Chevrolet 1980 Light Duty Truck Repair Manual
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Chevrolet 1980 Light Duty Truck Repair Manual

Chevrolet 1980 passenger cars and light duty trucks unit repair manual
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Table of Contents

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CHEVROLET
ST 333-80

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Summary of Contents for Chevrolet 1980 Light Duty Truck

  • Page 1 CHEVROLET ST 333-80...
  • Page 2 All inform ation, illustrations and specifications contained in this literature are based on the latest product information available at the time of publica­ tion approval. The right is reserved to make changes at any time without notice. CHEVROLET MOTOR DIVISION General Motors Corporation DETROIT, MICHIGAN...

  • Page 3: Important Safety Notice

    IMPORTANT SAFETY NOTICE P rop er se rv ic e an d repair is im p o r ta n t to th e sa fe , re lia b le o p e r a tio n o f all m o to r v e h ic le s .
  • Page 5 SECTION INDEX SECTION NAME AIR CONDITIONING 1980 COMPRESSOR UNIT REPAIR (OVERHAUL) MANUAL STEERING REAR AXLE FRONT WHEEL DRIVE BRAKES CAUTION This vehicle contains some parts dim ensioned in the m etric system as w e ll as in the custom ary system. Som e fasteners are m etric and are very d ose in dimension to fam iliar custom ary fasteners in the inch system.

  • Page 7: Table Of Contents

    AIR CO NDITIO NING COMPRESSOR OVERHAUL 1D-1 SECTION 1D AIR CONDITIONING COMPRESSOR OVERHAUL For Compressor R E M O V A L A N D IN S T A L L A T IO N , see Air Conditioning Section. D IS C H A R G IN G , A D D I N G OIL,...

  • Page 8: M In O R Repair Procedures For The A-6 Compressor

    1D-2 AIR CO NDITIO NING COMPRESSOR OVERHAUL They have been prepared sequence order o f accessibility o f the com ponents. Pad fender/skirt and secure com pressor near top o f fender skirt w ith wire, rope, etc. when performing on-car service. W hen an A -6 or R -4 com pressor is removed from the vehicle for servicing, the am ount o f oil remaining in the com pressor should be drained and measured.
  • Page 9 I ' ■ O-RING FR O N T HEA D S H A FT SEAL ASSEM BLY SEAL SEAT SEAL SEAT R E T A IN E R RING O -RINGS ABSORBENT SLEEVE ' SLEEVE R E T A IN E R PRESSURE RELIEF V A L V E C LUTCH CO IL R E T A IN E R RING...
  • Page 10 1 D-4 AIR CO NDITIO NING COMPRESSOR OVERHAUL F R O N T S U C T IO N R E E D D IS C H A R G E V A L V E P L A T E S H A F T S E A L ASM .

  • Page 11: Compressor Pulley And Bearing Assembly

    AIR CO NDITIO NING COMPRESSOR OVERHAUL ID -5 S N A P -R IN G PLIERS (# 2 1 ) J-5403 RETAINER 4968 Figure 1D-6 Removing or Installing Retainer Ring in A-6 Clutch Figure 1D-9 Installing A-6 Drive Plate Drive Plate NOTICE: M ake certain key remains in place w hen pressing hub on shaft.
  • Page 12 1 D-6 AIR CO NDITIO NING COMPRESSOR OVERHAUL SN A P RING PLIERS J-6435 (# 2 6 ) RETAINER PULLEY RING ASSEM B LY Figure 1D-12 Removing A-6 Pulley Retainer Ring Pulley and Bearing asssem bly should be cleaned with naphtha, Stoddard solvent, kerosene or equivalent solvent before reinstallation.

  • Page 13: A-6 Compressor Pulley Bearing

    AIR CO NDITIO NING COMPRESSOR OVERHAUL 1D-7 J-9398 w ith Universal H andle J-8092, drive Bearing assembly out o f pulley (Figure I D - 16). U N IV E R S A L H A N D LE J -8 0 9 2 U N IV E R S A L H A N D L E J-8092 PULLEY &...

  • Page 14: Major A-6 Compressor Repair Procedures

    1 D-8 AIR CONDITIO NING COMPRESSOR OVERHAUL U N IVE R S A L HANDLE J-8092 THIS RIDGE OF TO O L M U S T BE UP W H E N IN STA LLIN G Figure 1D-18 Removing A-6 Coil Housing Retainer Ring BEARING PULLEY A N D BEARING...

  • Page 15: A-6 Compressor Shaft Seal

    AIR CO NDITIO NING COMPRESSOR OVERHAUL 1.D-9 Remove Systems"). T he sam e holds ture for any disassembly o f the internal A -6 com pressor cylinder and shaft assembly. 1. "Discharge the Refrigerant System" according to the If the A -6 Com pressor Internal Cylinder and Shaft D IS C H A R G IN G , A D D IN G OIL, E V A C U A T IN G A N D C H A R G IN G P R O C E D U R E S...
  • Page 16 1D-10 AIR CONDITIO NING COMPRESSOR OVERHAUL Replace 1. Coat the new seal seat O-ring in clean 525 viscosity referigerant oil and assemble onto O -Ring Installer J -2 1508 (see Figure ID -23). completely 2. Insert the O -R ing Installer J-21508 down into com pressor...

  • Page 17: Compressor Pressure Relief Valve Or Pressure Switch

    AIR CO NDITIO NING COMPRESSOR OVERHAUL ID-11 shaft seal leaks may be the result of mispositioning of axial plate compressor shaft. m ispositioning o f the axial plate m ay be caused by improper procedures used during pulley and driven plate removal, pounding, collisions or dropping the compressor.

  • Page 18: Removal

    1D-12 AIR CO NDITIO NING COMPRESSOR OVERHAUL 2. A ll oil in com pressor should be drained and measured. A ssist draining by positioning com pressor w ith Record the amount of oil drained oil drain plug down. from the compressor (See "C.C.O.T. Refrigerant Oil Distribution"...
  • Page 19 AIR CO NDITIO NING COMPRESSOR OVERHAUL 1D-13 Figure 1D-32 Removing A-6 Rear Scution Reed SEALING O IL PIC K -U P TU B E SURFACES R E M O V E R J-5 1 3 9 REAR HEAD SHELL TO HEAD iL PIC K -U P T U B E RING OIL PUMP...

  • Page 20: D Isa Ssem B

    ID - 1 4 AIR CONDITIO NING COMPRESSOR OVERHAUL S U C T IO N PASS CO VER Figure 1D-36 Separating A-6 Cylinder Halves CYLINDER A S S E M B L Y NOTICE: U N D E R N O C IR C U M ST A N C E SH O U L D Figure 1D-34 Removing A-6 Suction Cross-Over Cover SH A F T BE S T R U C K A T E IT H E R E N D in an effort to separate upper and low er cylinder halves because the...

  • Page 21: Gaging Operation

    AIR CO NDITIO NING COMPRESSOR OVERHAUL ID -1 5 N eedle bearings m ay be rem oved if necessary by driving them out with special Thin-W all Socket J-9399. Insert socket in hub end (inner side) o f cylinder head and drive bearing out.
  • Page 22 1D-16 AIR CO NDITIO NING COMPRESSOR OVERHAUL rests on hub o f axial plate. Then add one thrust bearing and a SE C O N D Z E R O T H R U ST R A C E onto shaft. Lubricate races and bearing with petrolatum.
  • Page 23 AIR CO NDITIO NING COMPRESSOR OVERHAUL 1D-17 Figure 1D-44 Assembling A-6 Cylinder Halves Figure 1D-45 Gaging A-6 Rear Piston Ball 17. R otate shaft another 120° and again repeat Step 15 o f 14 steel thrust races, including a basic ZER O race, are between these same parts and record measurements.
  • Page 24 1D-18 AIR CO NDITIO NING COMPRESSOR OVERHAUL SHOE DISC THRUST BEARING RACE IDENTIFICATION PART NO. MIN.FEELER PART NO. IDENTIFICATION DIAL INDICATOR STAMP ENDING IN GAGE READING ENDING IN STAMP READING .0000 .0000 17-1/2 .0175 .0050 .0180 5-1/2 .0055 18-1/2 .0185 .0060 .0190 6-1/2...

  • Page 25: A-6 Teflon Piston Ring Replacement

    AIR CONDITIONING COMPRESSOR OVERHAUL ID -1 9 J-24608-1 (Figure ID -54). The piston should go through the The rem oved ZER O thrust race may be put aside for re-use in additional Gaging or rebuilding operations. Ring Gage with a 6-lb. force or less w ithout lubrication. If not, repeat Steps 6 and 7.
  • Page 26 1D-20 AIR CO NDITIO NING COMPRESSOR OVERHAUL y J-24608-5 J-24608-2 R IN G IN S T A L L E R R IN G IN S T A L L E R J-24608-6 G U ID E R IN G S IZ IN G T O O L J-24608-1 P IS TO N R IN G G A G E Figure 1D-50 A-6 Teflon Piston Ring Installing, Sizing and Gaging Tools...

  • Page 27: Re-Install

    AIR CONDITIONING COMPRESSOR OVERHAUL 1D-21 "SELECTED" REAR DISC "S ELECTED" REAR THRUST RACE BEARING THRUST RACES LIFT SHAFT UPWARD "Z E R O " FRONT AND HOLD THE SHOE DISC THRUST RACES AND BEARING AGAINST HUB THRUST BEARING 0920 Figure 1D-56 Installing 1st A-6 Piston Assembly Into Front Figure 1D-53 Turning A-6 Piston and Ring Assembly Into Ring Sizing Tool Figure 1D-54 Gaging A-6 Piston Ring Size...
  • Page 28 1D-22 AIR CO NDITIO NING COMPRESSOR OVERHAUL P ISTO N S IN " S T A IR S T E P " P O S IT IO N Figure 1D-60 A-6 Pistons Positioned in Stair-Step Figure 1D-59 Installing A-6 Discharge Cross-over Tube Shaft A ssem blies that have been disassembled in the field (A lso see Figure ID -58).
  • Page 29 AIR CONDITIONING COMPRESSOR OVERHAUL ID -2 3 B U S H IN G F R O N T D IS C H A R G E D O W E L P IN S V A L V E P L A T E A S S E M B L Y D O W E L P IN S Figure 1D-62 Installing O-Ring On A-6 Discharge Cross-Over...

  • Page 30: Compressor

    1D-24 AIR CO NDITIO NING COMPRESSOR OVERHAUL COMPRESSOR SHELL FRONT HEAD OIL PUMP CASTING SHAFT FRONT DISCHARGE VALVE PLATE ASSEMBLY O-RING SUPPORT BLOCK J-21352 OIL INTAKE TUBE HOLE SUPPORT BLOCK J-21352 Figure 1D-66 Installing A-6 Front Head Casting Figure 1D-68 - Installing A-6 Compressor Shell OIL PICK-UP TUB OIL PUMP FRONT...
  • Page 31 AIR CO NDITIO NING COMPRESSOR OVERHAUL ID -2 5 22. Install Suction Screen in rear head casting, using If Rear H ead assembly w ill not slide down over dowels care not to dam age screen. in Internal Cylinder and Shaft Assem bly, twist Front Head assembly back-and-forth very slightly by-hand until Rear 23.

  • Page 32: Compressor Clutch Plate And Hub A Sse M B Ly

    1D-26 AIR CONDITIO NING COMPRESSOR OVERHAUL MINOR REPAIR PROCEDURES FOR THE R-4 COMPRESSOR T H E F O L L O W IN G O P E R A T IO N S TO T H E R -4 2. Keep the clutch hub from turning with the Clutch C O M PR ESSO R C LU TC H P L A T E A N D H U B , R O TO R Hub H olding T ool J-25030, and remove, discard and later A N D B E A R IN G , A N D C O IL PU L L E Y R IM A R E...
  • Page 33 S P E C IA L W A S H E R -P U L L E Y R IM P U L L E Y R IM M O U N T IN G S C R E W L O C K IN G O -R IN G , PR E S S U R E C O IL A N D H O U S IN G A S S E M B L Y RELIEF VA L V E...
  • Page 34 1D-28 AIR CO NDITIO NING COMPRESSOR OVERHAUL T H R U ST A N D BELLEVILLE W ASHERS M A IN BEARING — FRONT COMPRESSOR SHELL PULLEY RIM M TG . SCREW CLUTCH COIL TE R M IN A LS PULLEY RIM PULLEY RIM M TG .
  • Page 35 AIR CO NDITIO NING COMPRESSOR OVERHAUL 1 D-29 DRIVE PLATE J 9480*1 J 9401 HUB AND CLUTCH DR IVE PLATE DRIVE PLATE INSTALLER ASM. REMOVER BEARING CLUTCH AIR GAP AND HUB ASM. .0 4 0 " ! CLUTCH P LATE AND HUB Figure 1D-80 Installing R-4 Clutch Plate and Hub Assembly J 25008...

  • Page 36: R Eplace R Otor And Bearing

    1D-30 AIR CO NDITIO NING COMPRESSOR OVERHAUL 4. If the pulley rim m ounting screws and washers were rem oved in Step 2, only the Clutch R otor and Bearing assembly w ill be removed for replacement. The Clutch Coil and H ousing assembly is pressed onto the Front Head of the com pressor with a press fit and will not be removed J-25031-2...

