting. and pump inlet strainer from the bottom of the fuel 12.
Page 197 6 M - 1 8 CARBURETORS The carburetor should be cleaned in a cold immersion type cleaner. 1. Thoroughly clean carburetor castings and metal parts in an approved carburetor cleaner. CAUTION: Any rubber parts, plastic parts, diaphragms, pump plungers, electric parts and solenoids, should not be immersed in carburetor cleaner.
Page 198 CARBURETORS 6 M - 1 9 mixture needle and limiter cap kit. This cap must be installed after the idle mixture needle has been set on engine (see Specifications), by backing off the new mixture needle the same number of turns, after bottoming, as was required to bottom the original needle which was pre-set and sealed by the m anufacturer before it left the factory.
Page 199 6 M - 2 0 CARBURETORS align float with legs, then install retainer pin Assembly of Air Horn to Float Bowl through splash shield and float. 1. Place air horn on bowl, making certain that accelerator pump plunger is properly positioned 12.
Page 200: Rochester 4Mv (Q Uadrajet)
CARBURETORS 6 M -2 1 2. Bend retaining ears on lockwasher over flats on nut bores. Place the adjustable "T" scale gauge on top of air so that nut is locked securely in place. horn ring. Bend the pump rod at lower angle to obtain specified dimension to the top of the pump rod.
Page 201 6 M - 2 2 CARBURETORS 12. Remove baffle from secondary side of bowl. 13. Remove retaining screw from choke assembly on side of float bowl and remove assembly from bowl; then remove secondary lockout lever from cast boss on bowl. 14.
Page 202: Assembly And Adjustments
CARBURETORS 6 M - 2 3 S e c o n d a ry Throttle Pow er Piston S p rin g Float N eedle Pull Fuel Inlet Nut Lockout Prim ary M e te rin g Clip G a sk e t Throttle Body-to-Bow l R o d s Float Needle...
Page 203: Float Bowl
6 M - 2 4 CARBURETORS (plain end) then holding choke rod, with grooved end pointing inward, position choke rod actuating lever in well of float bowl and install choke assembly engaging shaft with hole in actuating lever (fig. Q5). Install retaining screw and tighten securely.
Page 204 CARBURETORS 6 M - 2 5 NOTE: Make sure retaining pin is held firmly in place and tang of float needle is seated on float needle. Fig. Q7-Air Horn Tightening Sequence b. Bend float up or down for proper adjustment. lever into rod.
Page 205 6 M - 2 6 CARBURETORS Fig. Q 8--lnstalling Secondary M etering Rods SPECIAL TOOLS 22973 J—9789 J—1137 J—5197 J—4552 BENDING TOOLS J—8328 J-1137 Choke Rod J-9789 Universal Bending Carburetor K it J-4552 Choke Rod J-22973 Ther-Mac Bending (1 2 bbl.) Thermometer J-5197 Unloader Bending...
Page 206 E N G IN E ELECTRICAL 6Y-1 SECTION 6Y ENGINE ELECTRICAL CO NTENTS OF SECTION Starting Motor 6Y-< ..................... Starting Solenoid...............6Y- STARTING MOTOR INDEX Disassembly ..............6Y-4 Cleaning and Inspection............6Y-3 Turning the Commutator..........6Y-4 Testing and Repairs ....
Page 207 6Y-2 EN GINE ELECTRICAL D rive H o u sin g O v e rru n n in g C lu tc h S o le n o id Case 22 . G ro u n d e d Brush S h ift Lever B o lt S cre w and Lock A s s e m b ly...
Page 208: Cleaning And Inspection
E N G IN E ELECTRICAL 6Y-3 forcing the collar toward the clutch and removing lock ring from end of tube. 3. Check brush holders to see that they are not deformed or bent, but will properly hold brushes against the commutator. 4.
Page 209 6Y-4 ENGINE ELECTRICAL Fig. 4S~Arm ature Short C ircuit Test the field connector bar (fig. 6S). If the lamp does not light, the field coils are open and will require Flg' 6S Field Co11 °Pen Circuit Test replacement. Field Coil Test For Ground NOTE: Be sure to disconnect the shunt coil before perform ing...
Page 210 EN G IN E ELECTRICAL 6Y-5 1/32". This undercut must be the full width of b. Slide clutch assembly onto armature shaft with insulation and flat at the bottom; a triangular pinion outward. groove will not be satisfactory. After undercutting, c.
Page 211 6Y-6 EN GINE ELECTRICAL BATTERY Fig. 10S-Forcing Snap Ring Into Retainer washer on armature shaft and slide commutator end frame onto shaft. 6. Reconnect the field coil connectors to the "m otor" solenoid terminal. 7. After overhaul is completed, perform "Pinion Fig.
Page 212 E N G IN E ELECTRICAL 6Y-7 Fig. 12S-Checking Pinion Clearance STARTING SOLENOID INDEX 6Y-7 Replacement of Contacts..........6Y-7 Removal. Installation................6Y-7 Removal Replacement of Contacts (fig. 13S) 1. Remove the outer screw and washer from the motor connector strap terminal. 1. With solenoid removed from motor, remove nuts and washers from switch and motor connector strap Remove the two screws retaining solenoid housing terminals.
Page 213 6Y-8 EN G INE ELECTRICAL 3. Install outer screw and washer securing motor counterclockwise to engage the flange key in the connector strap terminal. keyway slot. 4. Install starter motor as previously described. 2. Install two screws retaining solenoid housing to end frame.
Page 214 EN G IN E ELECTRICAL 6Y-9 material, and also a piece of tape over the shaft at the slip ring end. CAUTION: Brushes may drop onto the rbtor shaft and become contaminated with bearing lubricant. Clean brushes prior to installing with a non- toxic cleaner such as trichlorethylene or a soft dry cloth.
Page 215 6 Y -1 0 ENGINE ELECTRICAL O H M M ETER (CHECK FOR SHORTS AND OPENS) OHMMETER OHMMETER (CHECK FOR OPENS) (CHECK FOR GROUNDS) Fig. 3C--Checking Rotor Fig. 4 C -C hecking S ta to r ring. If the lamp fails to light or if the ohmmeter reading is high, the windings are open.
Page 216 E N G IN E ELECTRICAL 6Y-11 NOTE: There are two diode trio units done all six diodes are checked with two readings taken differing in appearance used in the generator for each diode. but they are completely interchangeable. NOTE: The diodes are not replaced individu The diode trio may also be checked for a grounded ally.
Page 217 6 Y -1 2 ENGINE ELECTRICAL REPAIRS Brush Holder and Regulator Replacement (fig. 7C) 1. If not previously removed, remove the three stator lead attaching nuts, the stator, diode trio brush lead screw and diode trio from the end frame. 2.
Page 218 E N G IN E ELECTRICAL 6Y-13 sleeve, it must not be interchanged with either of the other two screws. 5. Position rectifier bridge to end frame. Install attaching screw and the "BAT" terminal screw. Connect capacitor lead to bridge. 6.
Page 220 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7M-1 SECTION 7M CLUTCHES AND MANUAL TRANSMISSIONS CONTENTS Single Plate Diaphragm Spring C lutch....7M-1 4-Speed Muncie Transmission (Model 465)..7M-37 Single Plate Coil Spring Clutch.........
Page 221 7 M - 2 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S Throwout Bearing Flywheel Pressure Plate Fork Diaphragm Spring Dowel-hole Retracting Spring Cover Pilot Bushing Driven Disc Fig.
Page 222: Single Plate Coil Spring Clutch
CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 3 3. Inspect pressure plate and flywheel for scores on the contact surfaces. Use a straight-edge and check for flatness of contact surfaces.
Page 223 7 M - 4 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S Fig. 2E--Compressing Clutch Fig. 3 E -D isassem bly of Clutch R ele ase Lever Pressure Plate Anti-Rattle S p rin g Eyebolt...
Page 224 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 5 9 SPRINGS 3 SPRINGS PAINTED UNPAINTED LIGHT BLUE ADJACENT TO LEVERS 3 SPRINGS PAINTED 9 SPRINGS LIGHT GRAY PAINTED ORANGE...
Page 225 7 M - 6 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S NOTE: On assemblies with three levers, the of the lever identified by "Lever". Use the 10-1/2, three flat machined lands of the gauge plate 11 step for 12"...
Page 226: 3-Speed Saginaw Transmission
CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M -7 3-SPEED SAGINAW TRANSMISSION INDEX Disassembly of Transm ission..........7M-7 Countergear Anti-Lash P la te ..........7M-9 Disassembly of Mainshaft .............7M-7 Repairs ..................
Page 227 S n a p R in g - B e a r in g 1st S p e e d G ear D rive G ear B e arin g D r iv e G e a r B e a r in g A n ti-L a sh Plate to M a in s h a ft 1st S p e e d Blocker...
Page 228 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 9 Front and Rear Bearings 1. Wash the front and rear ball bearings thoroughly in a cleaning solvent. 2.
Page 229: Disassembly
7 M - 1 0 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S different key cavities on either side. Slide the sleeve REPAIRS onto the hub aligning the marks made before disassembly.
Page 230 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S 7 M - 1 1 12. Install rear ball bearing with snap ring slot Clutch Bearing Retainer Oil Seal downward; press onto mainshaft. If the lip seal in the retainer needs replacement;...
Page 231 7 M - 1 2 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S 1-2 S yn ch ro nizer Hub T hru st W a sh e r - Front 3rd Speed B lo cke r G asket B earing W asher...
Page 232 CLUTCHES MANUAL TRANSMISSIONS 7M-13 5. Load the mainshaft pilot bearings (14) into the Install extension to case retaining bolts. drive gear cavity and assemble the 3rd speed Install front bearing outer snap ring to bearing and blocker ring onto the drive gear clutching surface position bearing over stem of drive gear and into with its teeth toward the gear.
Page 233 7M-14 CLUTCHES MANUAL TRANSMISSIONS THREE-SPEED MUNCIE TRANSMISSION INDEX Countergear Anti-Lash Plate........7M-16 Disassembly of Transmission ........7M-14 Repairs................. 7M-16 Disassembly of Mainshaft..........7M-14 Clutch Keys and Springs Cleaning and Inspection..........7M-14 Replacement..............7M-16 Transmission Case............7M-14 Extension Oil Seal or Bushing......... 7M-16 Front and Rear Bearing..........
Page 234 D rive Gear 1st S p e e d Rear Bearin g-to-Sha ft Reverse Idler S h a f t D rive G e a r B e a r in g S yn c h ro niz er Rin g S n a p R in g C o u n t e r g e a r Retainer...
Page 235 7 M - 1 6 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S Fig. 2G-Removing Reverse Idler Shaft counter shaft and reverse idler shaft at the same time, replace if necessary.
Page 236 CLUTCHES AND M A N U A L T R A N S M IS S IO N S 7 M - 1 7 0 = 3 R eta ining Clip 1 8. S h o u ld e r (P a rt o f Drive Gear Bearing 1 4.
Page 237 7 M - 1 8 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S with fork slot up; press it onto splines on the blocker ring onto the drive gear clutching surface mainshaft.
Page 238 CLUTCHES MANUAL TRANSMISSIONS 7M-19 G a sk e t Synchronizer Ke ys Cou nterge ar B e a rin g R e ta in e r 2nd a n d ' 3rd Shifter 1st and Reverse C ou ntershaft B o lt and Lock Fork Synchronizer Hub W o o d r u f f Key...