  • Page 37: R Eplace R Otor And Bearing A Ssem Bly (On B E N C H

    AIR CO NDITIO NING COMPRESSOR OVERHAUL 1D-31 B E A R I S TA K E L O C A T IO N S 4695 Figure 1D-85 R-4 Rotor and Bearing Assembly C. Plug clutch coil connector onto Clutch Coil. D .

  • Page 38: R-4 Compressor Clutch Coil

    1D-32 AIR CONDITIO NING COMPRESSOR OVERHAUL 7. Rotate the pulley rim and rotor to insure that pulley rim is rotating "in-line". If pulley rim is distorted (does not rotate in-line) adjust or replace pulley rim. 8. Tighten pulley rim m ounting screws to 100 inch- pounds torque and lock screw heads in place by bending special lock washers (Figure ID -88).
  • Page 39 AIR CO NDITIO NING COMPRESSOR OVERHAUL 1 D-33 rim or every other m ounting screw location.) D o not remove the screws in the "mounting notches". 3. Tem porarily m ake a trial fit o f the Inertia R ing to the P ulley Rim.

  • Page 40: Major R-4 Compressor Repair Procedures

    1D-34 AIR CO NDITIO NING COMPRESSOR OVERHAUL Figure 1D-92 R-4 Pulley Rim and Inertia Ring Mounting Detail 11. A ssem ble the Inertia R ing onto the Pulley Rim 15. Spin the R otor and Pulley assem bly to ascertain being careful to align the Inertia R ing m ounting holes with that the pulley runs "in line".

  • Page 41: R-4 Compressor Shaft Seal

    AIR CO NDITIO NING COMPRESSOR OVERHAUL 1 D-35 disassembly o f the internal R -4 com pressor cylinder and Place Seal Protector J-22974 over the end o f the shaft shaft assembly. to prevent chipping the ceram ic seat. Fully engage the knurled tangs o f Seal Seat R em over-Installer J-23128 into If the R -4 Compressor Internal Cylinder and Shaft the recessed portion o f the seal seat by turning the handle...
  • Page 42 1D-36 AIR CO NDITIO NING COMPRESSOR OVERHAUL Figure 1D-95 Removing R-4 O-Ring (On Car) Figure 1D-97 Installing Seal (On Car) Seal Seat and Seal are free o f lint and dirt that could damage shaft and J-22974 Seal Protector and push the Seat into place with a rotary m otion (Figure ID -98).

  • Page 43: Compressor Shaft Seal Replacement (Off Car)

    AIR CO NDITIO NING COMPRESSOR OVERHAUL 1 D-37 10. R e-install com pressor belt and tighten bracketry. J 9392 11. "Evacuate and Charge the Refrigerant System" SHAFT SEAL REMOVER according D IS C H A R G IN G , A D D IN G OIL, AND IN S T A LLE R...
  • Page 44 1 D-38 AIR C O NDITIO NING COMPRESSOR OVERHAUL FRONT HEAD MOUNTING SCREWS (4! O IL HOLE TO F R O N T H E A D S H A F T SEAL A R E A S E A L IN G R IN G M A IN B E A R IN G T H R U S T...

  • Page 45: Compressor Thrust And Belleville Washers

    AIR CO NDITIO NING COMPRESSOR OVERHAUL ID -3 9 Before fully seating the assembly onto the Front Head, T H R U S T be sure the clutch coil terminals are in the proper location W A S H E R S in relation to the com pressor and that the three protrusions on the rear o f the clutch coil align with the locator holes in the Front Head.
  • Page 46 1D-40 AIR CO NDITIO NING COMPRESSOR OVERHAUL J 24895 BEARING INSTALLER MAIN BEARING FRONT HEAD Figure 1D-107 Installing R-4 Main Bearing Figure 1D-108 Releasing R-4 Shell Retaining Strap 2. Thoroughly clean exterior o f com pressor to prevent dirt from getting into com pressor during shell removal. 3.

  • Page 47: Compressor Discharge Valve Plate A N D /O R Retainer

    AIR CONDITIONING COMPRESSOR OVERHAUL 1D-41 4. A lso coat inner surface o f com pressor Shell with the "Evacuate and Charge the Refrigerant System" oil and swab oil onto shell-to-cylinder O-rings. Place the according D IS C H A R G IN G , A D D IN G OIL, com pressor Shell on the cylinder and rotate the retaining...

  • Page 48: Compressor Cylinder And Shaft Assembly

    1D-42 AIR CO NDITIO NING COMPRESSOR OVERHAUL 6. R em ove the Thrust and Bellville W ashers as 5. Re-install com pressor Shell as described in "R-4 described "R-4 Com pressor Thrust Bellville Compressor Shell an d /o r O -Rings "Replacement Washers"...
  • Page 49 AIR CONDITIONING COMPRESSOR OVERHAUL ID -4 3 10. Install a shaft nut on the com pressor crankshaft if 16. Observe the reading on H IG H pressure gage at the the drive plate and clutch assembly are not installed. com pletion o f the tenth revolution o f the compressor. The pressure reading for a good pum ping com pressor should be 11.
  • Page 51 STEERING 3B-1 SECTION 3B STEERING CONTENTS OF THIS SECTION M anual Steering G ear..................3B-1 Power Steering P u m p ..................3B -5 Integral Pow er Steering G ear..............3B -8 Special T o o ls ......................3B-19 MANUAL STEERING GEARS OVERHAUL MANUAL...
  • Page 52 3B-2 STEERING R EM O V E A N D IN S T A L L W O R M S H A F T SEA L-G E A R A S S E M B LE D INSTALL REMOVE W rap 0.1 mm to 0 2 mm Install parts as shown ( 005"...

  • Page 53: Steering 3B

    STEERING 3B-3 R EM O V E A N D IN S TA L L W O R M S H A F T D IS A S S E M B L E A N D A S S E M B LE W O RM A N D BALL N U T B E A R IN G A D JU S T E R...
  • Page 54 3B-4 STEERING A D JU S T W O R M B E A R IN G PR E LO A D Tighten w orm bearing adjuster u n til it bo ttom s then loosen on e-qu arte r turn C a re fu lly turn the w o rm sh a ft all the way to end of travel then tu rn back o n e -h a lf turn.

  • Page 55: Power Steering Pump

    STEERING 3B-5 POWER STEERING PUMP N O T IC E : If when overhauling a power steering gear or pump, broken com ponents or foreign material are encountered, the remaining com ponents o f the entire hydraulic system should be disassembled, inspected, thoroughly cleaned and flushed before servicing is com pleted, or damage to the other com ponents may occur.
  • Page 56 3B-6 STEERING 4. REMOVE AND INSTALL R O TATIN G GROUP. I. REMOVE AND INSTALL DRIVE SHAFT SEAL WITHOUT DISASSEMBLING THE PUMP. RE M O V E IN S T A L L REM O VE IN S T A L L 1 .

  • Page 57: Integral Pow Er Steering G Ear

    STEERING 3B-7 POWER STEERING GEAR (605 MODEL) GENERAL DESCRIPTION This Integral Power Steering Gear has a NOTE: Whenever a part which forms a control valve which directs oil to either side sealing surface for an “0 ” ring seal is of the rack piston.
  • Page 58 3B-8 STEERING R EM O V E AND IN S TA LL PITM A N SHAFT 1. R E M O V E A N D IN S T A L L P IT M A N SHA FT AND S ID E COVER S EA LS IN CAR INSTALL REM O VE...
  • Page 59 STEERING 3B-9 5. R E M O V E A N D IN S T A L L R A C K P IS T O N A N D 7. R E M O V E A N D IN S TA LL VALVE V A L V E A S S E M B L Y A S S E M B LY F R O M W O R M A SS E M B LY REMOVE...
  • Page 60 ■ 3B-10 STEERING 10. R EM O VE AND INSTALL PITM AN S H A FT 9. REM OVE A N D INSTALL STUB SHA FT SEALS AND BEARING SEALS A ND B EA RING S REMOVE INSTALL REMOVE INSTALL 1.

  • Page 61: Special Tool

    STEERING 3B-11 12. A D JU S T W O R M B EA RING PR ELO A D 1 3. A D JU S T “ OVER C E N T E R ” P RELO A D Tighten adju ster plug until it B M e as u re 13m m ( ”) c oun­...
  • Page 62 3B-12 STEERING POWER STEERING GEAR (800 AND 605 MODELS) GENERAL DESCRIPTION Repair procedures for these two These Integral Power Steering Gears models are different. Note the side have a control valve which directs oil cover differences in the sketch to either side of the rack piston. The below.
  • Page 63 tmrt N aan Kry No. Port Nome Key No P o rt Nom e 3 7 - S C R E W ASSY., LOCKWASHER & (2) ) - H O U S IN G , STEERING GEAR 19- P L U G , ADJUSTER 2 0 - B E A R IN G .
  • Page 64 3B-14 STEERING 3. REMOVE AND INSTALL H O U SING END 1. REM OVE A ND INSTALL PITM AN SHAFT PLUG SEALS IN CAR REMOVE INSTALL REMOVE INSTALL 1. Install parts as shown. 1. Clean exposed end 1. Install parts as shown. 1.
  • Page 65 STEERING 3B-15 5. REM OVE A N D INSTALL ADJUSTER PLUG 7. REM OVE A N D INSTALL B EA RING , W ORM, ASSEMBLY A N D VALVE ASSEMBLY REMOVE INSTALL REMOVE INSTALL 1. Loosen lo ck nut. 1. Install parts G rasp stub shaft and In stall parts as as show n.
  • Page 66 3B-16 STEERING 10. REM OVE A ND INSTALL PITM A N SHAFT D ISA SSEM B LE AND A SSEM B LE RACK PISTON SEALS A N D BEARING REMOVE INSTALL DISASSEMBLE ASSEMBLE 1. C le an e nd of 1.
  • Page 67 STEERING 3B-17 11. R EM O V E A N D IN S TA L L C H E C K VALVE 13. P ITM A N SHAFT “ O V E R -C E N TE R SECTOR A D JU S T M E N T INSTALL REMOVE 1.