Page 239 7M-20 CLUTCHES MANUAL TRANSMISSIONS FOUR SPEED SAGINAW TRANSMISSION INDEX Disassembly of transmission........7M-20 Reverse Idler Gear Bushing........7M-23 Countergear Anti-Lash Plate........7M-23 Disassembly of M ainshaft..........7M-20 Repairs................. 7M-23 Cleaning and Inspection..........7M-20 Clutch Keys and Springs Replacement....7M-23 Transmission Case............7M-20 Extension Oil Seal or Bushing.........
Page 240 1 1 12 13 14 15 16 17 Drive Gear 1 1. 2nd S peed Blocker Extension Thrust W asher-F ront C o u nterge ar B e arin g Retainer Ring Ve nt Thrust W as h e r -R e a r A s s e m b l y Pilot Be ar in gs 1-2 Spe ed Synch.
Page 241 7 M - 2 2 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S C O U N T E R J - 2 2 2 4 6 SH A FT Fig.
Page 242 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S 7 M - 2 3 Fig. lOX-First and Second Synchronizer Snap Ring Countergear Anti-Lash Plate Inspect the plate teeth for wear or other damage. The plate and two damper springs are retained to the countergear by three rivets.
Page 243 7 M - 2 4 CLUTCHES AND M A N U A L T R A N S M IS S IO N S SCREWDRIVER Fig. 14X--Removing Bearing Retainer Oil Seal onto the hub aligning the marks made before Fig. 12X--Extension Bushing Replacement 1.
Page 244 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 2 5 Drive Gear Bearing First Speed Gear Drive Gear Thrust Washer Mainshaft Pilot Spring Washer Bearings Rear Bearing 3-4 Synchronizer...
Page 245 Detent S p r i n g Thrust W asher-F ront 3rd S p e e d Block e r Gask et-E xte n sion to B e a r in g Retainer 3-4 Detent C a m R in g C a s e Ga sk et-Re ta ine r to Gear...
Page 246 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 2 7 5. Install the second speed gear with clutching teeth CAUTION: Be sure countershaft picks up both upward;...
Page 247 7 M - 2 8 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S Fig. 19X--Loading Countergear Bearings Fig. 20X--Loading Mainshaft Pilot Bearings...
Page 248 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S 7 M - 2 9 FOUR-SPEED MUNCIE TRANSMISSION INDEX Disassembly................7M-29 Cleaning and Inspection..........7M-32 Transmission Case............7M-32 Front and Rear Bearings..........7M-32 Bearing Rollers and Spacers........
Page 249 7 M - 3 0 CLUTCHES AND M A N U A L T R A N S M IS S IO N S T O P V IE W O F R E V E R SE ID LER G E A R S Reverse Idler Gear Bearing Retainer First and Second...
Page 250 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M -3 1 \{M- 60 \ VL° ou x \ 16 . 3 1 74 75 Bearing Retainer Clutch Keys Flat Thrust Washer Bearing Rollers (28)
Page 251 7 M - 3 2 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S Fig. 3B--Removing Main Drive Gear Retaining Nut Fig. 5B-Removing Speedometer Gear Fig. 4B--Removing Reverse Shifter Shaft Lock Pin Fig.
Page 252 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S 7 M - 3 3 Fig. 8B--Removing Countershaft With J-22246 Fig. 7B--Removing Main Drive Gear 2. Blow out bearings with compressed air. CAUTION: Do not allow the bearings to spin, but turn them slowly by hand.
Page 253 7 M - 3 4 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S DETENT BALL Fig. l l B - l n s t a lli n g Reverse Shifter Shaft and Detent Fig.
Page 254 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 3 5 : u iiv m iw v n \ wvi Fig. 13B-Installing Rear Bearing Fig. 14B-Installing Speedometer Gear 6.
Page 255 7 M - 3 6 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S grease. Position the front reverse idler gear next to the thrust washer, with the hub facing toward rear of the case.
Page 256 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 3 7 in the shaft with the holes in the boss and drive in the lock pin. Install shifter lever. Press bearing onto main drive gear (snap ring groove to front) and into case until several main drive gear retaining nut threads are exposed.
Page 257 7 M - 3 8 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S Thrust W a s h e r Mainshaft Rear Reverse Driven Gear Main Drive Gear S n a p Ring Bearing Poppet Spring...
Page 258 2 6 . D rive Gear B earing 1st-2nd Speed 2 n d S peed Gear 3 7 . Snap R ing 4 8 . R ear R e ta in e r G a s k et 2 7. R e ta in e r S y n c h ro n izer H u b 3 rd G ear B ushing...
Page 259 7 M - 4 0 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 3. Remove parking brake and brake flange plate assembly on models equipped with propeller shaft parking brake.
Page 260 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M -4 1 CAUTION: Exercise care so shaft detent balls, SU BASSEM BLY O PER A TIO N S springs and innerlock pin located in the cover are not lost as the shifter shafts are removed.
Page 261 7 M - 4 2 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 5. After 1st and 2nd fork is installed, place two innerlock balls between the low speed shifter shaft and the high speed shifter shaft in the crossbore of the front support boss.
Page 262 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 4 3 J-22872 Fig. 10Q--Removing Drive Gear Bearing J-22872 Fig. 9Q -P o sitio ning Tool J-22872 to Drive Gear Inspection 1.
Page 263: Oil Seal Replacement
7 M - 4 4 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S Fig. 13Q --lnstalling Bearing R etainer Oil Seal 2. Remove snap ring in front of 3rd-4th synchronizer assembly.
Page 264 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S 7 M - 4 5 2 n d S p eed B lo c k e r 3 rd S p eed B lo c k e r 4 th Speed B lo c k e r 1 st S p e e d G ear Ring...
Page 265 7 M - 4 6 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S NOTE: Lubricate all bushing with E.P. oil before installation of gears. 5. Install synchronizer blocker ring and 2nd speed gear onto mainshaft and against synchronizer hub.
Page 266 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 4 7 J - 2 2 8 7 5 3 R D & 4T H G E A R S Y N C H R O N I Z E R 3 R D G E A R B U S H I N G...
Page 267: Remove Tool
7 M - 4 8 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S SPACER Fig. 2 0 Q -P osition in g Tool J-22832 On Countershaft 5. Install clutch countergear thrust washer and front Fig.
Page 268: Remove Tool
CLUTCHES AND M A N U A L T R A N S M IS S IO N S 7 M - 4 9 J-22874-2, drive bearing into place (fig. 25Q). Rotate case, install snap ring on countershaft at rear bearing and then remove Tool J-22874-2. 10.
Page 269: Dana Model 20 Transfer Case
7 M - 5 0 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S 16. Move all transmission gears to neutral except the reverse idler gear which should be engaged approximately 3/8 of an inch (leading edge of reverse idler gear taper lines.up with the front edge of the 1st speed gear).
Page 270 CLUTCHES AND M A N U A L T R A N S M IS S IO N S 7 M -51 R e ar O u t p u t S h a f t I n t e r m e d i a t e S h a f t D r a i n Pl u g I n p u t S h a f t R e a r B e a r i n g C u p...
Page 271 7 M - 5 2 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S Fig. 2D-Rem oving Intermediate Gear Shaft Fig. 4D-Rem oving Front Output Shaft Fig. 3D--Removing Rear Output Shaft Sub-Assembly Fig.
Page 272 CLUTCHES AND M A N U A L T R A N S M IS S IO N S 7 M - 5 3 Rear Output Be aring Intermediate Gears Spa ce r Cover Bolts (4) Retainer T a n ge d Thrust Front Output Shaft Front Output Be aring Rear Retainer Bolts...
Page 273 7 M - 5 4 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S J-8331 Fig. 9D--lnstalling Rear Output Shaft Front Bearing Fig. 7D--Removing Rear Output Shaft Front Bearing J-23422 BEARING CUP Fig.
Page 274 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 5 5 J-23423 J-6219 Fig. 1 3 D -ln s ta llin g Front O u tp ut Shaft Rear Bearing Fig.
Page 275 7 M - 5 6 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S J-22833 A L I N E S H A F T S L O T W IT H BOLT H O L E Fig.
Page 276: New Process Model 205 Transfer Case
CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 5 7 NEW PROCESS MODEL 205 TRANSFER CASE Index Disassembly of Transfer C ase..7M-57 Assembly of Transfer Case.........7M-59 Rear Output Shaft Assembly..
Page 277 7 M - 5 8 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 8 9 10 9 8 11 45 44 414241 R ear B e ar in g In p u t S h a f t Id ler G ea r S h a f t Be a ri n g S l i d i n g Cl u t c h...
Page 278 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 5 9 POPPET NUTS SHIFT RAIL LINK REAR OUTPUT ASSEMBLY IDLER SHAFT COVER FRONT INPUT FRONT OUTPUT SHAFT ASSEMBLY SHAFT ASSEMBLY FRONT OUTPUT SHAFT...
Page 279 7 M - 6 0 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S RANGE SHIFT RAIL 4-WHEEL SHIFT RAIL SHIFT RAIL Fig. 5C--Removing Gear Retaining Ring ^g. 7C--Shift R a *l Removal “T ”...
Page 280 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M -6 1 Rear Output Shaft Lo cknut S lid in g Clutch Cover G a sk e t W a s h e r Input Shaft Rear Cover...
Page 281 7 M - 6 2 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S J-8092 J-9276-2 Fig. 11C-Checking Idler Gear End Play Fig. IOC-In stalling New Bearing Cups Miscellaneous down in clutch gear groove.
Page 282 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 6 3 J-22836 Fig. 13C-Installing Idler Shaft Fig. 16C-Installing Front Output Bearing Retainer Seal COVER FLAT J-23431 Fig.
Page 283 7 M - 6 4 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S SPEEDOMETER GEAR SPACER REAR OUTPUT L O W GEAR CLUTCH GEAR Fig. 18C--lnstalling Rear Output Shaft Spacer and Speedometer Gear Fig.
Page 284: Disassembly Of Transfer Case
CLUTCHES A ND M A N U A L T R A N S M IS S IO N S 7 M - 6 5 Remove retainer from shaft and discard gasket. DISASSEMBLY OF TRANSFER CASE Recover any roller bearings which may fall from rear cover.
Page 285 7 M - 6 6 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S Speedometer Drive Gear Drive Chain Adapter Rear O utput Rear Brg. Gasket Input Drive Gear Pilot Brgs. Brg.
Page 286: Subassembly Repairs
CLUTCHES AND M A N U A L T R A N S M IS S IO N S 7 M - 6 7 INPUT GEAR FRONT OUTPUT SHAFT ASSY CHAIN HOUSING RANGE SELECTOR HOUSING COUNTER GEAR Fig. 2F—Front View of Transfer Case Fig.
Page 287: Lockout Clutch Assembly
7 M - 6 8 CLUTCHES A ND M A N U A L T R A N S M IS S IO N S S N A P R IN G Fig. 8F—Removing D iffe re n tia l C a rrie r Snap Ring Fig.
Page 288: Input Shaft Assembly
CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 6 9 Fig. 1 IF —Removing Front O utput Shaft Fig. 12F—Removing In te rm e diate (C hain) Housing retaining drive gear to clutch assembly.
Page 289 7 M - 7 0 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S Fig. 13F—T ransfer Case Exploded View OVERHAUL MANUAL...
Page 290 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M -71 Adapter Thrust Washer Input Gear Bearing Retainer Lubricating Thrust Washer Input Gear Bearing Retainer Gasket Retaining Ring Input Gear Bearing Retainer Seals 51 .
Page 291 7 M - 7 2 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S S N A P R IN G Fig. 15F—Removing Input S haft Bearing-to-Retainer Fig. 14F—Removing In p ut Shaft-to-Bearing Snap Ring Snap Ring 2.
Page 292 CLUTCHES AND M A N U A L T R A N S M IS S IO N S 7 M - 7 3 the outer shifter shaft before the shaft assembly bottoms out. 10. Install lower shift lever and retaining ring. 11.
Page 293 7 M - 7 4 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S S N A P RIN G Fig. 17F—Removing Rear O utput Bearing R etaining Ring installed on transfer case so shim requirements may Fig.
Page 294 CLUTCHES AND M A N U A L T R A N S M IS S IO N S 7 M - 7 5 J—2 2 8 3 6 Fig. 2 1 F—P ositioning Range Box for Assem bly Fig. 20F—In stalling Front O u tp ut Bearing Retainer Seal 4.
Page 295: Adapter Assemblies
7 M - 7 6 CLUTCHES AND M A N U A L T R A N S M IS S IO N S Fig. 23F—In stalling In te rm e diate Housing to Range Fig. 24F—Checking Rear O u tp ut Shaft End Play front output shaft to check for binding of the rear output shaft.
Page 296 CLUTCHES AND M A N U A L T R A N S M IS S IO N S 7 M - 7 7 S N A P R IN G SNAP RING ! ■ : i : : ; ' J v ( f t ■ $*:<...
Page 297 7 M - 7 8 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S SEAL J-8092 J-7137 Fig. 3 H -In s ta llin g A dapter Seal 2.
Page 298: Special Tools
CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 7 9 SPECIAL TOOLS 1. J-6456 Height Gauge 2. J • 1048 Gauge Plate 3. J 1522 Pilot Bearing D river 4.
Page 299 7 M - 8 0 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 1. J - 1 126 Transmission Guide Pins 7. J-1453-01 Speedometer Drive Gear Press Plates and 2.
Page 300 CLUTCHES AND M A N U A L T R A N S M IS S IO N S 7 M -8 1 8. J-22874-1 Bearing Installer 1. J-22832 Countergear Rear Bearing Remover 9. J-22874-5 M ainshaft Support Tool 2. J 8433-1 Bearing Puller 10.
Page 301 7 M - 8 2 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 1. J-23432-1 Snap Ring Picks. 2. J 23432 Snap Ring Pliers. 3. J-8092 Handle. 4.
Page 302 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S 7 M - 8 3 1. J - 2 2 8 3 6 - F r o n t O u tp u t S h a ft B earing R e ta in e r Seal 3 .
Page 303 7 M - 8 4 CLUTCHES AND M A N U A L T R A N S M IS S IO N S 1. J-8092 Handle. 2. J-8331 Rear Output Shaft Front Bearing Remover. 3. J-23422 Rear O utput Shaft Front Bearing Cup Installer. 4.
Page 304 SECTION 7 A AUTOMATIC TRANSMISSION CONTENTS OF THIS SECTION Powerglide Transmission............... 7A-1 Turbo Hydra-Matic 350 Transm ission........7A-22 Turbo Hydra-Matic 375/400/475 Transmission....7A-59 Special Tools..................7A-118 POWERGLIDE INDEX Assembly................7A-15 Disassembly of Transmission.........7A-1 Valve Body................7A-16 Extension, Governor and Governor Support..7A-1 Removal................7A-16 Internal Components............
Page 305 7A-2 A U T O M A T IC T R A N S M IS S IO N Transmission Case Extension Rear Bushing Welded Converter Output Shaft Oil Pump Seal Assembly Speedometer Drive and Driven Gear Oil Pump Body 40A.
Page 306 A U T O M A T IC T R A N S M IS S IO N 7A-3 the weight side of the governor, then remove the shaft and governor valve from the opposite side of the governor assembly (fig. 4PG) and the urethane washer.
Page 307: Remove Tool
7A-4 A U T O M A T IC T R A N S M IS S IO N Fig. 6PG--Removing Oil Pump Fig. 5PG--Removing Governor Assembly CAUTION: Use care so as not to damage the machined face on the front of the clutch drum. 12.
Page 308 A U T O M A T IC T R A N S M IS S IO N 7A-5 Fig. 8PG-Rem oving Rear Piston Spring Retainer Fig. 9PG -Applying Air to Remove Rear Piston Snap Ring Oil Pan and Valve Body NOTE: The oil pan and valve body may be serviced without the necessity of removing the extension and internal components...
Page 309 7A-6 A U T O M A T IC T R A N S M IS S IO N ” t M A N U A L V A L V E LEVER P A R K IN G P A W L B R A C K ET TV LEVER S P R IN G...
Page 310 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ AUTOMATIC TRANSMISSION 7A-7 R everse Ring G ear T ransm ission Case 3 1 . G o vernor S u p p o rt Reverse C lutch Pack 1 3A Transm ission Case 3 2 .
Page 311 7A-8 A U T O M A T IC T R A N S M IS S IO N Converter Assembly Oil Pump Cover and Low Brake Band Clutch Drive Plates Input Shaft Converter Stator Clutch Drum (Waved) Shaft Input Shaft Oil Seals Clutch Drum Bushing Clutch Hub Drive Oil Pump to Case...
Page 312 A U T O M A T IC T R A N S M IS S IO N 7A-9 Park Lock and Range Park Lock Pawl Shaft Park Lock and Range Selector Inner Lever Park Lock Pawl Selector Outer Lever Park Lock Pawl Shaft Park Lock and Range and Shaft...
Page 313 7 A -1 0 A U T O M A T IC T R A N S M IS S IO N Fig. 16PG-Checking Pump Body Bushing to Fig. 18PG-Driven Gear to Crescent Clearance Converter Pump Hub Clearance Fig. 19PG -Checking Gear End Clearance use J-6585 pullers and J-6585- 3 adapters to remove pum p assembly.
Page 314 A U T O M A T IC T R A N S M IS S IO N 7A-11 be removed using Tool J-9557 (and Handle J-7079) and Do not use rags to dry parts. CAUTION: reinstalled using Tool J-6582, pressing or driving the 2.
Page 315 7 A -1 2 A U T O M A T IC T R A N S M IS S IO N 3. Place the springs in position on the piston, then Planet Assembly and Input Shaft place the retainer in place on the springs. Inspection 1.
Page 316 A U T O M A T IC T R A N S M IS S IO N 7A-13 » * a m. 0 ’ Pinion Shaft Lock Short Planet Pinion Input Sun Gear Plate Gear Input Sun Gear Pinion Thrust W a s h e r Needle Bearings Thrust W a s h e r Pinion Shaft...
Page 317 7 A - 14 A U T O M A T IC T R A N S M IS S IO N while the short planet pinions are located in the openings. 17. Feed the second J-4599 in from the top picking up the upper thrust washer and the planet pinion and pushing the already installed Tool J-4599 out the lower end.
Page 318 A U T O M A T IC T R A N S M IS S IO N 7A-15 Inner W e ig h t Body to Hub Screws Valve to Shaft Inner W e ig h t to Outer Retaining Snap Ring and Lock W ashers Valve...
Page 319 7 A -1 6 A U T O M A T IC T R A N S M IS S IO N NOTE: Upper and lower valve body gaskets Valve Body are the same. Removal 2. Carefully install the lower valve body and gasket Remove valve body as described under "Transmission- and install 15 1-3/8"...
Page 320 A U T O M A T IC T R A N S M IS S IO N 7A-17 * ■ S n a p Ring Low and Drive Valve High Speed Dow n Detent Valve Hydraulic M odu lator Throttle Valve Sp rin g Inner S p rin g Shift T im ing Valve...
Page 321 7 A -1 8 A U T O M A T IC T R A N S M IS S IO N 4. Inspect rear oil seal and replace if damaged or NOTE: This is a precision bushing and if worn.
Page 322: Remove Tool
A U T O M A T IC T R A N S M IS S IO N 7A-19 around the outer diameter of the piston to start the seal ring into the bore. 9. With the support fixture turned so that the transmission case is facing up, install the 17 reverse piston return springs and their retainer ring.
Page 323 7 A -2 0 A U T O M A T IC T R A N S M IS S IO N pump body and the two seal rings on the pump 18. Remove the rubber seal ring from the oil pump cover extension.
Page 324 A U T O M A T IC T R A N S M IS S IO N 7A-21 30. Install new suction screen and gasket. 31. Install the guide plate (fig. 34PG) making sure that the inner lever properly picks up the manual valve. Install attaching bolts.
Page 325 7 A -2 2 A U T O M A T IC T R A N S M IS S IO N TURBO HYDRA-MATIC 3 5 0 TR ANSM ISSIO N INDEX Low and Reverse Roller Clutch Support.....7A-50 Transmission Disassembly and Reassembly.... 7A-24 Disassembly..............
Page 326 C O N V E R T E R IN T E R M E D IA T E IN T E R M E D IA T E F O R W A R D A S S E M B L Y C L U T C H O V E R R U N B A N D C L U T C H...
Page 327 7 A -2 4 A U T O M A T IC T R A N S M IS S IO N TRANSMISSION DISASSEMBLY AND REASSEMBLY 2. Remove extension housing from case and remove DISASSEMBLY square cut "O " ring seal from extension housing. 1.
Page 328 A U T O M A T IC T R A N S M IS S IO N 7 A -25 G O V E R N O R C O V E R E X T E N S IO N H O U S IN G B U S H IN G G O V E R N O R C O V E R T O CAS E "...
Page 329 7 A -2 6 A U T O M A T IC T R A N S M IS S IO N Fig. 10M--Removing Oil Pump Suction Screen Fig. 9M--Removing Transmission Oil Pan (Strainer) from Valve 9. Remove oil pan attaching screws (fig. 9M), oil pan, Body and gasket.
Page 330 A U T O M A T IC T R A N S M IS S IO N 7A-27 V A L V E B O D Y SPACER PLATE R A N G E SELECTOR IN N ER LEVER DETENT C O N T R O L VA LVE WIRE V A L V E B O D Y SPACER PLATE...
Page 331 7 A -2 8 A U T O M A T IC T R A N S M IS S IO N MAN U A L SHAFT TO CASE RETAINER V k Jf SCREWDRIVER OI L PUMP PRESSURE SCREEN Fig. 16M--Removing Oil Pump Pressure Screen Fig.
Page 332 A U T O M A T IC T R A N S M IS S IO N 7A -29 11. Remove manual shaft to case lip seal (fig. 21M). 12. Remove parking lock; lock bracket (fig. 22M). (Special Bolts). 13.
Page 333 7 A -3 0 A U TO M A TIC T R A N S M IS S IO N 15. Remove intermediate servo piston and seal ring. Remove washer, spring seat and apply pin (fig. 25M). REMOVAL OF OIL PUM P AND INTERNAL CASE COMPONENTS 1.
Page 334 A U T O M A T IC T R A N S M IS S IO N 7A-31 Fig. 29M -Rem oving Intermediate Clutch Plates Fig. 31M -Re m ovin g Intermediate Overrun Brake Band Fig. 3 0M -Re m ovin g Intermediate Clutch Pressure Fig.
Page 335 7 A -3 2 A U T O M A T IC T R A N S M IS S IO N INPUT R I N G G E A R 1 ‘ r INPUT RING G EA R F R O N T INPUT R I N G G E A R THRUST W A S H E R Fig.
Page 336 A U T O M A T IC T R A N S M IS S IO N 7A-33 R E T A I N I N G R IN G v L O W & R E V E R S E C L U T C H SU P P O R T Fig.
Page 337 7 A - 3 4 A U T O M A T IC T R A N S M IS S IO N O U T P U T R I N G G E A R A N D S H A F T A S S E M B L Y OUTPUT RING G E A R T A N G E D THRUST W ASH ER R E A C T I O N C A R R I E R...