  • Page 68: Steering Gear

    3B-18 STEERING GENERAL SPECIFICATIONS LUBRICATION Lubricant ......................Power Steering Fluid No. 1050017 or equivalent ADJUSTMENTS Valve Assembly and Seal D r a g ......................0.1 to 0.4 N*m (1 to 4 in. lbs.) Thrust Bearing Pre-load ........0.3 to 0.4 N*m (3 to 4 in. lbs.) in excess o f valve assembly and seal drag. Ovcrcenter Adjustment .
  • Page 69 STEERING 3B-19 POWER STEERING PUMP □ J-25033 J-23600 <£ — 3 J-25034 J-22616 BT-7515 J-7132-2 POWER STEERING GEAR J-6221 J-7576 J-8947 f T ~ —^ ^ J-21552 J-6222 J-6217 J-5188 J-29107 J-6278 J-24319-01 J-22407 J-7624 J-5176-01 Pressure Testing Manifold J-7576 Rack-Piston Teflon Ring Compressor J-5188 End Cover Seal and Needle Bearing Installer...
  • Page 71 REAR AXLE DIFFERENTIAL 4B-1 SECTION 4B REAR AXLE DIFFERENTIAL CARRIER 8 -1 /2 A N D 8 -7 /8 " RING GEAR INDEX Differential C a se ..............4B-1 Setting Pinion D e p th ............4B-5 R em oval and D isassem bly..........4B-1 Installation and A djustm ent..........4B-9 In sp ection ................
  • Page 72 4B-2 REAR AXLE DIFFERENTIAL TRUCK REAR AXLE IDENTIFICATION All rear axles used in Chevrolets are stamped with a prefix code designating the axle ratio and vehicle identification, build date, axle source, and shift code. EXAMPLE: Day Code Source Code Shift Code Axle &...
  • Page 73 REAR AXLE DIFFERENTIAL 4B-3 1. Com panion Flange D iffe r e n tia l Case 13. C over 19. Thrust W asher D e fle c to r Shim Pinion Shaft 2 0 . D iffe re n tia l Pinion Pinion O il Seal G asket Ring G e a r...
  • Page 74 4B-4 REAR AXLE DIFFERENTIAL Fig. 2B --D ifferential Case Removal Fig. 4 B -D iffe re n tia l Bearing Installatio n 6. Tighten lock bolt on side o f tool. 10. Install left shim first, then w edge right shim between bearing cup and spacer.
  • Page 75 REAR AXLE DIFFERENTIAL 4B-5 6. To rem ove the drive pinion, first thread the original pinion nut h alf way on the pinion, for thread protection. 7. Place the differential cover tem porarily back onto the housing, using tw o screws. T his will prevent the pinion from falling to the floor during removal.
  • Page 76 4B-6 REAR AXLE DIFFERENTIAL A - S E R V IC E SPACER - S E R V IC E S H IM C - FEELER G A U G E B E A R IN G C A R R IE R C A R R IE R Tool J-22779 R IN G G EA R...
  • Page 77 REAR AXLE DIFFERENTIAL 4B-7 Fig. 8B--M easuring Gage Plate Thickness Fig. 10B ~C hecking Ring Gear Backlash thousandths on the rear face o f the pinion, this indicates that m ake sure they are properly seated. See figure 18B for the pinion during testing was found to have best tooth illustration o f proper positioning.
  • Page 78 4B-8 REAR AXLE DIFFERENTIAL 11. R ock the plunger rod slow ly back and forth across determined in step 13. the button until the dial indicator reads the greatest a. If the pinion is stamped with a plus ( + ) number, deflection.
  • Page 79 REAR AXLE DIFFERENTIAL 4B-9 Fig. 16B — Installing Pinion Rear Bearing Cup In s ta lla tio n and A d ju s tm e n t 6. Tighten nut until all end play is rem oved from drive pinion. 1.
  • Page 80 4B-10 REAR AXLE DIFFERENTIAL J - 2 1 7 7 7 -4 5 DIAL (LARGE STEP) INDICATO R " Z E R O " T H E I N D I C A T O R , W IT H T H E P R O B E O N T H E H I G H P O IN T O F T H E G A U G I N G S U R F A C E .
  • Page 81 REAR AXLE DIFFERENTIAL 4 B -1 1 Fig. 24 B ~ M e asu ring R otating Torque pinion head and inner race o f rear bearing. The shim is used Fig. 22 B ~ ln sta llin g Rear Bearing differential com pensate manufacturing...
  • Page 82 4B-12 REAR AXLE DIFFERENTIAL Fig. 26B~G ear Tooth C ontact Pattern Check SERIES 2 0 -3 0 TRUCK DIFFERENTIAL 1 0 -1 /2 " RING GEAR INDEX Pinion Bearing P reload............4P-17 D ifferential C a se ..............4B-12 4L-17 Side Bearing P r e lo a d ............
  • Page 83 REAR AXLE DIFFERENTIAL 4B-13 R e ta in e r S crew 10. S tra d d le Bearing 1. C o m p a n io n Flange 2 0 . B earing Cap 1 1 . R ing G ear 2.
  • Page 84 4B-14 REAR AXLE DIFFERENTIAL Fig. 4E ~ D ifferential B earing Removal Fig. 2E -C over Removed from C arrier 4. Inspect bearings and hub for nicks, burrs or evidence Inspection o f abnormal wear. Inspect the differential gears, pinions, thrust 5.
  • Page 85 REAR AXLE DIFFERENTIAL 4B-15 Fig. 6 E -M e a su rin g B acklash Fig. 7E -R em oving Retainer Bolts The differential m ay be installed into the carrier at D R IV E P IN IO N A S S E M B L Y this point, or may be installed after servicing the drive Rem oval pinion.
  • Page 86 4B-16 REAR AXLE DIFFERENTIAL Fig. 10E~Pressing Drive Pinion from Bearing Retainer Fig. 8E -R em oving Pinion Nut 5. Place bearing retainer, with cups in position, onto In s p e c tio n the drive pinion. Install a new collapsible spacer into 1.
  • Page 87 REAR AXLE DIFFERENTIAL 4B-17 Fig. 1 2E~Removing S trad dle Bearing Fig. 1 4 E— In sta llin g S traddle Bearing N O TIC E: O ver-tightening o f pinion nut may collapse free from foreign material. spacer too m uch, requiring its replacement. 5.
  • Page 88 4B-18 REAR AXLE DIFFERENTIAL G ear Tooth N om enclature T he side o f the ring gear tooth which curves outward, CODE NUMBER ON ORIGINAL PINION or is convex, is referred to as the "drive" side. The concave side is the "coast" side. The end o f the tooth nearest center o f ring gear is referred to as the "toe-in"...
  • Page 89 REAR AXLE DIFFERENTIAL 4B-19 D A N A DIFFERENTIALS 1 0 -1 /2 . RING GEAR INDEX D ifferntial Case - R em oval and D isassem b ly........4B-20 D rive Pinion - R em oval and D isassem bly..........4B-21 D ifferential Case - R eassem b ly ..............4B-22 Shim Requirem ents - G aging P rocedures..........4B-22 D rive Pinion - A ssem bly and In stallation ..........4B-23...
  • Page 90 4B-20 REAR AXLE DIFFERENTIAL D iffe re n tia l Spider P inion Rear Bearing P inion N u t D iffe re n tia l Side Gear D rive P inion Washer Washer R ing Gear C om panion Flange P inio n Gear D iffe re n tia l Case O il Seal...
  • Page 91 REAR AXLE DIFFERENTIAL 4B-21 Fig. 2F~Spreading the C arrier Fig. 4 F -ln te rn a l Parts Inspection dim ensions and location o f the side bearing shim s. R em ove Inspection the spreader tool. 1. Clean all gears and bearings in solvent. Inspect cups, races and rollers for scoring, chipping or evidence o f Disassem bly excessive wear.
  • Page 92 4B-22 REAR AXLE DIFFERENTIAL J -8 0 9 2 J—24383 Fig. 5F~Rem oving Pinion Nut Fig. 7 F--I nsta 1 1 i ng Side B earing Inspection D IF F E R E N T IA L CASE Reassem bly 1.
  • Page 93 REAR AXLE DIFFERENTIAL 4B-23 gear set. This dim ension is controlled by the shim m ing behind the inner bearing cup. W henever baffles or oil slingers are used, they becom e a part o f the adjusting shim pack. For example: if a pinion is etched + 3 , this pinion w ould require .003"...
  • Page 94 4B-26 REAR AXLE DIFFERENTIAL an equal am o u n t. Backlash is adjusted by m eans o f the side bearing shim To decrease backlash, decrease an equal am ount, adjusting shim s which m oves the entire case and ring gear right shim and increase left shim assembly closer to, or farther from the drive pinion.
  • Page 95 REAR AXLE DIFFERENTIAL 4B-27 G ENERAL D E S C R IP T IO N The pinion assembly incorporates an inner and outer This D ana Spicer axle is similar in design to other bearing shim. The inner shim is used to maintain proper Salisbury type axles w ith the follow ing exceptions: pinion depth.
  • Page 96 4B-28 REAR AXLE DIFFERENTIAL J 2 2 8 8 8 Fig. 16F~Removing D iffe re n tia l Side Bearings R em ove inner pinion cone and roller using T ool J- 22912, installed as shown in Figure 18F, and press pinion from bearing.
  • Page 97 REAR AXLE DIFFERENTIAL 4B-29 6. Place differential case in carrier and install bearing caps. Care should be taken to install caps in original position. U se mark placed on caps and carrier at removal. Tighten caps just enough to keep bearing caps in place. 7.
  • Page 98 4B-30 REAR AXLE DIFFERENTIAL 12. Install oil slinger, gasket and using T ool J-22804 install oil seal. 13. Install flange, washer and nut. Torque nut to specifications. D IF F E R E N T IA L CASE Preload and A d ju s tm e n t 1.
  • Page 99 REAR AXLE DIFFERENTIAL 4B-31 New Pinion Marking Old Pinion Marking + 0 .0 0 7 + 0 .0 0 8 + 0 .0 0 6 + 0 .0 0 5 + 0 .0 0 4 + 0 .0 0 3 + 0 .002 + 0.001 + 0 .0 0 7...
  • Page 100 4B-32 REAR AXLE DIFFERENTIAL Fig. 24 F ~ ln sta llin g Pinion Flange O V E R H A U L M A N U A L...
  • Page 101 REAR AXLE DIFFERENTIAL 4B-33 TRUCK DIFFERENTIAL 1 2 -1 /4 " RING GEAR INDEX Ring Gear R ep la cem en t..........4B-36 Case and D rive Pinion............. 4B-34 Differential Bearing R ep lacem en t......4B-36 R em oval................4B-34 Differential R ea ssem b ly ..........4B-36 D isassem bly..............
  • Page 102 4B-34 REAR AXLE DIFFERENTIAL U n iversal J o in t Yoke A xle S h aft Ring G ear Thrust Pad Pinion B earing Oil Ring G ear D iffe re n tia l B earing Seal and R e tainer D iffe re n tia l S p id er D iffe re n tia l B earing Oil Seal...
  • Page 103 REAR AXLE DIFFERENTIAL 4B-35 REAR PINION BEARING PR E SS PLATE Fig. 2G ~Pinion Rear Bearing Removal Fig. 3G ~Drive Pinion Front Bearing Removal 5. R em ove differential and ring gear assembly from the 2. Press the oil seal into the reatiner. Position seal lips carrier.
  • Page 104 4B-36 REAR AXLE DIFFERENTIAL Fig. 7G ~D ifferentia! Bearing Removal 7. Check differential side bearings and cups for broken D iffe re n tia l Disassem bly races, discoloration or roughness. 1. Check differential case to make sure that the two 8.
  • Page 105 REAR AXLE DIFFERENTIAL 4B-37 Fig. 8G --D ifferential B earing In sta lla tio n Fig. 9 G -B a ck la sh and Preload A djustm en t Reassem bly left hand adjusting nut one notch and tighten right hand nut one notch.
  • Page 106 R eassem bly................. 4B-40 A sse m b ly ................4 B 4 7 Testing P roced ure.............4B-47 Chevrolet Limited S lip ............4 B 4 2 D isassem bly................ 4B-42 Eaton Positive Locking D ifferentials In spection ................4B-42 1 /2 Ton and 3 /4 Ton U n it s ...........
  • Page 107 REAR AXLE DIFFERENTIAL 4B-39 Ring Gear-to-Case Ring Gear Spring Retainer Bolt Shim Pinion Thrust washer Differential Case Clutch Pack Guide Pinion Gear Side Bearing Clutch Disc Pinion Shaft Pinion Lock Screw Clutch Plates Preload Spring and Washer Side Gear F ig . 1 D - E a t o n L im it e d S lip E x p lo d e d V i e w EATON LIM ITED SLIP - FIGURE I D as shown in figure 5D.
  • Page 108 4B-40 REAR AXLE DIFFERENTIAL F ig . 2 D ~ R e m o v in g P r e lo a d S p r in g P a c k (T y p ic a l) be necessary to assist pinion gear upon its seat by prying on F ig .
  • Page 109 REAR AXLE DIFFERENTIAL 4B-41 F ig . 9 D - A s s e m b l i n g C lu t c h P a c k F ig . 7 D ~ R e m o v in g D if f e r e n t i a l P in io n G e a r s 18.
  • Page 110 F ig . 1 4 D - - M e a s u r i n g P o s it r a c t io n R o t a t in g T o r q u e CHEVROLET LIM ITED SLIP - FIGURE 15D...
  • Page 111 REAR AXLE DIFFERENTIAL 4B-43 SHIM BOLT (PINION SHAFT) SPLINED DISC (3) PINION FIXED SHAFT DISC (4) THRUST WASHER BOLT PINION (RING GEAR) GEAR ^PRELOAD SIDE SPRING BEARING F ig . 1 5 D ~ C h e v r o le t L im it e d S lip - E x p lo d e d 4.
  • Page 112 4B-44 REAR AXLE DIFFERENTIAL BORG W A RN ER (CONE TYPE) L U B R IC A T IO N D E S C R IP T IO N The differential should be checked for leaks and level The limited slip differential can be identified by a tag every oil change.
  • Page 113 REAR AXLE DIFFERENTIAL 4B-45 4. Install second co n e/gear assembly face down on spring block so that gear w ill mesh with pinion gears. 5. Install flange half o f differential case over cone, insert case bolts finger tight. (Fig. 4B -20D ). 6.
  • Page 114 4B-46 REAR AXLE DIFFERENTIAL F ig . 4 B - 2 1 D - B o l t T o r q u e S e q u e n c e Install unit into axle carrier follow ing instructions given for Standard Differential.
  • Page 115 REAR AXLE DIFFERENTIAL 4B-47 Friction Plate-T abb ed Differential Case Bolt Friction Plate-Tabbed Side Gear Ring Differential (Belleville) (Flat) Side Gear Friction Disc-Toothed Case-Plain Half Friction D isc-Toothed Pinion Gears (Flat) Cross Shafts Differential (Belleville) C ase-Flanged Half F ig . 2 2 D - P o w e r - L o k D if f e r e n t i a l be corrected by grinding 1/32"...
  • Page 116 4B-48 REAR AXLE DIFFERENTIAL special tool. Disregard breakaway torque and observe only If the torque reading is less than 40 foot-pounds or the torque required to continuously turn the wheel more than 200 ft. lbs., the unit should be disassembled and sm oothly.
  • Page 117 REAR AXLE DIFFERENTIAL 4B-49 SCREW (3) CASE HALF — L.H SHIM GUIDE CLIP (6) DISC PACK S/A THRUST WASHER (3) CASE HALF — R.H GUIDE CLIP (6) PINION ‘GEAR (3) GOVERNOR ASSEMBLY SHIM SIDE GEAR EARED DISC (3) SPLINED DISC (2) PINION YOKE LATCHING BRACKET...

  • Page 118: Possible Cause

    4B-50 REAR AXLE DIFFERENTIAL D IF F E R E N T IA L DIAGNOSIS Complaint Possible Cause Correction D o e s n o t lo c k : L i t t le o r n o s p rin g R e p la c e g o v e r n o r a s s e m b ly p r e lo a d o n th e la tc h in g a n d la tc h in g b r a c k e t.
  • Page 119 REAR AXLE DIFFERENTIAL 4B-51 2. U sing bushing puller tool N o. J-26252, rem ove governor assembly and latching bracket by pulling the retaining bushings as shown in Figure 4B-5H . Pull the latching bracket spring out o f the way w hile pulling the governor assembly bushing to prevent damage.
  • Page 120 4B-52 REAR AXLE DIFFERENTIAL 3. Lock an axle shaft in vise, in a vertical position. M ount the differential case over the end o f the axle shaft engaging the spline o f the side gear with the shaft. Grease the two pinion gear thrust washers and locate them in their proper position.
  • Page 121 REAR AXLE DIFFERENTIAL 4B-53 Inspect com ponents for damage. If the governor assembly and latching bracket are the only item s to be replaced, rem ove and proceed to Step 7 o f reassembly procedure. Pry under pinion yoke and remove and proceed with detailed inspection if further damage is observed.
  • Page 122 4B-54 REAR AXLE DIFFERENTIAL 2. Install cam gear assembly and original shim in right side case half. If a new thrust ring has been pressed on the cam gear, reshimming may be necessary. Measure the overall length o f the new cam gear assembly, including the shim and compare to the dim ension obtained in Step A o f cam gear service section.
  • Page 123 REAR AXLE DIFFERENTIAL 4B-55 10. R em ove disc pack from side gear and carefully Differential w ill lock if turned ra p id ly -5 0 lower disc pack assembly into left side case half. M ake sure rpm or greater. car guide clips are in their proper position.
  • Page 124 4B -56 REAR AXLE DIFFERENTIAL SPECIAL TOOLS n e J f — P in io n S e ttin g Gauge 9. J -2 2 8 8 8 D iffe r e n tia l B e a rin g R e m o v e r 1.
  • Page 125 REAR AXLE DIFFERENTIAL 4B-57 J - 2 2 9 1 2 Press P la te J -8 0 0 1 D ia l In d ic a t o r S e t J - 1 4 5 3 P in io n B ea rin g Press P la te J - 0 9 7 2 D if f e r e n t ia l N u t W re n c h J - 8 1 0 7...

  • Page 127: Front A Xle D Ifferential

    R eassem bly................4C-2 GENERAL IN FO R M A TIO N K 10-20 M odels use a Chevrolet or a D ana (44 Series) If front axle assembly is removed from vehicle, mount style front axle, which incorporates an 8-1/2" ring gear. The assembly in suitable holding fixture.

  • Page 128: R Em Oval

    4C-2 FRONT WHEEL DRIVE 3. D rive the pinion shaft lock pin out of case. 4. R em ove ring gear bolts from case and separate ring gear from case. 5. R em ove pinion shaft, pinions, side gears and thrust washers from case.
  • Page 129 FRONT W HEEL DRIVE 4C-3 N u t D iffe re n tia l Bearing Cone D iffe re n tia l Case T h ru s t Washer Washer D iffe re n tia l Bearing Cup D iffe re n tia l Bearing A d ju s tin g R ing Gear B o lt Pinio n Flange Bearing Cap...
  • Page 130 B o lt (D iffe re n tia l Cover and Plug Shims (In n e r Pinion N u t Bearing Cap) Lock Pin (Pinion Bearing) Washer B o lt (R ing Gear) Shaft) Cup ( In n er Pinion C om panion Flange Pinion S haft D iffe re n tia l Case...

  • Page 131: D Rive P In Ion

    FRONT WHEEL DRIVE 4C-5 J 2 2 8 8 8 F ig . 4 C - 7 - - R e m o v in g In n e r P in io n B e a r in g C o n e a n d R o lle r F ig .
  • Page 132 4C-6 FRONT WHEEL DRIVE N e w P in io n M a rk in g O ld P in ion M a rk in g 0 .0 0 2 0 .0 0 1 + 0 .0 0 8 + 0 .0 0 7 + 0 .0 0 6 + 0 .0 0 5 + 0 .0 0 4...

  • Page 133: Preload And A Djustm Ent

    FRONT WHEEL DRIVE 4C-7 In s ta llatio n J -5 5 9 0 1. Spread differential carrier, using spreader as shown in Figure 4C-1 and 4C-2. 2. install differential bearing cups in their correct locations then install differential case into carrier. 3.

  • Page 134: A D Ju Stm En

    FRONT WHEEL DRIVE 4C-8 A d ju s tm e n ts A ffe c tin g Too th C o n ta c t Tw o adjustments can be m ade which will affect tooth contact pattern. These are backlash and position o f drive pinion in carrier.
  • Page 135 FRONT WHEEL DRIVE 4C-9 J -8 6 1 4 01 H o ld e r and R em over - J-24385 S preader - A x le C arrie r C o m p a n io n Flange P uller - Side Bearing J -2 2 8 8 8 J -2 3 4 7 6 In sta ller - C om p a n io n Flange...
  • Page 137 BRAKES SECTION 5 BRAKES The following notice applies to one or more steps in the assembly procedure o f com ponents in this portion o f the m anual as indicated at appropriate locations by the term inology "See Caution on page 1 o f this section".
  • Page 138 BRAKES F ig . 5 - 2 A - - P o w e r P is to n G r o u p - E x p lo d e housing and rem ove the power piston bearing from the 8.
  • Page 139 BRAKES straight out. A considerable force will be required. 14. R em oval o f the air valve push rod assembly w ill disassembly the control valve retainer. 15. R em ove the "O" ring from the air valve. 16. A ir valve push rod assemblies with a formed eye on the end o f the push rod w ill be serviced using a com plete assembly, since the floating control valve cannot be removed over the eye end of the push rod.
  • Page 140 BRAKES T O O L J - 2 8 4 5 8 F ig . 5 - 7 A ~ l n s t a l lin g P r im a r y S u p p o r t P la t e a n d D i a p h r a g m F ig .
  • Page 141 BRAKES bottom o f the cavity. 28. Place the power piston bearing in rear housing center hole so that the formed flange o f the housing center hole fits into the groove o f the power piston bearing. The thin lip o f the bearing w ill protrude to the outside o f the housing.
  • Page 142 BRAKES Fig. 5-1 1A~Gaging Piston Rod O V E R H A U L M A N U A L...
  • Page 143 BRAKES BENDIX T A N D E M POWER BRAKE UNIT UNIT REPAIR Disassembly 11. A ttach base o f H olding Fixture J-22805 to front housing with nuts and washers and draw down tight to 1. Scribe a line across the front and rear housings to elim inate bending or dam age to studs.
  • Page 144 BRAKES 23. Twist the rear diaphragm plate counterclockw ise, using hand leverage on the outer edge o f the plate. It may be necessary to use a 1" x 1-3/16" x 8" wood strip as a lever in cover slot on outside circum ference of rear plate. 24.
  • Page 145 BRAKES SQUARE SECTIONED O-RING VALVE RETURN SPRING VALVE PLUNGER REAR DIAPHRAGM PLATE, REAR DIAPHRAGM, REAR DIAPHRAGM RETAINER REAR SHELL VALVE POPPET POPPET RETAINER VALVE ROD SPRING SILENCER SILENCER RETAINER FRONT SHELL SPRING REACTION DISC FRONT DIAPHRAGM PLATE RONT DIAPHRAGM CENTER PLATE F ig .
  • Page 146 5-10 BRAKES F ig . 5 - 6 B - R e m o v i n g R e a r S e a l n e w 15. Place rear housing over front housing, and align 21. Install check valve and grom m et scribe marks.
  • Page 147 BRAKES 5-11 shorter section (higher level) o f the gage. M ove gage from side to side to check piston rod height. 7. A ny variation beyond these tw o lim its must be F ig . 5 - 1 0 B - l n s t a l l i n g A ir V a lv e P lu n g e r com pensated for by obtaining the service adjustable piston rod and adjusting the self-locking screw to m eet the gaging specifications.
  • Page 148 5-12 BRAKES R em ove seal from front housing, and if defective, 1. R em ove power piston assem bly from rear housing. vacuum check valve. 2. R em ove silencer from neck o f power piston tube. 3. R em ove lock ring from power piston by prying one P o w er Piston A ssem bly Group (Fig.

  • Page 149: Cleaning Of Parts

    BRAKES 5-13 PUSH ROD REACTION RETAINER—, REACTION LEVERS-7 REACTION BUMPER LOCK RING " O ” RING SNAP RING REACTION PLATE POWER PISTON AIR VALVE SPRING AIR VALVE SPRING RETAINER SUPPORT PLATE O ” RING FLOATING CONTROL VALVE ASSEMBLY AIR FILTER AIR SILENCER RETAINER CLIP JAM NUT...
  • Page 150 5-14 BRAKES LOCK RING F ig . 5 - 4 C - - R e m o v in g L o c k R in g F r o m P o w e r P is to n brake unit.
  • Page 151 BRAKES 5-15 3 /8 " EXTENSION POWER PISTON J-9746 -SUPPORT PLATE O W E R P IS TO N SUPPORT PLATE REM O VER A N D F ig . 5 - 1 0 C - - R e m o v in g A ir V a lv e A s s e m b ly INSTALLER J-21524 6.
  • Page 152 5-16 BRAKES IN S P E C TIO N C H A R T Corrective Action Inspect For Part 1. Cracks, disto rtio n , 1. Clean up or replace. Pow er Piston and S u p po rt chipping, damaged lever Plate and Reaction seats, p itted or rough R etainer...

  • Page 153: Final Assembly

    BRAKES 5-17 tube down, in a tool, fabricated from a piece of wood, 2" x 4" x 8" long with a 1-3/8" hole in the center, clam ped in a vise. 18. W ith Snap R ing Pliers J-4880, assem ble snap ring into groove in air valve.
  • Page 154 5-18 BRAKES piston assembly, master cylinder piston or master cylinder assembly is replaced with a new part. The gage measures how far the m aster cylinder push-rod projects from front housing. This dim ension must be correct to insure proper clearance in master cylinder between primary cup and com pensating port.
  • Page 155 BRAKES 5-19 A ir V a lv e M aster C y lin d e r V a lv e R e tu rn S p rin g V a c u u m C h e c k V a lv e F r o n t H o u s in g Seal M o u n tin g S tu d G r o m m e t...
  • Page 156 5-20 BRAKES 8. Place Spanner W rench J-9504 over studs on rear housing and attach with nuts and washers. D raw nuts down tight to elim inate bending or dam aging o f studs (fig. 5-2A ). 9. Press down on Spanner W rench J-9504 and rotate the rear housing clockw ise to separate the two housings.
  • Page 157 BRAKES 5-21 Front Housing Group 1. R em ove check valve from grom m et and then rem ove grom m et from front housing; discard valve and grommet. 2. Rem ove front housing and holding fixture from vise; then remove holding fixture from front housing. Cleaning U se clean brake fluid to thoroughly clean all reusable brake parts.
  • Page 158 5-22 BRAKES Final Assembly A ttach base o f H olding Fixture J-22805 to front housing w ith nuts and washers and draw down tight to elim inate bending or damage to studs. Clamp base in bench vise w ith power section up (fig. 5-1 A). NOTICE: Be sure to align tool so that the check valve in the front housing is not damaged.
  • Page 159 BRAKES 5-23 SPOOL RETURN SPRING F ig . 5 - 1 E ~ B e n d ix H y d r o - B o o s t E x p lo d e - T y p ic a l T he Bendix H ydraulic Brake Booster utilizes the retainer, the piston return spring and output rod from the hydraulic pressure supplied by the power steering pump to...
  • Page 160 5-24 BRAKES F ig . 5 - 3 E ~ O u t p u t R o d , S p r in g a n d R e t a in e r 8. R em ove the booster assembly from the vise and w hile holding the unit over a pan, separate the cover from 14.
  • Page 161 BRAKES 5-25 assembly. F ig . 5 - 7 E ~ A c c u m u la t o r In s t a lla t io n N O TICE: T he clearance between the spool valve and the spool valve bore o f the housing assem bly is points w ith...
  • Page 162 5-26 BRAKES F ig . 5 - 1 3 E—I n s ta 1 1 i n g In p u t R o d a n d P is t o n A s s e m b ly in to B o o s t e r ( T y p ic a l) 7.
  • Page 163 BRAKES 5-27 J-24551 (JB8, JF9) F ig . 5 -1 4 E—I n s ta 1 1 i ng B a f f l e a n d S p r in g R e t a in e r 18.
  • Page 164 5-28 BRAKES HYDRO-BOOST II 1. Remove And Install Spool Valve Plug And Seal In Car. IN S TA LL R EM O VE 1. Turn engine " O F F " and pum p brake 1. Install parts as shown. pedal 4 or 5 times to deplete accum ulator.
  • Page 165 5-29 BRAKES 3. Remove And Install Bracket. REM O VE IN S TA LL 1. Cut nu t w ith chisel. 1. Install parts as shown. 2. Remove parts as shown. TO R Q U E W RENCH HOUSING COVER IN S T A L L NEW N U T W ITH S T A K IN G B R A C K E T...
  • Page 166 5-30 BRAKES 4. Remove And Install Spool Valve, Power Piston/Acuumulator And Seal. R E M O VE IN S T A L L 1. Remove parts as shown. 1. Install parts as shown. 2. If rem oving spool valve plug 2.