Page 338 A U T O M A T IC T R A N S M IS S IO N 7A -35 Fig. 45M -Compressing Low and Reverse Clutch Fig. 4 7 M -R e m ovin g Low and Reverse Clutch Piston Piston Spring Retainer Compress low and reverse clutch piston spring...
Page 339 7 A - 3 6 A U T O M A T IC T R A N S M IS S IO N J-23069 REVERSE CLUTCH PISTON CENTER SEAL INNER SEAL Fig. 50M -Re m ovin g Accumulator Piston Cover Retaining Ring Fig.
Page 340 A U T O M A T IC T R A N S M IS S IO N 7A-37 9. Remove direct clutch accumulator piston, and metal oil seal ring, and spring. 10. From the next bore down from the direct clutch J-21885 accumulator, remove the detent actuating lever bracket bolt, bracket, actuating lever and retaining...
Page 341 7A 38 A U T O M A T IC T R A N S M IS S IO N © *- © SS3=SSSte= | ImTTuTt c= s> = m m m » ® fks § fUMUAI © SSiS^5 fteSniip Bfc W >...
Page 342 A U T O M A T IC T R A N S M IS S IO N 7A-39 * » 2. Remove pump cover to body attaching bolts 5/16 x 4. Remove intermediate clutch piston inner and outer seals (fig. 57M). 18-1 1/2 (fig.
Page 343: Assembly
7 A -4 0 A U T O M A T IC T R A N S M IS S IO N NOTE: A needle bearing is used on C series pump body and check pump body face to gear face Truck instead of a thrust washer.
Page 344 A U T O M A T IC T R A N S M IS S IO N 7A-41 EXHAUST EXHAUST PU M P INTERMEDIATE PRESSURE CLUTCH REVERSE CO OL ER BY-PASS VALVE J - 2 1 3 5 9 COOLER OUT ( FROM RADIATOR ) OOLER IN...
Page 345 7 A -4 2 A U TO M A T IC T R A N S M IS S IO N 5. Remove direct clutch pressure plate to clutch drum retaining ring and pressure plate (fig. 70M). 6. Remove drive plates and steel driven plates (fig. 71M).
Page 346 A U T O M A T IC T R A N S M IS S IO N 7 A -43 DIRECT CLUTCH DRUM TO FORW ARD CLUTCH H O U S IN G NEEDLE ROLLER BEARING Fig. 67M~Rem oving Overrun Clutch Retaining Ring Fig.
Page 347 7 A - 4 4 A U T O M A T IC T R A N S M IS S IO N STEEL PLATES Fig. 71M--Removing Face Plates and Steel Separator Fig. 7 2M -C o m p re ssin g Direct Clutch Spring Seat Plates Reassembly 1.
Page 348 A U T O M A T IC T R A N S M IS S IO N 7A-45 DIRECT CLUTCH-^ DRUM CLUTCH PISTON CENTER SEAL Fig. 7 6 M -In s ta llin g Direct Clutch Springs, Spring Fig. 74M--Removing Direct Clutch Piston Center Seal Seat and R etaining Ring C L U T C H A S S E M B L IE S .020"...
Page 349 7 A -4 6 A U T O M A T IC T R A N S M IS S IO N F O R W A R D C L U T C H P I S T O N A S S E M B L Y R E T A IN I N G S T E E L S E P E R A T O R P L A T E S ' R IN G...
Page 350 A U T O M A T IC T R A N S M IS S IO N 7A-47 FORWARD CLUTCH BALL CHECK J-23327-1 EXHAUST FORWARD CLUTCH DRUM Fig. 80M -C om pressing Forward Clutch Piston Return Seat Fig. 8 2 M -F o rw a rd Clutch Exhaust Check Ball .020"...
Page 351 7 A -4 8 A U T O M A T IC T R A N S M IS S IO N the lower edge of the notch on the inner surface of the drum to the end of the drum (dimension B). U S E W H E N D IM .
Page 352 A U T O M A T IC T R A N S M IS S IO N 7A-49 Fig. 8 5 M -P la n e ta ry Gear T ra in-E xploded View OVERHAUL MANUAL...
Page 353 7 A -5 0 A U T O M A T IC T R A N S M IS S IO N S U N G E A R R E T A I N I N G R IN G S U N G E A R D R IV E S H E L L Fig.
Page 354 A U T O M A T IC T R A N S M IS S IO N 7A-51 L O W A N D R E V E R S E C L U T C H S U P P O R T R O L L E R C L U A S S E M B L Y I N N E R R A C E...
Page 355 7 A -5 2 A U T O M A T IC T R A N S M IS S IO N 4. Remove low and reverse roller clutch assembly (fig. Disassembly 92M). 1. Cut off one end of each governor weight pin and remove pins, governor thrust cap, governor weights, Inspection and springs.
Page 356 A U T O M A T IC T R A N S M IS S IO N 7A-53 10. Check valve opening at entry and exhaust (.020 inch minimum). J-8 0 9 2 Governor Driven Gear Replacement To facilitate governor repair in the field, a governor driven gear and replacement pins are available for service use.
Page 357 7 A -5 4 A U T O M A T IC T R A N S M IS S IO N outer bushing 3/32" below front face (fig. 98M). Install Stator Shaft Front Bushing new front bushing (fig. 97M). With stator shaft properly supported, remove front bushing using tool J-21465-16 and slide hammer with adapter J-2619-01 (fig.
Page 358 A U T O M A T IC T R A N S M IS S IO N 7A-55 CAPE CHISEL B U S H I N G J -8 0 9 2 J-2 3 0 6 2 -5 INPUT RING G E A R DIRECT CLUTCH DRUM Fig.
Page 359 7 A -5 6 A U T O M A T IC T R A N S M IS S IO N 18. Install direct clutch assembly, and special thrust 7. Install reaction carrier assembly into output ring washer to forward clutch assembly. gear and shaft assembly.
Page 360 A U T O M A T IC T R A N S M IS S IO N 7A-57 5. Attach extension housing to case using attaching bolts. Torque to 25 ft. lb. J-5294 6. If necessary, install a new extension housing seal, using seal installer J-5154 or J-21426 (fig.
Page 361 7 A -5 8 A U T O M A T IC T R A N S M IS S IO N 5. Install valve body transfer plate and gasket assembly. 6. Install valve body to transfer plate gasket. 7. Install valve body. Connect manual control valve link to range selector inner lever.
Page 362 A U T O M A T IC T R A N S M IS S IO N 7A-59 TURBO HYDRA-MATIC 3 7 5 / 4 0 0 / 4 7 5 TRANSM ISSION INDEX Transmission Disassembly and Reassem bly.....7A-61 Pinion Replacement............7A-99 Disassembly of Major Units........7A-61 Output Shaft, Rear Internal Gear,...
Page 363 7 A -6 0 A U T O M A T IC T R A N S M IS S IO N Fig. IT -S id e Cross Section-Typical OVERHAUL MANUAL...
Page 364 A U T O M A T IC T R A N S M IS S IO N 7A-61 TRANSMISSION DISASSEMBLY A N D ASSEMBLY DISASSEMBLY OF MAJOR UNITS 1. With transmission in cradle on portable jack, remove converter assembly by pulling straight out. NOTE: Converter contains a large amount of oil.
Page 365 7 A -6 2 A U T O M A T IC T R A N S M IS S IO N Fig. 5T-R em oving Governor Cover A ttaching Screws Fig. 7T-R em oving Filter Retainer Bolt Fig. 8T--Removing Filter Assem bly and " 0 " Ring 3.
Page 366 A U T O M A T IC T R A N S M IS S IO N 7A -63 LEAD WIRE ASM PRESSURE SWITCH ASM. Fig. 8T-A~Disconnecting Pressure Switch Lead Wire Assembly Fig. 9T-R em oving D etent Roller and Spring Assembly Fig.
Page 367 7 A 6 4 A U TO M A T IC T R A N S M IS S IO N S E R V O C O V E R G O V E R N O R S C R E E N A S S Y .
Page 368 A U T O M A T IC T R A N S M IS S IO N 7A-65 GASKET Fig. 14T--Removing Detent Solenoid and Gasket 5. Remove detent solenoid attaching screws, detent solenoid and gasket (fig. 14T). Fig. 13T--Checking Rear Band Apply Pin 6.
Page 369 7 A -6 6 A U T O M A T IC T R A N S M IS S IO N S E R V O P IS T O N R E T A IN E R R IN G S E R V O P IN ! S E R V O S P R IN G S E R V O P IS T O N...
Page 370 A U T O M A T IC T R A N S M IS S IO N 7A-67 R E T A IN IN G S P R IN G S H A F T Fig. 23T-Rem oving Rear Oil Seal from Case Extension Fig.
Page 371 7 A -6 8 A U T O M A T IC T R A N S M IS S IO N Selective washer controlling this end play is the washer located between pump cover and forward clutch housing. If more or less washer thickness is required to bring end play within specifications, select proper washer from the following chart: F RO NT END WASHER THICKNESS...
Page 372 A U T O M A T IC T R A N S M IS S IO N 7A-69 J-9539 Fig. 29T-Rem oving Direct Clutch Assembly Oil Pump and Internal Case Components Removal 1. If necessary to replace, pry front seal from pump (fig.
Page 373 7 A -7 0 A U T O M A T IC T R A N S M IS S IO N Fig. 30T--Removing Front Band Fig. 31T-Rem oving Sun Gear Shaft 8. Remove front band assembly (fig. 30T). 9. Remove sun gear shaft (fig. 3 IT). DIAL INDICATOR Check Rear End Play as Follows (Fig.
Page 374 A U T O M A T IC T R A N S M IS S IO N 7A-71 Fig. 35T-Rem oving Center Support to Case Retaining Snap Ring Fig. 33T~Removing Center Support Bolt 12. Remove intermediate clutch backing plate, three (3) composition, and three (3) steel clutch plates (fig.
Page 375 7A -7 2 A U TO M A T IC T R A N S M IS S IO N SE L E C T IV E W A S H E R Fig. 37T~Removing Selective Washer Fig. 38T-Rem oving Rear Band 16.
Page 376 A U T O M A T IC T R A N S M IS S IO N 7A-73 THRUST W ASH ER ROLLER CLUTCH ASSEMBLY REACTION CARRIER GEAR PLASTIC GEAR RING OUTPUT CARRIER C O N S T A N T BLEED O R IF IC E P L U G Fig.
Page 377 7 A -7 4 A U TO M A T IC T R A N S M IS S IO N Fig. 43T-Rem oving Output Shaft to Carrier Snap Ring R EAR IN T E R N A L G E A R Fig.
Page 378 A U T O M A T IC T R A N S M IS S IO N 7A-75 Speedometer Drive Gear Replacement If removal and installation or replacement of the speedometer drive gear is necessary, proceed as follows: Nylon Speedometer Drive Gear N Y L O N 1.
Page 379 7 A -7 6 A U TO M A T IC T R A N S M IS S IO N Fig. 48T--Governor--Exploded Disassembly 1. Cut off one end of each governor weight pin and remove pins, governor thrust cap, governor weights, and springs.
Page 380 A U T O M A T IC T R A N S M IS S IO N 7A-77 gear, two governor weight retaining pins and one governor gear retainer split pin. Replacement of gear must be performed with care in the following manner: 1.
Page 381 7 A -7 8 A U TO M A TIC T R A N S M IS S IO N Fig. 50T-Front Servo Assembly-Exploded View 4. Remove washer, spring, and spring retainer. assemblies and governor sleeve, and install new pins. Crimp both ends of pins to prevent them from falling out.
Page 382 A U T O M A T IC T R A N S M IS S IO N 7A-79 4. Remove front accumulator piston and spring (fig. 54T). 5. On the right side adjacent to the manual valve, remove the 1-2 valve train as follows: a.