  • Page 167: Special T O O

    ■— ■— — — — - I .. 1 1 1 BRAKES SPECIAL TOOLS J - 4 8 8 0 S n a p R in g P liers 1 3 . J - 2 3 1 7 5 C o n t r o l V a lv e In s ta lle r J - 2 1 5 2 4 P o w e r P is to n R e m o v e r a n d In s ta lle r 1 4 .

  • Page 169: Automatic Transmission

    A U T O M A T IC TR A N S M IS S IO N (200)7A1-1 SECTION 7 A AUTOMATIC TRANSMISSION UNIT REPAIR (OVERHAUL) CONTENTS 200 A utom atic Transm ission W /T C C .........7A1-1 250C A utom atic T ransm ission............ 7A5-1 350 A utom atic Transmission W /T C C .........(350)7A-1 400 A utom atic T ransm ission............

  • Page 170: Utom Atic T Ransm Ission

    7A1-2 AUTOMATIC TRANSMISSION (200) RIGHT WRONG Figure 7A 1 -16 Teflon Oil Seal Rings Figure 7A 1 -1 5 Transmission in Holding Fixture 4. N ew angle cut or full circle teflon seal rings may appear to be distorted after being installed. Once exposed to normal transmission oil temperatures, the new seal rings will return to their normal shape and fit freely in their bores.
  • Page 171 AUTOMATIC TRANSMISSION (200) 7A1-3 a. R em ove throttle lever and bracket assembly. (Figure 7A1-18). D o not bend throttle lever link. NOTICE: T.V. exhaust valve lifter and spring may separate from throttle lever and bracket assembly. m m m . H T .
  • Page 172 7A1-4 AUTOMATIC TRANSMISSION (200) a. R em ove lead wire from electrical connector and from solenoid wire clip. (Figure 7A 1-24A ) b. Compress fingers on electrical connector sleeve and withdraw. (Figure 7A 1-24B) 9. Intermediate Servo Assembly: a. U sing tw o oil pan bolts, install J-28653 on case to CONTROL V A L V E ASSY depress servo cover.
  • Page 173 AUTOMATIC TRANSMISSION (200) 7A1-5 GOVERNOR COVER J — 28653 INTERMEDIATE SERVO C O V E R S — 607C2 INTERMEDIATE SERVO RING 907A3 Figure 7A1-24 Removing Governor Cover R E T A I N I N G Figure 7A1-25 Removing Intermediate Servo Retaining Ring Figure 7A1-24A Removing Lead Wire Figure 7A 1-26 Removing Intermediate Servo A pply 12 N -m (100 lb.

  • Page 174: Front Unit Parts

    7A1-6 AUTOMATIC TRANSMISSION (200) a. U sing a No. 4 easy out, remove the check valve assembly from the case by turning and pulling straight out. (Figure 29B) b. Install new check valve assembly, small end first, into case. Position the oil feed slot in tube so it faces the servo cover.

  • Page 175: Front Gear Parts

    AUTOMATIC TRANSMISSION (200) 7A1-7 OIAL INDICATOR J -2 5 0 1 3 -5 8001 OR 26900 12 607C 28 Figure 7A 1-30 Installing Tools on Rear End of Case c. R em ove pump to case bolt and washer and install 278mm (11") long bolt and locking nut as shown.
  • Page 176 7A1-8 AUTOMATIC TRANSMISSION (200) c. Install dial indicator J-8001 and plunger extension J-7057. Position extension against end o f output shaft and set dial indicator to zero. (Figure 7A1-41). d. M ove output shaft upward by turning adjusting 24773- screw on J-25013-5 until the white or scribed line on sleeve J-25013 begins to disappear;...

  • Page 177: Rear Gear Parts

    AUTOMATIC TRANSMISSION (200) 7A1-9 NOTICE: The front sun gear to front carrier thrust NOTICE: This thrust bearing requires only one thrust bearing assembly may com e out as the front carrier is race. removed. 7. Input drum and rear sun gear assembly: a.

  • Page 178: Manual Shaft And Parking P A W L

    7A1-10 AUTOMATIC TRANSMISSION (200) F R O N T C A R R IE R L L E R T H R U S T A R IN G A SSY. Figure 7A1-43 Removing Front Carrier and Roller Thrust Bearing F R O N T S U N G E A R Figure 7A1-46 Removing Cup Plug and Seal Assembly T H R U S T B E A R IN G A SSY.

  • Page 179: Inspection And R Eassem B Ly

    AUTOMATIC TRANSMISSION (200) 7A1-11 LO & R E V E R S E C L U T C H H O U S IN G TO CASE SPACER O UTPUT SHAFT 9R7A15 Figure 7A 1-52 Removing Rear Internal Gear REAR OIL SEAL 607C46 Figure 7A1-49 Proper Location of Low and Reverse Housing to Case Spacer...
  • Page 180 7A1-12 AUTOMATIC TRANSMISSION (200) M A N U A L S H A F T S E A L M A N U A L S H A F T - P IN ( M A N U A L S H A F T T O C A S E ) I N S I D E D E T E N T M A N U A L D E T E N T L E V E R A N D P I N --------- t ~...

  • Page 181: M Anual Shaft And Parking P A W L

    AUTOMATIC TRANSMISSION (200) 7A1-13 M A N U A L SHAFT AND PARKING PAW L PARTS (FIGURE 7A1-65) Inspection 1. A lign actuator rod tangs with hole in inside detent lever and separate. 2. Inspect parking lock actuator rod for damage, or broken retainer lugs.

  • Page 182: Rear Gear Parts

    7A1-14 AUTOMATIC TRANSMISSION (200) IN T E R M E D IA T E EXHAUST BOOST IN T E R M E D IA T E i - j a m D IR E C T CLU TCH ^ £ 3 I E X H A U S T R E V E R S E LO &...

  • Page 183: Steel Speedometer Drive Gear

    AUTOMATIC TRANSMISSION (200) 7A1-15 Figure 7A 1-68 Installing Parking Pawl Cup Plug Figure 7A1-65 Manual Shaft and Parking Shaft Parts P A R K IN G L O C K B R A C K E T M A N U A L S H A F T 1 3 M M (o r 9 / 1 6 ”...

  • Page 184: Rear Internal Gear

    7A1-16 AUTOMATIC TRANSMISSION (200) 3. Position speedometer gear, larger chamferred inside J-8433 diameter first, over rear end o f output shaft. (Figure 7A1- 74). 4. Using T ool J-28578 drive gear to 156.15mm (6 -5 / 32") from rear end o f output shaft to rear face o f gear. SPEEDOMETER D R IV E GEAR J-21427-01...
  • Page 185 AUTOMATIC TRANSMISSION (200) 7A1-17 R E A R I N T E R N A L T H R U S T B E A R I N G A S S Y . ( I N S I D E D I A M E T E R R A C E G E A R R E A R C A R R I E R A G A I N S T G E A R )

  • Page 186: Low And Reverse C Lu Tch

    7A1-18 AUTOMATIC TRANSMISSION (200) THRUST WASHER ENERG IZING ROLLER SPRING REAR CARRIER ASSEMBLY 6 0 7 C 7 3 607 C 49 Figure 7A1-80 Installing Roller Into Cage Figure 7A 1-83 Installing Thrust Washer O U T P U T S H A F T R E A R C A R R I E R R E A R I N T E R N A L G E A R ROLLER CLUTCH...

  • Page 187: Low And Reverse Clutch Housing Assembly

    AUTOMATIC TRANSMISSION (200) 7A1-19 3. Inspect low and reverse clutch splines and snap ring OUTPUT SHAFT groove for damage or burrs. R em ove any burrs on splines or snap ring groove. 4. Inspect low and reverse clutch piston and clutch apply ring assembly for distortion, cracks or damage.
  • Page 188 7A1-20 AUTOMATIC TRANSMISSION (200) LO & REVERSE LO & REVERSE C LUTCH LO & REVERSE C LUTCH LO & REVERSE HOUSING LO & REVERSE C LU TC H APPLY SPRING STEEL CLUTCH ASSEM BLY PISTON SEALS RING R E T A IN E R PLA TE SNAP HO USING...

  • Page 189: Front Gear Parts

    AUTOMATIC TRANSMISSION (200) 7A1-21 d. R em ove tool (input drum and rear sun gear). W AVE RELEASE LO & REVERSE e. Loosen adjusting screw on J - 2 5 0 on output shaft SPRING CLUTCH HOUSING to install snap ring. f.

  • Page 190: Front Carrier Assembly

    7A1-22 AUTOMATIC TRANSMISSION (200) 200 CLUTCH PLATE AND APPLY RING USAGE CHART LO V & R E V E R SE C L U T C H F O R W A R D C L U T C H D I R E C T C L U T C H M O D E L S C o m p .

  • Page 191: Front Internal Gear And Thrust W Asher

    AUTOMATIC TRANSMISSION (200) 7A1-23 Thoroughly plean, air dry and inspect closely, front carrier to front internal gear roller thrust bearing assembly for pitted or rough conditions. Reassembly 1. Install front carrier to front internal gear roller thrust bearing assem bly by placing the sm aller diameter race against carrier.

  • Page 192: Check Rear U Nit End P La Y

    7A1-24 AUTOMATIC TRANSMISSION (200) NOTICE: Selective washer controlling this end play is located between the front internal gear thrust washer and output shaft snap ring. If more or less washer THRUST BEARING ASSY. thickness required bring end play within (INSIDE DIAMETER RACE AGAINST CARRIER) specifications, select...
  • Page 193 AUTOMATIC TRANSMISSION (200) 7A1-25 D I A L I N D I C A T O R * J 8001 J-25013-5 T L U I X J U t i n 1 EXTENSION J 7 0 5 7 S H A F T C L A M P L O C A T I O N 607C 28...
  • Page 194 7A1-26 AUTOMATIC TRANSMISSION (200) SNAP RING D IR E C T C L U T C H C L U T C H IN N E R S EA L P IS TO N (L IP UP) Figure 7 A 1 -1 16 Removing Direct Clutch Piston Inner Seal DIRECT CLUTCH HOUSING...

  • Page 195: Forward Clutch Housing Assembly

    AUTOMATIC TRANSMISSION (200) 7A1-27 (Figure 7A 1 -114). A n arbor press and 4. R em ove snap ring and inspect for damage. (Figure 7 A 1-124). J-23327-1 can be used to compress the retainer and spring assembly. 5. R em ove backing plate from the forward clutch 10.

  • Page 196: Interm Ediate Band Assembly

    7A1-28 AUTOMATIC TRANSMISSION (200) between the outer seal and the housing. Refer to Figure 7A1-130. 4. Install retainer and spring assembly. NOTICE: Retainer could locate is snap ring groove and forcing retainer to com press springs, could damage retainer plate. O M ITTE D 5.

  • Page 197: Installation

    AUTOMATIC TRANSMISSION (200) 7A1-29 FORW ARD T U R B IN E FO R W A RD FO R W A RD CLUTCH W AVED FORW ARD SHAFT CLUTCH C LUTCH R E T A IN E R & STEEL CLUTCH SEAL HO USING...
  • Page 198 7A1-30 AUTOMATIC TRANSMISSION (200) CLUTCH INNER SEAL (LIP UP) UTER SEAL (LIP UP) O R W A R D FORW ARD CLUTCH PISTON C LU TC H PISTON Figure 7 A 1 -127 Removing or Installing Inner Piston Seal FO RW AR D CLUTCH HOUSING 7B7A528...

  • Page 199: Pum P A Sse M B Ly

    AUTOMATIC TRANSMISSION (200) 7A1-31 FORWARD CLUTCH HOUSING 15.8 mm (5 /8 ” ) DIRECT CLUTCH HOUSING RIGHT WRONG Figure 7A 1 -134 Forward Clutch Properly Seated in Direct Figure 7A 1-132 Teflon Oil Seal Rings Clutch I N T E R M E D I A T E B AN D 607C33 Figure 7A 1-132A Installing Intermediate Band Assembly...

  • Page 200: Pressure Regulator

    7A1-32 AUTOMATIC TRANSMISSION (200) 4. Rem ove solenoid assembly. (Figure 7A 1-139B ) 5. Rem ove "0"-ring seal from solenoid assembly. 6. Inspect solenoid assembly ball check valve for nicks or damage. CONVERTER CLUTCH APPLY VALVES: Inspection 1. R em ove the converter clutch valve bushing retaining pin.

  • Page 201: Converter Clutch A Pply V Alve

    AUTOMATIC TRANSMISSION (200) 7A1-33 R ETA IN IN G Figure 7 A 1 -13 9 Removing Pressure Regulator Valve Figure 7A 1-139C Removing Retaining Pin C O N VERTER CLUTCH V A L V E BUSHING SOLENOID ASSEMBLY Figure 7A 1-139A Removing Solenoid Attaching Bolts Figure 7A 1-139D Removing Valve Bushing C O N VERTER CLUTCH V A L V E BUSHING BORE...

  • Page 202: Pum P B Od Y

    7A1-34 AUTOMATIC TRANSMISSION (200) a 7.14m m (9 /32 " ) diameter rod on the two sm aller plugs and a 7.92mm (5/1 6 " ) diameter rod on the four larger plugs. Stake top o f hole two places, directly opposite each other, P U M P B O D Y to retain plug.
  • Page 203 AUTOMATIC TRANSMISSION (200) 7A1-35 PUMP DRIVEN GEAR w ■ (ID EN TIFIC ATIO N MARK DOWN) Figure 7A 1-143 Installing Pump Driven Gear SCREEN Figure 7A1-141B Removing Screen O P TIO N A L ID E N T IF IC A T IO N Figure 7A 1-144 Pump Driven Gear Identification PLUG Figure 7A 1-141C Installing Cup Plug...
  • Page 204 7A1-36 AUTOMATIC TRANSMISSION (200) D /R ECT DIRECT CLUTCH CONVERTER CLUTCH AIR BLEED TO COOLER TO ACTUATOR VALVE ORIFICE (T.C.C. APPLY) REVERSE VOID LUBE HOLE CONVERTER FROM COOLER FEED & T.C.C. TO LUBE RELEASE DIRECT CLUTCH Figure 7 A 1 -147 Pump Cover Oil Passages OIL PRESSURE CONTROL ORIFICE LINE BOOST...
  • Page 205 AUTOMATIC TRANSMISSION (200) 7A1-37 0 ” RING S EA L SOLENOID PUMP TO CASE A SSEM BLY G ASKET Figure 7A 1-150C Install Solenoid Assembly Figure 7A 1 -15 0 Installing Pressure Regulator Valve T H R U S T WASHER PUMP ASSEM BLY C O N VERTER CLUTCH...

  • Page 206: External Parts

    7A1-38 AUTOMATIC TRANSMISSION (200) NOTICE: If turbine shaft cannot be rotated as pump is being pulled into place, the forward or direct clutch housings have not been installed properly to index with all the clutch plates. This condition must be corrected before pump is pulled fully into place.

  • Page 207: Intermediate Band Anchor Pin

    AUTOMATIC TRANSMISSION (200) 7A1-39 4. Install governor and cover assembly, aligning 1980 TH M 200 IN T E R M E D IA T E S ER VO CO VER A N D governor shaft with shaft hole in case. (Figure 7 A 1-155). PISTON USAGE Rotate governor and cover assembly and output shaft Servo Cover...

  • Page 208: Interm Ediate Servo P Is To N

    7A1-40 AUTOMATIC TRANSMISSION (200) Disassem bly A pply 12 N *m (100 lb. in.) o f torque to hex nut on side o f gage. Slide dial indicator over gage pin J-25014-1. 1. U sing J-22269-01, com press interm ediate servo (Figure 7A 1-160).
  • Page 209 AUTOMATIC TRANSMISSION (200) 7A1-41 9.5 mm ( 3/ 8") ROD 1 0 & REVERSE CLUTCH SEAL I 907A13 M " ' "4 Figure 7A 1 -164 Installing Low and Reverse Clutch Housing to Case Cup Plug and Seal 3. Connect short solenoid lead wire to the electrical connector.

  • Page 210: Control Valve Assembly

    7A1-42 AUTOMATIC TRANSMISSION (200) ground sides to fit inside the pin, rem ove the inner coiled Control Valve Assembly pin. (Figure 7A 1-168). R em ove the throttle valve. Disassem bly From upper left bore, remove coiled pin, interm ediate boost spring and intermediate boost valve. NOTICE: A s each valve train is removed, place the 11.
  • Page 211 AUTOMATIC TRANSMISSION (200) 7A1-43 ( M > i 23 , : I 24 € 32 IffPfffflEI 0 C = N O T E : 1980 M O D E L S C X O N L Y USE A D E T E N T PIN 4 5 46 (IT E M ^ 3 5 ).

  • Page 212: Installation

    7A1-44 AUTOMATIC TRANSMISSION (200) C O N T R O L V A L V E ASSY. 607C145 Figure 7A 1 -168 Removing Inner Coiled Retaining 2 3 T H R O T T L E 12. If rem oved, install new seal ring on 1-2 accum ulator PIN S L O T V A L V E B U S H IN G piston.
  • Page 213 AUTOMATIC TRANSMISSION (200) 7A1-45 6. Install 4 check balls into ball seat pockets in control valve assembly and retain with petrolatum. (See Figure 7A 1- 174 for check ball location.) 7. Place the control valve assembly to spacer plate gasket marked "VB" on the control valve assembly. 8.
  • Page 214 E X H A U S T I N T E R M E D IA T E L IN E R N D I R N D B O O S T D R IV E D R IV E R E V E R S E B O O S T P U M P IN T A K E P A R T T H R O T T L E...

  • Page 215: Oil Pan

    AUTOMATIC TRANSMISSION (200) 7A1-47 Press solenoid lead wires into wire clips. (Figure 7A 1-173B ) Oil Pan 1. Clean and inspect oil pan for damage. 2. Install new oil pan to case gasket on case. 3. Install oil pan and retaining bolts. Torque bolts to 16 N -m (12 lb.

  • Page 216: Rear Bushing

    7A1-48 AUTOMATIC TRANSMISSION (200) J-7004-1 J-24036 T.V. EXHAUST VA LV E LIFTER PUMP THROTTLE LEVER & C O V E R BRACKET ASSEMBLY THROTTLE LEVER TO CABLE LINK 7 B 7 A 5 4 2 607C16 Figure 7A 1 -181 Removing Pump Cover Bushing - Front Figure 7A 1 -178 Installing Throttle Valve and Bracket Assembly U sing T ool J-25019-2 with Driver H andle J-8092, drive...

  • Page 217: Direct Clutch Housing

    AUTOMATIC TRANSMISSION (200) 7A1-49 J-7004-1 * - ,# - J-8092 J -2 5 0 1 9 -1 4 J-25019-12 PUMP B O D Y P UM P C O V E R , X' 7 B 7 A 5 4 7 7 B 7 A 5 4 4 Figure 7A 1-186 Installing Pump Body Bushing Figure 7 A 1-183 Removing Pump Cover Bushing - Rear...

  • Page 218: Rear Sun Gear

    7A1-50 AUTOMATIC TRANSMISSION (200) Front Internal Gear Bushing U sing Tool J-25019-3 with Driver Handle J-8092, remove bushing (Figure 7A 1-191). J-8092 J -2 50 19-9 D IR E C T C L U T C H H O U S IN G J-8092 J-250 19-3 F R O N T...

  • Page 219: Rear Carrier Bushing

    AUTOMATIC TRANSMISSION (200) 7A1-51 J-7004-1 J-7004-1 J-2 5 0 1 9 -1 4 J-25019-16 LO & REVERSE G E A R R E A R S U N CLUTCH HOUSING 7B7A556 7 B 7 A 5 5 4 Figure 7A 1-193 Removing Rear Sun Gear Bushing Figure 7A 1-195 Removing Lo and Reverse Clutch Housing Bushing J-8092...
  • Page 220 7A1-52 AUTOMATIC TRANSMISSION (200) remove bushing (Figure 7A 1-199). U sing T ool J-21424-9 with Driver Handle J-8092, drive or press new bushing, Part N o. 6261109, to a distance o f approximately 17.3mm (or 11/16" ) between rear end o f the bushing and rear end o f the case (Figure 7A 1-199).
  • Page 221 AUTOMATIC TRANSMISSION (200) 7A1-53 T O R Q U E S P E C IF IC A T IO N S DESCRIPTION OF USAGE QUANTITY SIZE TORQUE ASSEMBLY Pu m p B od y T o P u m p Cover x 1 .2 5 x 4 5 2 0 .
  • Page 222 7A1-54 AUTOMATIC TRANSMISSION (200) & I C J & ® ’ M M lk, | & & & 1 4 . J 2 5 0 2 2 En d - P la y C h e c k i n g F i x t u r e A d a p t e r J 2 5 0 1 5 Oil P u m p B o d y a nd C ov er A l i g n m e n t B and 1 5.
  • Page 223 A U TO M A TIC TR A N SM IS S IO N 7A5-1 250C AUTOMATIC TRANSMISSION UNIT REPAIR (OVERHAUL) INDEX Transmission D isassem bly and R eassem b ly ... .7A5-1 R eassem bly.............. 7A5-14 Transm ission D isassem b ly..........7A5-1 Sun Gear and Sun Gear D rive Shell....

  • Page 224: Pressure Switch

    7A 5-2 A U T O M A T IC TR A N SM IS S IO N A U X IL IA R Y SUPPORT PLATE V A L V E BODY DETENT V A L V E CONTROL V A L V E ACTUATOR LEVER S "...
  • Page 225 A U TO M A T IC TR A N SM IS S IO N 7A5-3 Figure 7A 5-16 Removal of Manual Shaft Retaining Clip Figure 7A 5-18 Check Ball Locations [SUPPORT! AUX!LIARY| I V A L V E BODY! Figure 7A5-17 Auxiliary Valve Body and Support Plate Figure 7A 5-19 Oil Pump Screen 6.
  • Page 226 7A 5-4 A U T O M A TIC TR A N SM IS S IO N Figure 7A5-21 Removal of Actuator and Range Selector Figure 7A 5-23 Pump Removal Figure 7A 5-22 Park Pawl Removal Figure 7A5-24 Intermediate Band Anchor Bolt R em ove parking pawl shaft retaining plug, parking pawl shaft,...
  • Page 227 A U T O M A TIC TR A N SM IS S IO N 7A5-5 disassembly and reassembly o f the direct and forward clutches. INPUT RING GEAR 7. R em ove interm ediate servo, cushion spring, and washer from case from input ring gear. 8.
  • Page 228 7A 5-6 A U TO M A TIC TR A N SM ISSIO N Figure 7A5-31 Low & Reverse Clutch Support Retaining Ring Figure 7A 5-34 Low & Reverse Clutch Plate Removal R em ove reaction carrier assembly, output ring gear, shaft assembly, and clutch plates from case.
  • Page 229 ■ ■ ■ ■ ■ ■ ■ A U TO M A T IC TR A N SM IS S IO N 7A5-7 REVERSE CLUTCH PISTON CENTER SEAL O UTP UT R I N G G E A R O U T P U T R I N G •INNER SEAL G E A R TO CASE NEEDLE B E A R I N G...
  • Page 230 7A 5-8 A U TO M A TIC TR A N SM IS S IO N IN TER M EDIATE CLUTCH ACCUM ULATOR COVER COMPRESSOR J-23069 Figure 7A 5-42 1-2 Accumulator-Exploded View Figure 7A5-41 1-2 Accumulator Removal nrrom I © m r m r r m % | 20 2 1 22 .«...
  • Page 231 A U TO M A T IC TR A N SM IS S IO N 7A 5-9 Reassem bly 2. Inspect valve body for cracks, scored bores, interconnected oil passages and flatness o f m ounting face. 1. Install apply valve, spring, seat and retaining pin. 3.
  • Page 232 7A 5-10 A U TO M A TIC TR A N SM ISSIO N NOTICE: Solvents may be harmful to rubber seals. R em ove pump outside diameter to case (square cut) "O" ring seal. Discard seal. 2. Inspect pump gears for nicks or damage. Inspection 3.
  • Page 233 A U TO M A T IC TR A N SM IS S IO N 7 A 5 -1 1 • D IR E C T C IU T C H DRUM STEEL SEPARATOR D IR ECT CLUTCH FA C ED PLATE P ISTO N A SSEM B LY D IR ECTC LU TCH PRESSURE PLATE' R ET A IN IN G R IN G '...
  • Page 234 7A 5 -1 2 A U T O M A TIC TR A N SM ISSIO N . 0 2 0 ” MUSIC WIRE CRIMPED O U T E R SEA L INT O COPPER TUBING D IR E C T C L U T C H P I S T O N PISTON I N N E R SEAL...
  • Page 235 A U TO M A TIC TR A N SM IS S IO N 7A 5-13 FORWARD CLUTCH PISTON ASSEMBLY RETAINING RING FORWARD CLUTCH DRUM STEEL SEPARATOR PLATE CUSHION S P R IN G i INPUT SHAFT T E F L O N S E A L FACED PLATE —...
  • Page 236 7A 5-14 A U TO M A TIC TR A N SM ISSIO N . 0 2 0 " M U S I C WI RE CRIMPED I N T O COPPER T UB I NG P I S T O N F O R W A R D CLUTCH PISTON...
  • Page 237 A U TO M A TIC TR A N SM IS S IO N 7 A 5-15 Figure 7A 5-69 Planetary Gear Train-Exploded View SUN GE AR DRIVE SHELL SUN GEAR SUN GE AR R E T A I N I N G RI N G S U N GEAR DRIVE SHELL FLAT THRUST W A SH E R...
  • Page 238 7A 5-16 A U TO M A TIC TR A N SM IS S IO N to w and Reverse Clutch Support (Figure 7A 5-72) Disassembly 1. R em ove low and reverse clutch to sun gear shell thrust washer. 2.
  • Page 239 A U TO M A TIC TR A N SM IS S IO N 7A 5-17 L O W & REVERSE ROLLER CLUTCH ASSEMBLY " ^ . < ■ Figure 7A5-75 Roller Clutch Assembly Figure 7A 5-77 Servo Apply Piston Retainer Removal as a com plete assembly.
  • Page 240 7A 5-18 A U T O M A TIC TR A N SM IS S IO N Perform follow ing inspections and replace governor driven gear, if necessary. CUSHION PISTON Inspection E" RETAINER 1. W ash all parts in cleaning solvent, air dry and blow out all passages.
  • Page 241 A U T O M A T IC T R A N S M IS S IO N 7A 5-19 use. The service package contains a nylon driven gear, two governor weight retaining pins and one governor gear retainer split pin. R eplacem ent o f gear m ust be performed with care in the follow ing manner: 1.
  • Page 242 7A 5-20 A U TO M A TIC TR A N SM IS S IO N LOW A N D REVERSE REACTION CLUTCH SUPPORT CARRIER LOW A N D REVERSE CLUTCH SUPPORT RETAINER SPRING OUTPUT RING GEAR A N D OUTPUT SHAFT 7C-210 7C-209 7A 5-85 Low &...
  • Page 243 A U TO M A T IC TR A N SM IS S IO N 7A5-21 NOTICE: D o not over stress snap ring, damage may occur. 17. Install input gear front thrust washer. 18. Install needle bearing to forward clutch assembly. 19.
  • Page 244 7A 5-22 A U TO M A TIC TR A N SM ISSIO N Speedometer Drive Gear and Extension 3. install parking pawl shaft into case and through parking pawl. 1. Place speedom eter drive gear retaining clip into hole 4.
  • Page 245 A U TO M A TIC TR A N S M IS S IO N 7A 5-23 10. Install solenoid and connect wires. If removed install governor pressure switch. 11. Install detent roller and spring assem bly to valve body. 12.