Page 383 7 A -8 0 A U TO M A T IC T R A N S M IS S IO N R E T A IN IN G “ E " R IN G S E R V O P IS T O N S E R V O PIN Fig.
Page 384 A U T O M A T IC T R A N S M IS S IO N 7A-81 I «T sfclsJsQ = 3 ..:;u F J Q = Q X 3 3 S ssjb h b k ) 22 23 gsq;...
Page 385 7 A -8 2 A U TO M A T IC T R A N S M IS S IO N DRIVE MODULATOR OR INTERMEDIATE REVERSE EXHAUST COOLER INTAKE COOLER RETURN BREATHER HOLE Fig. 56T-lnstalling Detent Regulator Valve and CONVERTER LUBE Detent Valve PRESSURE REGULATOR...
Page 386 A U T O M A T IC T R A N S M IS S IO N 7 A -83 RETAINING PIN BORE PLUG PRESSURE REGULATOR VALVE- PRESSURE REGULATOR SPACER SPRING RETAINER WASHER-, PRESSURE REGULATOR SPRING PUMP COVER THRUST WASHER PRESSURE BOOST VALVE PRESSURE BOOST BUSHING PUMP OIL SEAL RING -...
Page 387 7 A -8 4 A U TO M A T IC T R A N S M IS S IO N S P R IN G R E T A IN E R W A S H E R RETAINING - P R E S S U R E R E G U L A T O R S P A C E R R E G U L A T O R V A L V E...
Page 388 A U T O M A T IC T R A N S M IS S IO N 7A-85 PUMP COVER FOR IDENTIFICATION- SQUARED OFF PRESSURE REG. BOSS. - ' Fig. 65T-Checking Pump Body Face to Gear Face Clearance Fig. 64T-Pressure Regulator Valve Identification 6.
Page 389 7 A -8 6 A U T O M A T IC T R A N S M IS S IO N FORWARD CLUTCH HUB THRUST WASHERS FORWARD CLUTCH HOUSING Fig. 66T-lnstalling Pump Cover to Pump Body Fig. 68T-Rem oving Forward Clutch Hub and Thrust W ashers Fig.
Page 390 A U T O M A T IC T R A N S M IS S IO N 7A-87 CLUTCH OUTER SEAL Fig. 71T-Rem oving Forward Clutch Piston Outer Seal Fig. 70T-Rem oving Forward Clutch Spring Retaining Snap Ring b. Inspect splines for damage. c.
Page 391 7 A -8 8 A U T O M A T IC T R A N S M IS S IO N FORWARD CLUTCH ASSEMBLY PLATES (5) THRUST WASHERS Fig. 73T~Forward Clutch Assembly-Exploded View Fig. 74T—Installing Forward Clutch Piston Fig. 75T—Installing Forward Clutch Composition and Steel Plates OVERHAUL MANUAL...
Page 392 A U T O M A T IC T R A N S M IS S IO N 7 A -89 FORWARD CLUTCH ASSEMBLY PUMP ASSEMBLY Fig. 76T--lnstalling Forward Clutch Housing to Direct Fig. 77T-Air Checking Forward Clutch Assembly Clutch Hub Snap Ring CAUTION: Do not confuse the flat steel clutch 11.
Page 393 7 A -9 0 A U T O M A T IC T R A N S M IS S IO N SNAP RING INTERMEDIATE CLUTCH RETAINER IN T E R M E D IA T E C L U T C H O U T E R R AC E I N T E R M E D IA T E R O L L E R...
Page 394 A U T O M A T IC T R A N S M IS S IO N 7A-91 CLUTCH RETAINER Fig. 81T"Rem oving or Installing Direct Clutch Snap Ring Fig. 79T~Removing Intermediate Clutch Retainer DIRECT CLUTCH Snap Ring PISTON ASSEMBLY DIRECT CLUTCH BA C KIN G PLATE DIRECT CLUTCH...
Page 395 7 A -9 2 A U TO M A T IC T R A N S M IS S IO N DIRECT CLUTCH H O U S IN G (1) W A V E D STEEL PLATE (5) C O M P O S IT IO N PLATES (4) FLAT STEEL PLATES CLUTCH OUTER SEAL DIRECT CLUTCH B A C K IN G PLATE...
Page 396 A U T O M A T IC T R A N S M IS S IO N 7 A -93 DIRECT CLUTCH BACKING PLATE FLAT STEEL PLATES C O M P O S ITIO N PLATES W AVED STEEL PLATE J-21362 J-21409 Fig.
Page 397 7 A -9 4 A U T O M A T IC T R A N S M IS S IO N INTERMEDIATE CLUTCH ROLLER ASSEMBLY Fig. 93T-Intermediate Roller Clutch Rotation DIRECT CLUTCH H O U SIN G AND CAM ASSEMBLY Fig.
Page 398 A U T O M A T IC T R A N S M IS S IO N 7A-95 Fig. 95T—Installing Intermediate Clutch Retainer Snap Ring 5. Remove intermediate clutch piston (Fig. 98TD). 6. Remove inner and outer piston seal. Fig.
Page 399 7 A -9 6 A U T O M A T IC T R A N S M IS S IO N SPRIN G INTERMEDIATE CLUTCH RETAINER- SPRING GUIDE Fig. 98TA— Removing Spring Retainer Fig. 98TC— Removing Intermediate Clutch Spring Guide IN T ERM EDIA TE CLUTCH RELEASE S P R IN G (3)
Page 400 A U T O M A T IC T R A N S M IS S IO N 7A-97 ROLLER ASSEMBLY CENTER SUPPORT ASSEMBLY INTERMEDIATE CLUTCH INNER SEAL INTERMEDIATE CLUTCH RELEASE SPRINGS THRUST WASHER SUPPORT TO TEFLON OIL CASE SPACER SEAL RINGS INTERMEDIATE CLUTCH OUTER SEAL...
Page 401 7 A -9 8 A U T O M A T IC T R A N S M IS S IO N Fig. 102T-Installing Intermediate Clutch Piston CLUTCH INNER SEAL Fig. 100T-Installing Intermediate Clutch Inner Seal INTERMEDIATE CLUTCH SPRING GUIDE Fig.
Page 402 A U T O M A T IC T R A N S M IS S IO N 7A-99 INT ERM ED IA TE CLUTCH RELEASE S P R IN G (3) Fig. 104T--Air Checking Intermediate Clutch Pistol Fig. 102TB— Installing Intermediate Clutch Release Springs Fig.
Page 403 7 A - 1 0 0 A U TO M A T IC T R A N S M IS S IO N PINION PIN BRONZE WASHER STEEL WASHER HEADED END PLANET PINION NEEDLE BEARINGS STEEL WASHER BRONZE WASHER Fig. 106T--Checking Output Carrier Pinion End Play Fig.
Page 404 A U T O M A T IC T R A N S M IS S IO N 7A-101 2. Inspect splines for damage. 3. Inspect housing for cracks or porosity. 3. Inspect bushings for scoring or galling. If necessary 4.
Page 405 7 A - 1 0 2 A U TO M A T IC T R A N S M IS S IO N 3. Apply suction to vacuum tube and check for 7. Inspect parking pawl shaft if removed for damaged diaphragm leaks.
Page 406 A U T O M A T IC T R A N S M IS S IO N 7 A -10 3 DRIVE lETENT EXHAUST REVERSE INTERMEDIATE LINE x DRIVE MODULATOR OR INTERMEDIATE REVERSE fc \J ? E VERSE fEVERSE TO CO O LER^ 3R LO lODULATOR...
Page 407 7 A - 1 0 4 A U TO M A T IC T R A N S M IS S IO N Fig. 114T-B-Checking Converter End Clearance Fig. 114T-A-Loosening Collet on Tool J-21571-8 while its plunger rests on the cap nut of Tool b.
Page 408 A U T O M A T IC T R A N S M IS S IO N 7 A -10 5 SNAP RING SPEEDOMETER DRIVE GEAR FLANGED THRUST WASHER (METAL) O.D. FLANGE I.D. FLANGE RACE RACE BEARING REAR INTERNAL GEAR O.D.
Page 409 7 A - 1 0 6 A U TO M A T IC T R A N S M IS S IO N O.D. FLANGED RACE I.D. FLANGED RACE THRUST BEARING Fig. 117T--lnstalling Rear Internal Gear to Sun Gear Bearing and Races FLANGED RACE Fig.
Page 410 A U T O M A T IC T R A N S M IS S IO N 7 A -10 7 SUN GEAR SHAFT I.D. FLANGED RACE THRUST BEARING I.D. FLANGED RACE Fig. 122T-lnstalling Center Support to Sun Gear Thrust Bearing and Races Install rollers that may have come out of the roller clutch cage, by compressing the energizing spring...
Page 411 7 A - 1 0 8 A U TO M A T IC T R A N S M IS S IO N ROLLER CLUTCH ASSEMBLY Fig. 126T-A Modification of Service Case for Corvette Fig. 124T-Installing Roller Clutch to Reaction Carrier Models NOTE: With reaction carrier held, center support should only turn counter-clockwise...
Page 412 A U T O M A T IC T R A N S M IS S IO N 7 A -10 9 Fig. 128T— Installing Parking Shaft Retaining Spring Fig. 129T-A—Installing Center Support to Case Spacer Using a "C " Clamp, clamp the transmission case firmly to a suitable bench, with the converter under pan 3.
Page 413 7 A - 1 1 0 A U T O M A T IC T R A N S M IS S IO N CENTER SUPPORT LOCATING TOOL Fig. 131T-A--lnstalling Center Support Bolt a. (All except CY Model) Oil and install three (3) steel and three (3) composition clutch plates.
Page 414 A U T O M A T IC T R A N S M IS S IO N 7A-111 Fig. 133T—Installing Front Band c. Move output shaft in and out to read end play. End play should be from .007"-.019". The selective washer controlling this end play is a Fig.
Page 415 7 A - 1 1 2 A U TO M A T IC T R A N S M IS S IO N FRONT SEAL Fig. 136T-Installing Direct Clutch Assembly Fig. 138T-Installing Pump Seal thrust washer on forward clutch hub. Retain with petrolatum.
Page 416 A U T O M A T IC T R A N S M IS S IO N 7 A -1 1 3 Fig. 142T-Location of Check Balls Read resulting travel or end play which should be .003"- .024". Selective washer controlling this end play is Fig.
Page 417 7 A - 1 1 4 A U TO M A T IC T R A N S M IS S IO N SPACER PLATE GASKET Fig. 144T—Installing Detent Solenoid and Gasket 5. Install detent solenoid gasket. 6. Install detent solenoid assembly with connector facing outer edge of case (fig.
Page 418 A U T O M A T IC T R A N S M IS S IO N 7 A -11 5 ACCUMULATOR f ^ T F NECTOR Fig. 147T--lnstalling Rear Accumulator Spring Fig. 145T-lnstalling Electrical Connector and ”0 " Ring Seal REAR SERVO NOTE: If transmission is in the vehicle,...
Page 419 7 A - 1 1 6 A U TO M A T IC T R A N S M IS S IO N REAR SERVO COVER G U ID E P IN S REAR SERVO GASKET Fig. 151T--lnstalling Control Valve Assembly and Fig.
Page 420 A U T O M A T IC T R A N S M IS S IO N 7 A -11 7 Fig. 152T--lnstalling Detent Roller and Spring Fig. 154T--lnstalling Governor Assembly Assembly NOTE: It is recommended that the filter be NOTE: The TCS wire is routed from the case replaced, rather than cleaned, whenever the electrical connector around the solenoid...