  • Page 246: Specifications

    7A 5-24 A U TO M A TIC TR A N SM IS S IO N ______________________ SPECIFICATIONS Pump Cover to Pump B o d y ........17 ft. lbs. Pump Assembly to Case........18-1/2 ft. lbs. Valve Body and Support P la t e ......130 in. lbs. Parking Lock B racket...........

  • Page 247: Special Tools

    A U TO M A TIC TR A N S M IS S IO N 7A 5-25 SPECIAL TOOLS J 2 1 3 6 3 J -2 1 4 0 9 J-21370-6 J - 213 6 6 J 2 1 3 6 2 J-2 1 3 6 8 J 7 0 0 4 J -2 1 3 6 9...
  • Page 249 A U T O M A T IC TR A N S M IS S IO N (3 5 0 )7 A-1 SECTION 7 A 350 AUTOMATIC TRANSMISSION UNIT REPAIR (OVERHAUL) INDEX Transm ission D isassem bly and R eassem bly....7A-3 Low and Reverse Roller Clutch Support....
  • Page 250 CONVERTER INTERMEDIATE INTERMEDIATE FORWARD ASSEMBLY CLUTCH OVERRUN BAND CLUTCH LO W A N D REVERSE OUTPUT CLUTCH GEAR SHAFT REACTION CARRIER G O VER N O R O W A N D REVERSE OVERRUN ROLLER INPUT SHAFT PARKING PAWL OUTPUT CARRIER INTERMEDIATE M A N U A L...
  • Page 251 A U T O M A T IC T R A N S M IS S IO N (3 5 0 )7 A-3 J-8763-01 F i g . 7 A - 2 B - - T r a n s m i s s i o n in H o l d i n g F i x t u r e F i g .
  • Page 252 (350)7A -4 A U TO M A TIC TR A N SM IS S IO N EXTENSION HOUSING BUSHING J-25020 Fi g . 7 A - 6 B - - C h e c k i n g C o n v e r t e r E n d C l e a r a n c e Converter End Clearance Check (Figs.
  • Page 253 A U T O M A T IC T R A N S M IS S IO N (350)7A-5 APPLY SEALANT G A S K E T G O V E R N O R C O V E R Fi g.
  • Page 254 (350)7A -6 A U TO M A TIC TR A N SM IS S IO N TORQUE WRENCH VALVE BODY ASSEMBLY MANUAL CONTROL VALVE"S” LINK SPACER SUPPORT PLATE DETENT SPRING AND ROLLER ASSEMBLY Fi g. 7 A - 1 B - R e m o v i n g T r a n s f e r ( S p a c e r ) S u p p o r t P l a t e 3.
  • Page 255 A U TO M A T IC TR A N SM IS S IO N (3 5 0 )7 A-7 i f C H E C K BALLS Fi g. 7 A - 2 0 B - R e m o v i n g G o v e r n o r F e e d S c r e e n F ig .
  • Page 256 (3 5 0)7 A-8 A U TO M A TIC TR A N S M IS S IO N SCREWDRIVER R A N G E SELECTOR I N N E R MANUAL SHAFT TO LEVER T O M A N U A L SHAFT CASE LIP SEAL N U T .
  • Page 257 A U T O M A T IC T R A N S M IS S IO N (350J7A-9 INTERMEDIATE SERVO PISTON A ND SEAL WASHER APPLY PIN SPRING SEAT SPRING Fi g. 7 A - 2 6 B - - R e m o v i n g P a r k i n g P a w l D i s e n g a g i n g S p r i n g F i g .
  • Page 258 (3 5 0 )7 A-10 A U TO M A TIC TR A N S M IS S IO N SLIDE I N T E R M E D I A T E C L U T C H HAMMERS FACED PLATES STEEL PLATESQ TIGHTEN JAM NUTS...

  • Page 259: Input Shaft

    A U T O M A T IC TR A N S M IS S IO N (3 5 0)7 A -1 1 IN P U T R I N G G E A R INTERMEDIATE OVERRUN F R O N T IN P U T R I N G BRAKE BAND G E A R THRUST W A S H E R Fi g.
  • Page 260 (350)7A -12 A U TO M A TIC TR A N S M IS S IO N O U T P U T C A R R IE R A S S E M B L Y INPUT RING GEAR Fi g .
  • Page 261 A U TO M A TIC T R A N S M IS S IO N (350)7A -13 R E T A I N I N G O U T P U T R I N G G E A R R IN G v A N D S H A F T A S S E M B L Y R E A C T I O N C A R R IE R...
  • Page 262 (350)7A -14 A U TO M A TIC TR A N SM IS S IO N OUTPUT RING GEAR T A N G E D THRUST WASHER F ig . 7 A - 4 6 B ~ R e m o v i n g O u t p u t R i n g G e a r T o r r i n g t o n B e a r i n g F i g .
  • Page 263 A U T O M A T IC T R A N S M IS S IO N (3 5 0)7 A-15 ♦ | A P P L Y A IR PRESSURE I HERE T O R E M O V E L O W & REVERSE C LUTCH PISTON .
  • Page 264 (3 5 0 )7 A-16 A U TO M A TIC TR A N SM IS S IO N 2. R em ove m anual valve from lower left hand bore. 3. From lower right hand bore remove the pressure regulator valve train retaining pin, boost valve sleeve, interm ediate boost valve, reverse and m odulator boost valve, pressure regulator valve spring, and the pressure...
  • Page 265 A U TO M A TIC TR A N SM IS S IO N (3 5 0 )7 A-17 3. Install the detent valve, washer, outer spring, inner spring, spring seat, and spring retainer. Install detent valve stop and detent valve actuating bracket. Torque bolt to 52 in.
  • Page 266 (350J7A-18 A U TO M A TIC TR A N SM IS S IO N RETURN SPRINGS (20) A U X IL IA R Y RETAINING V A L V E BODY PIN x APPLY V A L V E S aljagoy RETAINER INTERMEDIATE...