Page 421 7 A - 1 1 8 A U T O M A T IC T R A N S M IS S IO N 2. Install speedometer driven gear retainer and 3. Install vacuum modulator into case. attaching bolt. 4. Install modulator retainer and attaching bolt. Torque bolt 18 ft.
Page 422 A U T O M A T IC T R A N S M IS S IO N 7 A -1 1 9 SPECIAL TOOLS J-9 5 0 6 H o ld in g Fixtu re A d a p te rs J -70 79 H an d le J-3 2 8 9-0 1...
Page 423 7 A -1 2 0 A U T O M A T IC T R A N S M IS S IO N 1. J-8763-02 Transmission Holding Fixture 14. J-21424-7 Stator Shaft Front Bushing (Used with J-3289-20 Base) Installer (Used with J-8092) Transmission Holding Fixture 2.
Page 424 A U T O M A T IC T R A N S M IS S IO N 7A-121 J-8763 Transmission Holding Fixture J -2 1363 Seal Protector - Intermediate J-3 289-1 4 Holding Fixture Base Clutch - Inner J -2 1 427-1 Speedo Gear Remover J -2 1409 Seal Protector - Forward Clutch...
Page 425 7 A -1 2 2 A U TO M A T IC T R A N S M IS S IO N 1. J -6 1 16-01 Rear Unit Holding Fixture J-2 1795-2 Part of Above Holding Tool J-5384 Converter Holding Strap J-8092 Driver Handle Bushing Tool Set...
Page 426 SECTION 9 STEERING CO NTENTS OF THIS SECTION Manual Steering G ears..............9-1 Power Steering P u m p ...............9-8 Integral Power Steering G ear............9-13 Control Valve - Corvette.............. 9-25 Power Cylinder-Corvette.............. 9-29 Special Tools..................9-31 MANUAL STEERING GEARS INDEX Pitman Shaft Bushing Replacement...... 9-3 Overhaul Operations..............9-1 Side Cover Bushing Replacement......9-3 Disassembly.................9-1...
Page 427 9-2 STEERING PITM AN SHAFT W O R M BEARING SECTOR BALL N UT (LOW ER) W O RM SH A FT W O R M BEARING (UPPER) ADJUSTER PLUG SEAL SECTOR WORMSHAFT BEARING LOCK NUT BALL E X PA N SIO N BEARING CLAMP GUIDE...
Page 428 STEERING except Corvette-Using a suitable size screw the condition o f the pitman shaft bushing(s) driver, pry the lower bearing retainer from the and the upper wormshaft bearing race. adjuster plug housing and remove the bearing (fig. 2. A suitable size socket, pressing on the outer diameter of the seal, may be used to install new 9.
Page 429 9 -4 STEERING tightness, the unit should be disassembled, cleaned and inspected as follows: 1. Remove screws and clamp retaining the ball guides in nut. Draw guides out of nut. 2. Turn the nut upside down and rotate the wormshaft back and forth until all the balls have dropped out of the nut into a clean pan.
Page 430 STEERING LOWER CIRCUIT Fig. 12- Filling Ball Circuits-Corvette Fig. 1 3 -Filling Ball Guides-Corvette a. Place the wormshaft flat on the bench and slip up the spaces between the balls and fill the the nut over the worm with the ball guide holes circuit completely and solidly.
Page 431 9-6 STEERING W o rm B e a rin g A d ju ste r U p p e r W o rm B e arin g R ac e La sh A d ju ste r L o c k n u t P itm a n S h a ft Seal La sh A d ju ste r S h im W o rm B e a rin g A d ju ste r...
Page 432 STEERIN G 1. Side Cover Screws Expansion Plug 17. Worm Bearing Race—Upper Lash Adjuster Locknut 10. Steering Gear Housing 18. Adjuster Plug Side Cover and Bushing Pitman Shaft Seal Wormshaft Seal Lash Adjuster Shim 12. Worm Bearing Race—Lower Adjuster Plug Locknut Lash Adjuster Screw 13.
Page 433: Power Steering Pump
9-8 STEERING 5. Turn the lash adjuster screw clockwise to remove all Adjustment on Bench lash between the ball nut and sector teeth. Tighten the locknut. 1. Tighten the adjuster plug until all end play has been removed and then loosen one-quarter turn. 6.
Page 434 STEERING L-6 A N D S M A L L V -8 M A R K V -8 13 14 15 16 S p rin g M o u n tin g S tu d Squ are R in g U n io n U n io n "...
Page 435 9 -1 0 STEERING Fig. 21-lnstalling Seal U sin g Tool J-22670 1. Shaft 12. End Plate Retaining Ring 2 . W oodruff Key 13. Pressure Plate Spring 3 . Shaft Seal 14. Pump In le t Tube 4 . Pump Housing 15.
Page 436 STEERING 9-11 DOWEL PINS Fig. 24- lnstalling Shaft, Thrust Plate, and Rotor Fig. 2 6-lnstallin g Vanes Assembly A R R O W D O W E L C R O S S - O V E R H O L E P U M P P IN R I N G...
Page 437 9 -1 2 STEERING 6. Place pump housing in a vise and install shaft, 16. Install a new reservoir "O " ring seal, lubricated thrust plate and rotor assembly into housing, with Power Steering Fluid, onto housing. aligning the holes in the thrust plate with the dowel 17.
Page 438 4. Remove the pitman shaft and side cover as follows: Pliers J-4245. With a screw driver, pry the dust seal a. Loosen the over-center adjusting screw locknut and oil seal from the bore of the adjuster plug CHEVROLET OVERHAUL MANUAL...
Page 439 A D JU ST E R PLU G TEFLO N S E A L S THRUST P IT M A N SH A F T Fig. 31-Power Steering Gear-Typical Fig. 32--Removing End Cover R etaining Ring Fig. 3 3 -R em oving End Plug CHEVROLET OVERHAUL MANUAL...
Page 440 (fig. 37). Discard the oil seal. with a small screw driver (fig. 38). Remove the spacer, thrust bearing washer, thrust bearing and 2. If the thrust bearing ONLY is to be removed, pry washer. Discard the retainer. CHEVROLET OVERHAUL MANUAL...
Page 441 Assembly spacer (grooves of spacer away from bearing CAUTION: Place a block o f wood under the washer). adjuster plug to protect the thrust bearing 5. Install a new bearing retainer on the adjuster plug surface. CHEVROLET OVERHAUL MANUAL...
Page 442 Carefully disengage the shaft pin from the valve spool and remove the shaft assembly (fig. 43). 3. Push the spool valve out of the flush end of the valve body until the dampener "O" ring is exposed, CHEVROLET OVERHAUL MANUAL...
Page 443 7. Lubricate a new "O" ring with Power Steering Fluid and install it in the shaft cap end of the valve body assembly. Fig. 4 4 -Removing Spool Valve CHEVROLET OVERHAUL MANUAL...
Page 444: Remove Tool
3. If necessary to replace the teflon oil seal and "O " 5. Alternately install 7 balls into the return guide and ring, remove at this time. retain with chassis lubricant at each end of guide. CHEVROLET OVERHAUL MANUAL...
Page 445 1. If pitman shaft seals ONLY are to be replaced, J-8092. Place needle bearing (shouldered end first) remove the seal retaining ring with Internal Pliers on to Tool J-22407. Press bearing into gear housing J-4245 and remove outer steel washer. Pry out the CHEVROLET OVERHAUL MANUAL...
Page 446 D O N O T B O T T O M BEAR IN G IN H O U S IN G Fig. 51 --Installing P itm an Shaft Bearing Fig. 5 3 -Insta llin g P itm an Shaft Seals CHEVROLET OVERHAUL MANUAL...
Page 447 B EA R IN G W ASH ERS the same part number or with an equivalent part if replacement becomes necessary. Do not Fig. 54 -Worm and Valve Body -Exploded View use a replacement part o f lesser quality or CHEVROLET OVERHAUL MANUAL...
Page 448 Turn the stub shaft until the rack-piston teeth are centered in the pitman shaft opening, then Fig. 5 9 - Insta llin g Rack-Piston install the pitman shaft and side cover so that CHEVROLET OVERHAUL MANUAL...
Page 449 While holding the adjusting screw, tighten the lock-nut to 35 ft. lbs. using using Adapter J-5860 (fig. 62) and recheck the adjustment. J -5 8 6 0 Fig. 62--Torquing Over-Center Locknut Fig. 60—A d ju stin g T hrust Bearing Preload CHEVROLET OVERHAUL MANUAL...
Page 450 STEERING 9-25 CONTROL VALVE-CORVETTE INDEX Overhaul Operations............9-25 Repairs................9-27 Disassembly..............9-25 Assembly................9-27 Inspection.................9-27 Valve Balancing..............9-28 OVERHAUL OPERATIONS Disassembly 1. Place the valve in a vise as shown and remove dust cover (fig. 63). 2. Remove adjusting nut (fig. 64). 3. Remove valve to adapter bolts and remove valve housing and spool from adapter.
Page 451 9 -2 6 STEERING Fig. 66-Rem oving Valve Parts from Shaft Fig. 67-Rem oving Plug-to-Sleeve Key Fig. 68-Seal with Clam p Attachment Fig. 69-Turning Adjuster Plug out of Sleeve OVERHAUL MANUAL...
Page 452 STEERING 9 -27 9. Remove the adapter from the vise and invert, permitting the spring and one of the two ball seats to fall free. 10. Remove the ball stud and the other ball seat and the sleeve will fall free. Inspection 1.
Page 453 9 -2 8 STEERING Shsgi ~jU^p ■ Valve Shaft Dust Cover S p rin g Thrust W ash er Ball Seat S p rin g A dju sting Nut Valve Spring Ball Seat Sp rin g Retainer Vee Block Seal Ball Seat Valve Spoo l 1 4.
Page 454 STEERIN G 9 -2 9 a. If the piston rod remains retracted, turn the adjusting nut clockwise until the rod begins to move out. Then turn the nut counter-clockwise until the rod just begins to move in. Now turn the nut clockwise to exactly one-half the rotation needed to change the direction of the piston rod movement.
Page 455 9 -3 0 STEERING Backup Washer 1. Snap Ring Ball Stud Scraper Element End Plug and Lube Fitting Ball Seat " 0 " Ring Ball Stud Seal Piston Rod Scraper Spring Piston Body Snap Ring Spring Seat Piston Rod Piston Rod Seal Fig.
Page 456 STEERIN G 9-31 SPECIAL TOOLS Ball Retainer 18. J-7539 Pitman Arm Puller 1. J-6632 Spanner Wrench 19. J-7624 Pitman Arm Puller 2. J-5504 No. 23 Internal Pliers 20. J-4245 Shift Tube Installer 3. J-23073 Pump Shaft Seal Installer 21. J-22670 Shift Tube Remover 4.
Page 458: Specifications
SPECIFICATIONS PASSENGER CAR Section Page Heating and Air Conditioning ..........Body ..................... Front Suspension ..............Rear Suspension ............... Brakes ................... E ngine................... Carburetor..................Engine Electrical............... Clutch and Manual Transmission........Automatic Transmission............Steering..................Tire Usage Chart............... Chassis Sheet M etal..............Body and Chassis Electrical..........Radiator and G rille..............
Page 460: Body
PASSENGER CAR SPECIFICATIONS HEATER AND AIR CONDITIONING SECTION 1A H EA TER Torque Specifications Compressor Suction and Discharge Amps Connector B o lt ..........25 ft. lbs. (Cold) (Cold) Rear Head to Shell Stud N u ts.......23 ft. lbs. Volts Blower M o t o r ......13.5 6.25 Max.
Page 461: Front Suspension
SPECIFICATIONS 2 FRONT SUSPENSION SECTION 3 BOLT TORQUES $ CHEVELLE VE HICLE CH E VRO LE T NO VA C A M A R 0 CORVE TTE MONTE CARLO Ball Joint Stud Nuts Upper Stud *6 0 '# *5 0 '# Lower Stud *9 3 '# *9 0 '#...
Page 462 DIMENSIONS " Z " , "J", " K " & " D " V ER TIC A L TO GROUND AND APPLY TO REG. PROD. W ITH P/S, P/B AND RADIO CURB CURB TIRES CURB CURB CHEVROLET MODELS 9.69 9.67 WITH STANDARD V-8 G-78 6.24 3.13 9.72...
Page 463 M e asure 'J' an d 'K' H eigh t at the follow ing distance rearw ard of the front wheel or frontward of the rear wheel CHEVROLET MONTE CARLO CHEVELLE (CPE ONLY) CHEVELLE C A M A R O...
Page 464 @ Caster and Camber must not vary more than 1/2° from side to side. $ Toe setting must always be made after caster and camber. ttS e e explanatory copy in front suspension section. tSee Note under Specifications Chart concerning camber for Chevrolet, Monte Carlo and Chevelle. OVERHAUL MANUAL...
Page 465 SPECIFICATIONS 6 W HEEL A L IG N M E N T S P E C IF IC A T IO N S + (All Vehicles at Curb Weight) Service Checking Vehicle Inspection Service Reset Specification for diagnosis Specification for Specification for warranty repair or Periodic motor...
Page 466: Rear Suspension
- 8 7/8” T ru c k ......8 7/8" Passenger ..5.4 pints — Corvette........Bearing Caps............ Pinion Lock Screw ........8 7/8" Truck____ Filler Plug ..........TORQUE (FT. LBS.) Chevrolet Chevelle Except Monte Carlo Nova Camaro Corvette 116” W.B.
Page 467: Brakes
*Plus additional torque necessary to line up cotter pin hole. #See Wheel Alignment Chart in Front Suspension Specification Section. R ID IN G HEIGHTS See “Riding Heights” in Front Suspension Specification Section. BRAKES SECTION 5 TORQUE SPECIFICATIONS Chevelle, Chevrolet 116” and 125” W.B. Wagons Camaro Nova Corvette W.B. Wagons...
Page 468: Ngine
SPECIFICATIONS 9 ENGINE SECTION 6 GENERAL DATA: In Line Type Displacem ent (cu. in.) 215, 245 & 275 175* Horsepower @ rpm 5200 3200 4000 5200 4000 3600 3600 4 0 0 0 375 395 <® <sP Torque @ rpm 2400 2800 2800 4000 2000...
Page 469 SPECIFICATIONS Type In Line Displacem ent (cu. in.) 115 145 1 175 1 245 & 250 215. 245 & 275 Horsepower CRANKSHAFT: Auto. Man. .0008 # l-2 -3 -4 .0008-.0020 .0019 # l-2 -3 -4 .0013-.0025 .0013 .0020 .0031 .0025 #2-3-4 Main .0003...
Page 470 SPECIFICATIONS ENGINE TUNE UP Type Displacement Horsepower 215, 245 & 275 Compression ©(PSI) Standard AC-R46T Make AC-R44T & Number Cold AC-R45T AC-R43T .035” Point Dwell 31°-34° 29°-31° Point Gap .016” (Used) - .019” (New) Arm Spring Tension 19-23 Ounces Condenser .18-.23 Microfarad —...
Page 471 SPECIFICATIONS ENGINE TORQUES In Line Small V -8 Mark IV-V-8 Usage Size 1/4-20 Camshaft Thrust Plate 80 lb. in. Crankcase Front Cover 80 lb. in. Flywheel Housing Cover 80 lb. in. Oil Filter Bypass Valve 80 lb. in. Oil Pan (To Crankcase) 80 lb.
Page 472: Carburetor
SPECIFICATIONS CARBURETOR SECTION 6 M IDENTIFICATION PASSENGER CARS - EXCEPT VEGA Also refer to Rochester Carburetor Identification Illustrations in Overhaul. Vehicles Engines Passenger Car Carburetors — Except Vega deral Cali Fornia Barrel Displace (bbl) ment and Option Automatic Manual Automatic Manual Type Type...
Page 473 SPECIFICATIONS CARBURETOR ADJUSTMENTS PASSENGER CARS - EXCEPT VEGA Rochester Carburetors NUMBER Choke Rod Float Float Metering Air Valve Vacuum Model (A) Automatic Trans. Pump Rod (Fast idle Unloader Level Drop Wind-Up Break (M) Manual Trans. Cam) 7043014(A) .080 .300 .500 .245 7043017(M) .080...
Page 474 SPECIFICATIONS OTHER ADJUSTMENTS PASSENGER CARS - EXCEPT VEGA NOTE: Refer to “Additional External Settings and Adjustments'Vor "Idle Stop Solenoid Adjustment" and "CEC Valve Adjustment, as applicable, in Section 6M (Service Manual), under carburetors before using the following charts. NOTE: All idle speeds listed are to be set with air conditioning OFF. UNLESS OTHERWISE N O T IF IE D - ALWAYS USE C UR RENT SPECIFI...
Page 475: Engine Electrical
7000 RPM 1100573 All V-8 W/B02 & B07 4521 4 -4 .5 1100597 Camaro and Nova 4522 4 -4 .5 w/C60 Chevrolet, Monte 4 -4 .5 1100542 Carlo and Chevelle 4533 w/C60 1102346 L-6 W/B02 & B07 4521 4 -4 .5 1100950 Corvette, exc.
Page 476: Ignition Coil
SPECIFICATIONS STARTING MOTOR Model Free Speed Ring Gear Application Spec. No. Dia.-ln. Volts Amperes 1108365** 250 CID L-6 Engine 3573 w/Man. or Auto. Trans. (Low) 12-3/4 50-80* 5500-10500 1108512 307 CID V-8 3573 Engine w/Man. or Auto. Trans. (Low) 12-3/4 50-80* 5500-10500 1108418...
Page 477 SPECIFICATIONS DISTRIBUTORS Origi nal Ignition Ignition Centrifugal Vacuum Engine Point Equipment Advance Timing Description Distributor Advance Trans. Dwell Spark (Product (In Crank BTDC at (Crank Degrees @ Setting Plug Part No.) Engine RPM) Degrees) Engine Idle* Available C-4797 C-3933 0 @ 7” Hg 31°...
Page 478 SPECIFICATIONS DISTRIBUTORS (CONT’D.) Ignition Original Engine Ignition Centrifugal Vacuum Point Description Distributor Advance Advance Timing Equipment Dwell Trans. (In Crank Spark (Product (Crank Degrees @ B TD C at Setting Available Part No.) Engine RPM) Engine Idle* Plug Degrees) C-4888 C-6001 0 @ 1100 RPM 0 @ 6"...
Page 479: Automatic Transmission
SPECIFICATIONS 20 AUTOMATIC TRANSMISSION SECTION 7A TURBO HYDRA-MATIC—350 TURBO H Y D R A -M A T IC -3 7 5 /4 0 0 TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Pump Cover B o lts............18 ft. lbs. Pump Cover to Pump Body........17 ft. lbs. Parking Pawl Bracket B o lts ........18 ft.
Page 480: Steering
SPECIFICATIONS 21 STEERING SECTION 9 STANDARD STEERING Chevelle 116" W.B. Wagon Chevrolet Item Vehicle Nova Corvette Monte Carlo and Camaro A ll w/C-60 Model A L L A L L A L L others or LS4 Type Road Fast Steering...
Page 481 SPECIFICATIONS 22 TORQUE CHART Chevelle Components Chevrolet Nova Camaro Corvette & Monte Carlo Steering Gear 70 lbs. ft. 30 Ibs. ft. Mounting Bolts Pitman Shaft Nut 185 lbs. ft. 140 Ibs. ft. 185 Ibs. ft. 140 Ibs. ft. Pitman Arm to 45 lbs.
Page 482 SPECIFICATIONS 23 TORQUE C H A R T (CONT'D) Chevelle Chevrolet Nova Camaro Corvette Components & Monte Carlo Turn Signal Switch 25 lbs. in. Screws Column Lock Plate 20 lbs. in. Cover Screws Turn Signal Housing 45 lbs. in. Screws Lock Bolt Spring 35 lbs.
Page 483 White E78-14 E78-14, Letters Bias White Wall, E70-14 G70-14 White Z-15 (Not White letters Base V-8) Letters CHEVROLET STATION W AGO N S G78-14 H78-14 White L78-15B El Camino G78-14 Walls Station Wagon White Wall L78-15B G70-14 (125” W.B.) L78-15D,...
Page 484 Vehicles with luggage racks do not have a load limit greater than specified above. CHASSIS SHEET METAL SECTION 11 TORQUE SPECIFICATIONS Corvette Nova Camaro Chevrolet Chevelle Monte Carlo 25 ft. lbs. Hood Lock Striker 25 ft. lbs. 18 ft. lbs.
Page 485 C orvette......... 1895 Underhood......... Head Lamps Up (C o rvette)..... 1895 Headlamps Generator Indicator Chevrolet, Corvette Camaro, Chevrolet, N o v a ..Outer-High Beam ....37 1/2 4002 Chevelle, Monte Carlo ....Outer-Low B e am ....4002 Hi Beam Indicator Inner-High B e a m ....
Page 486 Adjust the low beam pattern as shown in Figure B. below. On full size Chevrolet and Corvette models, adjust the high 1. A horizontal line at the level of the centers of the beam pattern as shown in Figure C.
Page 487 A separate 30 amp circuit breaker mounted on the firewall (except Chevrolet, which is in the fuse panel) protects the power window, seat and top circuits. Where the current load is too IN-LINE FUSES...
Page 488: Bumpers
SPECIFICATIONS BUMPERS SECTION 14 BOLT TORQUES IN POUNDS Chevelle Component Chevrolet Monte Carlo Laguna 30 Ft. 55 Ft. 25 Ft. Front Bumper Beauty Bolts 55 Ft. 55 Ft. Front Bumper to Reinforcement Brackets 30 Ft. 30 Ft. 30 Ft. Rear Bumper Beauty Bolts 30 Ft.
Page 489 SPECIFICATIONS Camaro Base Rally Sport Corvette Beauty Front Urethane Cover 25 in. Front Face Bar 22 in. 17 ft. Impact Bar to Slider Brkt. 150 in. Lower (to Brace) Impact Bar to End Brkts. 52 ft. Front Face Bar 24 ft. Slider Brkt to Frame Ext.
Page 490: Accessories
SPECIFICATIONS 31 ACCESSO RIES SECTION 15 SUPERUFT REAR SHOCK ABSORBERS Minimum Pressure............10-15 psi Maximum Pressure (Vehicle L oaded)......90 psi Do not use superlifts to raise car above normal C A U T IO N : designed riding height. If superlifts are used in this manner for sustained driving periods, severe damage may result to the superlifts or the car mounting brackets.
Page 491: Heating And Air Conditioning
SPECIFICATIONS 32 LIGHT DUTY TRUCK SPECIFICATIONS HEATING AND AIR CONDITIONING SECTION 1A HEATER Am ps. V olts (C old) (Cold) Compressor Clutch Coil Blower Motor Ohms (at 8 0 ° F )............3.70 C-K Models....13.5 6.25 Max. 2550 Min. Amps, (at 8 0 °...
Page 492 SPECIFICATIONS 33 SECTION IB C AND K MODELS FRONT END END GATE (06) Windshield Wiper Linkage to Plenum..... 25 in. lb. Hinges—Hinge to B ody..........35 ft. lb. Sunshade S up po rt............20 in. lb. —Hinge to End Gate..........20 ft. lb. Inside Rear View Mirror to Bracket......45 in.
Page 493 SPECIFICATIONS 34 BODY MOUNTING (C-K MODELS)-FT. LBS. Model (03) — — — — (06) — — (14) — — (63) G MODELS M IRRORS AND SUNSHADE S LIDING SIDE DOOR Inside Rear View Mirror to Bracket ......15 in. lb. Remote Control (front latch) to D o o r......in.
Page 494: Front Suspension
SPECIFICATIONS 35 FRONT SUSPENSION SECTION 3 * WHEEL ALIGNMENT SPECIFICATIONS CASTER ** 4 1/4” 4 1/2” 4 3/4” 3 1/4” 3 1/2” 3 3/4” 4” 5” Dimension “A” in inches + 2 1/2" 2 3/4” 3” +3/4° +1/2° +1/4° 0° -1/4°...
Page 495 SPECIFICATIONS 36 FRONT SUSPENSION BOLT TORQUE (Ft. Lbs.) $ CP-10 CP-20-30 K-AII G-10 G-20-30 Lower Control Arm Shaft U-Bolt G 10-2045 G3085 Upper Control Arm Shaft Nuts — Control Arm Rubber Bushings w/Spacer 160 w/Spacer 190 Upper Control Arm Bushing Steel No Spacer 95 Used Used...
Page 496: Rear Suspension
UNIVERSAL JO IN T ATTACHM ENT 8 -7 /8 ” 3.5 Pints TORQUE SPECIFICATIONS Chevrolet 1 0 -1 /2 ” 5.4 Pints Strap Attachments ..15 Ft. Lbs. Dana 1 0 -1 /2 ”...
Page 497: Brakes
SPECIFICATIONS 38 TORQUE SPECIFICATIONS (FT. LBS.) (CONT'D.) Spring-to-Axle “U” Bolt Nuts 120(GP,20) 140(G30) Leaf Spring —Front Bushing Bolt —Rear Shackle Bolt Shock Absorber —Upper Attachment —Lower Attachment Propeller Shaft To Rear Axle (Strap) 12-17 12-17 12-17 — To Rear Axle (“U” Bolt) 18-22 18-22 Bearing Support-to-Hanger...
Page 498: N Gin E
SPECIFICATIONS 39 ENGINE SECTION 6 GENERAL DATA: Type In Line Displacement (cu. in.) Horsepower @ rpm 250 @ 4000 100 @ 3600 120 @ 3600 115 @3600 130 @4000 155 @4000 240 @ 4000 Torque @ rpm 175 @2000 215 @ 2000 205 @ 2000 220 @ 2200 255 @ 2400...
Page 499 SPECIFICATIONS 40 CRANKSHAFT: #l-2-3-4 2.7485 - 2.7494 2.4484 - 2.4493 #2-3-4 2.2983 2.2993 2.7481 - 2.7490 2.4479 - 2.4488 2.7478 - 2.7488 Main Journal Production .0002 (Max.) Tanor Service .001 (Max.) Out of Production .0002 (Max.) Round Service .001 (Max.) .0008 - .0020 #l-2-3-4 .0003...
Page 500 SPECIFICATIONS 41 TUNE-UP CHART In Line Type Displacement 115 & 130 240 & 250 Horsepower 150 psi 130 psi COMPRESSION AC-R44T AC-R46T AC-R44T Standard SPARK Make & Number PLUG AC-R43T Cold AC-R45T .035” 29°-31° 31°-34° Point Dwell .016” (Used) .019” (New) Point Gap 19-23 ounces Arm Spring Tension...
Page 501 SPECIFICATIONS 42 ENGINE TORQUES In Line Small V-8 Mark IV V-8 Usage Size 1/4-20 Camshaft Thrust Plate 80 lb. in. Crankcase Front Cover 80 lb. in. Flywheel Housing Pans 80 lb. in. Oil F iller Bypass Valve 80 lb. in. Oil Pan (To Crankcase) 80 lb.
Page 502: Carburetor
SPECIFICATIONS 43 CARBURETOR SECTION 6 M IDENTIFICATION TR U C K S A lso refer to Rochester C arburetor Id e n tific a tio n Illu s tra tio n in th e O verhaul M anual. VEHICLES ENGINE TRUCK CARBURETORS Displace...
Page 503 SPECIFICATIONS 44 ADJUSTMENTS TRUCKS Rochester Carburetors Choke Rod NUMBER Choke Float Float Metering (Fast Idle Air Valve Choke Model (A) Automatic Trans. Pump Rod Vacuum Level Drop Wind-Up Unloader (M) Manual Trans. Break 2nd Step) 7043022(A) .080 .245 .300 .500 7043021 (M) .080 .275...
Page 504 SPECIFICATIONS 45 OTHER ADJUSTMENTS - TRUCKS NOTE: Refer to "Additional External Settings and Adjustments" or "Idle Stop Solenoid adjustment and "C.E.C. Valve Adjustment", as applicable, in Section 6M (Service Manual), under carburetors before using the following charts. NOTE: All Idle Speeds listed are to be set with Air Conditioning OFF. UNLESS OTHERWISE NOTIFIED: Always use current specifications that agree with the "Vehicle Emission Control Information"...
Page 505: Engine Electrical
SPECIFICATIONS 46 ENGINE ELECTRICAL SECTION 6Y BATTERY No. of Plates Cranking Power Capacity @ 20 Model No. Application Per Cell @ 0 0 F. (Watts) Hour Rate (Amp. Hr.) 1980141 (Y86) 250 L-6 2300 1980145 (R88) 292 L-6, 307 V-8, 350 V-8 2900 1980149 (R88W) 454 V-8 &...
Page 506 SPECIFICATIONS 47 STARTING MOTOR Free Speed Application Spec No. Model No. Amperes Volts 1108479 C-K 10-20 w/250 L-6 to Auto. Trans. 50-80* 5500-10,500 3573 250 L-6 & 307 V-8 Base w/ 1108367 All Trans. Except as noted. 292 L-6 & 350 V-8 Except P-30 1108427 All Trans.
Page 507 SPECIFICATIONS 48 DISTRIBUTOR Ignition Centrifugal Vacuum Original Point Distributor Advance Advance Equipment Application Dwell Trans. (Product (Crank Degrees (In Crank Spark Setting Part No.) Engine RPM) Degrees) Plug 250 C.I.D. L-6 Engine, 1110499 C-4797 C-3933 31°-34° AC-R46T 10 Series Except 0 @ 930 0 @ 7”...
Page 508 SPECIFICATIONS 49 DISTRIBUTOR (CONT’D.) Centrifugal Vacuum Original Ignition Point Equipment Distributor Advance Advance Dwell Trans. Application Spark (Crank Degrees @ (In Crank Product Setting Degrees) Plug Part No.) Engine RPM) Manual AC-R44T C-4818 C-6001 29°-31° 350 C.I.D. V-8 Engine 1112093 0 @ 1100 0°@ 6”...
Page 509 SPECIFICATIONS 50 CLUTCH AND MANUAL TRANSMISSION SECTION 7 M THREE SPEED SAG INAW THREE SPEED MUNCIE Clutch Gear Retainer to Case B olts....15 ft. lbs. Clutch Gear Retainer to Case B olts....15 ft. lbs. Side Cover to Case B olts........15 ft. lbs. Side Cover to Case Bolts .......
Page 510: Automatic Transmissions
SPECIFICATIONS 51 NEW PROCESS TRANSFER CASE MODEL 203 Adapter Mount B o lts........25 ft. lbs. Adapter to Transfer Case Attaching Bolts . . . 38 ft. lbs.' Intermediate Case to Range Box Bolts ..30 ft. lbs. Adapter to Transmission Attaching Bolts.
Page 511: Steering
SPECIFICATIONS 52 STEERING SECTION 9 TORQUE VALU E S Components C10-30 K10-20 G10-30 P10-30 Tie Rod Ball Joint Nut C 10 35 lbs. ft.** G 10 35 lbs. ft.** 45 lbs. ft. Outer and Inner C 20-30 45 lbs. ft.*** G 20-30 45 lbs.
Page 512 SPECIFICATIONS 53 M A N U A L STEERING GEAR POWER STEERING GEAR Components All C, P, K and G Components G 10-30 C1p °103° K 10-20 P20 - 30 Steering Gear Ball Drag 3 lbs. in. Max. Worm Bearing 6 to 11 4 to 6 9 to 12...
Page 513: Wheels And Tires
SPECIFICATIONS 54 WHEELS AND TIRES SECTION 10 WHEELS Wheel Nut Torques - 10-30 Series SERIES DESCRIPTION TORQUES 7/16” Bolts (6) 55-75 ft. lbs. C, P10 1/2” Bolts (5) 65-90 ft. lbs. C, P20, 30 9/16” Bolts (8) 90-120 ft. lbs. Single Wheels C, P20, 30 9/16”...
Page 514 SPECIFICATIONS 55 BODY AND CHASSIS ELECTRICAL SECTION 12 LAMP USAGE G MODELS C-K-P MODELS Power Quantity Trade # Used in Quantity Trade # Power Used in 12 CP Dome Lamps 6 CP Dome lamp5 2 CP Pressure indicator lamp 2 CP Oil Pressure Indicator lamp1 2 CP Generator indicator lamp...
Page 515 SPECIFICATIONS 56 FUSE AND CIRCUIT BREAKER USAGE ________________________ G MODELS_______________________ Fuses located in the Junction Block beneath the dash on the driver's side. Heater, Rear A/C....................................20 amp Idle Stop Solenoid, T.C.S. Time Delay Relay Transmission Downshift................3 amp Cigarette Lighter....................................Fuel Gauge, Brake Warning Lamp, Dome Lamp, Temperature Warning Lamp, Generator Warning Lamp, Oil Pressure Warning Lamp..........................
Page 516 SPECIFICATIONS 57 WINDSHIELD WIPERS P MODELS C-K-G MODELS TWO-SPEED WIPER TWO-SPEED WIPER Crank Arm Speed (RPM’s) (No Load) Crank Arm Speed (RPM’s) (No Load) L o ................35 Min. L o ................34 Min. H i................60 Min. H i................65 Min. Current Draw.
Page 517 SPECIFICATIONS 58 RADIATOR AND GRILLE SECTION 13 TORQUE SPECIFICATIONS Grille 18 ft. lbs. 18 ft. lbs. Mounting Panel 150 in. lbs. 150 in. lbs. 120 in. lbs P (32) Fan Shroud 50 in. lbs. 42 in. lbs. 50 in. lbs. P (42) Coolant Recovery Tank Brkt.
Page 518 WEIGHTS AND MEASURES COMMON WEIGHT LINEAR MEASURE 16 o u n c e s ......= 1 pound 1/12 foot (ft.) .
Page 519: Decimal Equivalents
DECIMAL EQUIVALENTS >U4 .........515625 *4 ......... 0 1 5 6 2 5 V n ......... 0 3 1 2 5 .........53125 U< ......... 0 4 6 8 7 5 .........546 875 V\6 ......... 062 5 9 A .........5625 ......... 0 7 8 1 2 5 .........5 7 8 125 V * .........
Page 520 GAGES & U. S. S T A N D A R D G A G E * A M E R IC A N W IRE or B S G A G E G A G E N O . A p p ro x .
Page 521 DRILL SIZES Drill W ire D rill W ire D rill W ire Drill Letter D iom . G ag e D ia m . G ag e D ia m . G ag e D iam . Sizes Inches Sizes Inches Sizes...

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Chevrolet 1973 Overhaul Manual

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