  • Page 267: Stator Shaft

    A U TO M A TIC T R A N S M IS S IO N (350)7A -19 FORWARD CLUTCH OIL SEAL RINGS DIRECT CLUTCH OIL SEAL RINGS PUMP COVER TO DIRECT CLUTCH Fi g. 7 A - 6 3 B - C h e c k i n g P u m p B o d y t o G e a r F a c e C l e a r a n c e NEEDLE BEARING F i g .
  • Page 268 (3 5 0 )7 A-20 A U TO M A TIC TR A N S M IS S IO N I NTERMEDIATE CLUTCH C O O L ER OUT J - 2 13 5 9 FROM RADI A TO R C O O L E R IN R E VE R SE ( TO RADI ATOR |...
  • Page 269 A U T O M A T IC T R A N S M IS S IO N (350)7A-21 DIRECT C LU TCH DRUM STEEL SEPA RA TO R D IREC T CLUTCH FA C ED PLATE — R E T A IN IN G R IN G — P IS T O N A S S E M B L Y D IR EC T C LU T C H P R E S S U R E PLA T E R E T A IN IN G R IN G...
  • Page 270 (350)7A -22 A U TO M A T IC TR A N SM IS S IO N DIRECT CLUTCH DRUM TO STEEL FORWARD CLUTCH HOUSING PLATES NEEDLE ROLLER BEARING LINED PLATES ■ *■ F ig . 7 A - 7 2 B - - D i r e c t C l u t c h D r u m t o F o r w a r d C l u t c h H o u s i n g F i g .
  • Page 271 A U T O M A T IC T R A N S M IS S IO N (350)7A -23 .0 20" PIANO WIRE CRIMPED IN T O COPPER TUBIN G DIRECT CLUTCH H O U S I N G Fi g .
  • Page 272 (350)7A -24 A U TO M A TIC TR A N SM IS S IO N RETAININGV \ k FORWARD CLUTCH C L U T C H P L A T E S RING i l ASSEMBLY L o w /R e v e rs e In te rm e d ia te D ire c t F o rw a rd...
  • Page 273 A U TO M A TIC TR A N S M IS S IO N (350)7A -25 CLUTCH PISTON INNER SEAL Fi g. 7 A - 8 3 B ~ R e m o v i n g F o r w a r d C l u t c h , C l u t c h P a c k Fi g .
  • Page 274 (350)7A -26 A U TO M A TIC TR A N SM IS S IO N .020" PIANO WIRE CRIMPED I N T O COPPER TUBING PISTON FO R W A R D CLUTCH H O U S I N G FORWARD CLUTCH BALL CHECK EXHAUST...
  • Page 275 A U TO M A TIC TR A N S M IS S IO N (350)7A -27 WHEN DIM. C IS (OR EQUIVALENT) .0160— .0 5 2 0 6261072 .0 5 2 0 — .0 8 3 0 6261349 .0 8 3 0 — .1218 6 2 6 1 3 5 0 3.
  • Page 276 (350J7A-28 A U TO M A TIC TR A N SM IS S IO N S U N G E A R R E T A I N I N G R I N G S U N G E A R D R IV E SHELL Fi g.
  • Page 277 A U TO M A TIC T R A N S M IS S IO N (350)7A -29 L O W A N D R E V E R S E LUTCH S U P P O R T R O L L E R C L U T C H A S S E M B L Y S N A P R IN G IN N E R R A C E...
  • Page 278 (3 5 0)7 A -30 A U TO M A TIC TR A N SM IS S IO N L O W & REVERSE ROLLER L O W A N D REVERSE CLUTCH A S S E M B L Y O V E R R U N C LU TC H RACE F i g .
  • Page 279 A U T O M A T IC TR A N SM IS S IO N (350)7A-31 Governor Driven Gear Replacement To facilitate governor repair in the field, a governor driven gear and replacement pins are available for service use. The service package contains a nylon driven gear, two governor w eight retaining pins and one governor gear retainer split pin.
  • Page 280 (350)7A -32 A U TO M A TIC TR A N SM IS S IO N J - 2 1 4 6 5 - 1 5 J - 2 6 1 9 - 4 ADAPTER J - 8 0 9 2 J - 2 1 4 2 4 - 9 E X T E N S IO N H O U S I N G...
  • Page 281 A U TO M A TIC TR A N S M IS S IO N (350)7A -33 G EA R J -8 0 9 2 DRIVE SHELL J - 2 3 0 6 2 - 2 J -2 3 0 6 2 -3 SUN GEAR ASSEMBLY Fi g .
  • Page 282 (3 5 0)7 A -34 A U TO M A TIC TR A N SM IS S IO N 3. Install spring retainer and retaining ring. U sing tool J-23327, com press return seat so spring retainer retaining ring m ay be installed. Install output ring gear rear thrust bearing in case.
  • Page 283 A U T O M A T IC TR A N S M IS S IO N (3 5 0 )7 A-35 26. Install new pump assem bly to case square cut oil seal ring. 27. Install guide pins into case. 28.
  • Page 284 (3 5 0)7 A-36 A U TO M A TIC TR A N SM IS S IO N 9. Connect detent control valve wire to detent valve actuating lever, then attach lever to valve body. 10. Install detent roller and spring assembly to valve body.
  • Page 285 A U TO M A TIC T R A N S M IS S IO N (350)7A -37 SPECIFICATIONS TORQUE SPECIFICATIONS Pump Cover to Pump B o d y ........17 ft. lbs. Pump Assembly to Case........18-1/2 ft. lbs. Valve Body and Support P la t e ......130 in.
  • Page 286 (3 5 0 )7 A -3 8 A U TO M A TIC TR A N S M IS S IO N SPECIAL TOOLS Tr a n s m i s s i o n H o l d i n g F i x t u r e J - 5 1 5 4 o r E x t e n s io n H o u s in g O i l Seal J - 8 7 6 3 - 0 2...
  • Page 287 A U T O M A T IC TR A N S M IS S IO N S (4 0 0 )7 A-1 SECTION 7 A 400 AUTOMATIC TRANSMISSION INDEX Transmission D isassem bly and R eassem bly....7A-3 Output Shaft, Rear Internal Gear, Sun Gear and S h a ft.............
  • Page 288 (400)7A-2 A U TO M A TIC TR A N SM IS S IO N S Fig. 7 A - 1 C - 4 0 0 A utom atic Transmission, Side Cross S ectio n-T ypical OVERHAUL MANUAL...
  • Page 289 A U T O M A T IC TR A N S M IS S IO N S (4 0 0 )7 A-3 MODULATOR VALVE Fi g. 7 A - 2 C - T r a n s m i s s i o n in H o l d i n g F i x t u r e VACUUM MODULATOR D IS A S S E M B L Y OF M A J O R U N IT S F ig .
  • Page 290 (4 0 0 )7 A-4 A U TO M A TIC TR A N S M IS S IO N S STRAINER ASSEMBLY in t a k e PIPE LOCATOR TABS Fi g . 7 A - 8 C ~ R e m o v i n g F i l t e r A s s e m b l y a n d " O " R in g Fi g .
  • Page 291 A U T O M A T IC T R A N S M IS S IO N S (400)7A -5 C O N T R O L V A L V E F i g . 7 A - 1 0 C - - R e m o v i n g C o n t r o l V a l v e A s s e m b l y a n d G o v e r n o r P i p e s f r o m C a s e F ig .
  • Page 292 (400)7A -6 A U TO M A TIC TR A N SM IS S IO N S TORQUE WRENCH T O RQ UE WRENCH J-2 1370-6 J -2 1 3 7 0 -6 * * * Fi g. 7 A - 1 5 C ~ C h e c k i n g R e a r B a n d A p p l y Pin , E x c e p t M o d e l s F ig .
  • Page 293 A U T O M A T IC TR A N S M IS S IO N S (4 0 0 )7 A-7 Fi g. 7 A - 2 0 C - R e m o v i n g F r o n t S e r v o P i s t o n , R e t a i n e r R i n g , a n d F i g .
  • Page 294 (4 0 0 )7 A-8 A U T O M A TIC TR A N SM IS S IO N S RETAINING SPRING SHAFT F ig . 7 A - 2 5 C ~ R e m o v i n g P a r k i n g S h a f t R e t a i n i n g S p r i n g 5.
  • Page 295 A U T O M A T IC T R A N S M IS S IO N S (4 0 0 )7 A-9 DIAL I N D I C A T O R F i g . 7 A - 2 7 C - - R e m o v i n g R e a r O i l S e a l f r o m C a s e E x t e n s i o n J-8001 Removal of Rear Oil Seal and Case Extension Fi g .
  • Page 296 (400)7A -10 A U TO M A TIC TR A N SM IS S IO N S F i g . 7 A - 3 3 C ~ R e m o v i n g F o r w a r d C l u t c h A s s e m b l y a n d T u r b i n e S h a f t F i g .
  • Page 297 A U TO M A TIC TR A N S M IS S IO N S (4 0 0 )7 A -1 1 DIAL INDICATOR J-9539 Fi g. 7 A - 3 7 C - - C h e c k i n g R e a r U n i t E n d P l a y R E A R E N D W A S H E R T H IC K N E S S Fi g .
  • Page 298 (4 0 0)7 A -12 A U TO M A TIC TR A N SM IS S IO N S F i g . 7 A - 4 0 C ~ R e m o v i n g I n t e r m e d i a t e B a c k i n g P l a t e a n d C l u t c h P l a t e s 11.
  • Page 299 A U T O M A T IC TR A N S M IS S IO N S (4 0 0 )7 A -1 3 CENTER SUPPORT I TO CASE SPACER # LOCATE SPACER GAP ADJACENT TO * BAND A N C H O R PIN Fi g.
  • Page 300 (400J7A-14 A U TO M A TIC TR A N S M IS S IO N S SNAP RING ROLLER CLUTCH ASSEMBLY REACTION CARRIER GEAR PLASTIC GEAR RING Fi g. 7 A - 5 0 C - - R e m o v i n g O u t p u t S h a f t t o C a r r i e r S n a p R i n g OUTPUT CARRIER 9.
  • Page 301 A U T O M A T IC T R A N S M IS S IO N S (4 0 0 )7 A -15 SPEEDOMETER DRIVE GEAR CLIP F ig . 7 A - 5 4 C - l n s t a l l i n g S p e e d o m e t e r D r i v e G e a r C l i p Fi g .
  • Page 302 (4 0 0)7A -1 6 A U TO M A TIC TR A N S M IS S IO N S F ig . 7 A - 5 7 C ~ G o v e r n o r ~ E x p l o d e d serviced as a com plete assembly.
  • Page 303 A U TO M A TIC TR A N S M IS S IO N S (400J7A-17 Fi g. 7 A - 6 0 C ~ R e m o v i n g G o v e r n o r G e a r R e t a i n i n g Pin Fi g .
  • Page 304 (400)7A -18 A U TO M A TIC TR A N SM IS S IO N S Fig. 7 A - 6 1 C ~ F r o n t S e r v o A s s e m b l y - E x p l o d e d V i e w Front Servo Parts Inspection Rear Servo Assembly See Fig.
  • Page 305 A U T O M A T IC TR A N S M IS S IO N S (4 0 0)7 A -1 9 RETAINING “ E” RING SERVO PISTON ACCUMULATOR PISTON W A SH ER SERVO SPRING SERVO OIL SEAL OIL SEAL RING SPRING RETAINER SERVO PIN...
  • Page 306 (400J7A-20 A U TO M A TIC TR A N SM IS S IO N S Inspection NO TICE: See Fig. 7A -66C . D o not rem ove the teflon oil seal ring from the front accum ulator piston unless the oil seal ring requires replacement.
  • Page 307 A U TO M A TIC TR A N S M IS S IO N S (400)7A-21 M O D E L S C J, & C G — 1 1 1 I | 3 » i CjjjJijj 3=3; *» mmioam 1 4 1 5 M O D E L S C P , C C &...
  • Page 308 (400)7A -22 A U TO M A TIC TR A N SM IS S IO N S P U M P D R IV E G E A R ( T A N G S P U M P D R IV E N PU M P G E A R B O D Y...
  • Page 309 A U TO M A TIC TR A N S M IS S IO N S (400)7A -23 VENT CONVERTER LINE COOLER RETURN PUMP COVER COOLER INTAKE SEAL DRAIN BACK HOLE REVERSE FOR ID E N T IF IC A T IO N - SQUARED OFF PRESSURE DRIVE REG, BOSS.
  • Page 310 (400)7A -24 A U TO M A TIC TR A N SM IS S IO N S RETAINING PIN BORE PLUG PRESSURE REGULATOR VALVE- PRESSURE REGULATOR SPACER SPRING RETAINER W ASHER-i PRESSURE REGULATOR SPRING PUMP COVER THRUST WASHER PRESSURE BOOST VALVE PRESSURE BOOST BUSHING PUMP OIL SEAL RINGS SNAP RING...
  • Page 311 A U T O M A T IC T R A N S M IS S IO N S (400J7A-25 PUMP COVER PUMP BODY 5. Install boost valve into bushing, stem end out, and install both parts into pum p cover by com pressing bushing against spring.
  • Page 312 (400)7A -26 A U TO M A TIC TR A N SM IS S IO N S 1980 CLUTCH APPLICATION CHART 400,475 FO R W A RD CLUTCH D IR E C T CLUTCH IN T E R M E D IA T E CLUTCH FLA T STEEL NO.
  • Page 313 A U T O M A T IC TR A N S M IS S IO N S (400)7A -27 BOLT TURBINE SHAFT F ig . 7 A - 8 2 C ~ R e m o v i n g T u r b i n e S h a f t f r o m F o r w a r d C l u t c h H o u s i n g Fi g.
  • Page 314 (400)7A -28 A U TO M A TIC TR A N SM IS S IO N S 3. Inspect clutch hubs for worn splines, proper lubrication holes or scored thrust faces. 4. Inspect piston for cracks. 5. Inspect clutch housing for wear, scoring, open oil passages and free operation o f ball check.
  • Page 315 A U TO M A T IC TR A N S M IS S IO N S (400)7A -29 FORWARD CLUTCH ASSEMBLY FLAT STEEL FORWARD DIRECT SNAP CLUTCH HUB RING PLATES (4) CLUTCH HUB WAVED STEEL PLATE COMPOSITION PLATES (5) THRUST WASHERS Fig.
  • Page 316 (4 0 0)7 A -30 A U TO M A TIC TR A N SM IS S IO N S FORW ARD CLUTCH ASSEM BLY FORW ARD CLUTCH H O U S IN G SNAP RING PUM P ASSEM BLY Fi g.
  • Page 317 A U T O M A T IC T R A N S M IS S IO N S (400)7A-31 F i g . 7 A - 9 4 C - - R e m o v i n g o r I n s t a l l i n g D i r e c t C l u t c h S n a p R i n g F i g .
  • Page 318 (400J7A-32 A U TO M A TIC TR A N SM IS S IO N S 3. Inspect clutch housing for cracks, wear, proper opening o f oil passages or wear on clutch plate drive lugs. 4. Inspect com position-faces and steel clutch plates for sign o f wear or burning.
  • Page 319 A U T O M A T IC T R A N S M IS S IO N S (400)7A -33 FOR IDENTIFICATION— CHAMFER FOR IDENTIFICATION DIRECT CLUTCH HOUSING DIRECT CLUTCH HOUSING FOR 4 OR 5 PLATE PACK FOR 6 PLATE CLUTCH PACK F ig .
  • Page 320 (400)7A -34 A U TO M A TIC TR A N S M IS S IO N S INTERMEDIATE CLUTCH ROLLER ASSEMBLY DIRECT CLUTCH B A C K IN G PLATE FLAT STEEL PLATES C O M P O S IT IO N PLATES W A V E D STEEL PLATE DIRECT CLUTCH H O U S IN G Fi g.
  • Page 321 A U TO M A TIC TR A N S M IS S IO N S (400)7A -35 Fi g . 7 A - 1 1 OC --I n s t a 1 1 i n g I n t e r m e d i a t e C l u t c h R e t a i n e r S n a p R in g 13.
  • Page 322 (4 0 0)7 A-36 A U TO M A TIC TR A N SM IS S IO N S INTERMEDIATE CLUTCH RELEASE SPRING (3) Fi g. 7 A - 1 1 3 C - - R e m o v i n g I n t e r m e d i a t e C l u t c h P i s t o n S n a p Fi g.
  • Page 323 A U T O M A T IC TR A N S M IS S IO N S (4 0 0)7 A -37 INTERM EDIATE CLUTC Inspection (Fig. 7 A -1 1 8 C ) 1. Inspect roller clutch inner race for scratches or indentations.
  • Page 324 (4 0 0)7 A -38 A U TO M A TIC TR A N S M IS S IO N S F i g . 7 A - 1 2 1 C - l n s t a l l i n g I n t e r m e d i a t e C l u t c h P i s t o n CLUTCH INNER SEAL F i g .
  • Page 325 A U T O M A T IC TR A N S M IS S IO N S (400)7A -39 I N T E R M E D I A T E C L U T C H RELEASE S P R I N G ( 3 ) Fi g .
  • Page 326 (4 0 0)7 A -40 A U TO M A TIC TR A N S M IS S IO N S T he reaction carrier w ith the undercut and spacer ring is used optionally and interchangeably w ith the reaction carrier w hich does not have an undercut and spacer ring.
  • Page 327 A U T O M A T IC TR A N S M IS S IO N S (400J7A-41 using petrolatum to hold bearings in place. U se pinion pin P IN IO N PIN as guide (Fig. 7A -131C ). BRONZE W ASHER 7.
  • Page 328 (400)7A -42 A U TO M A TIC TR A N SM IS S IO N S 4. Inspect oil seal for damage. If replacement is required, proceed as follows: a. Pry oil seal from extension. b. A pply non-hardening sealer to outside o f new oil seal, and install oil seal into case extension using tool (J- 24057) (see Fig.
  • Page 329 A U T O M A T IC T R A N S M IS S IO N S (4 0 0)7A -43 R E T A I N I N G INSIDE D E T E N T L E V E R A S S E M B L Y P A R K I N G LOCK B R A C K E T PLUG...
  • Page 330 (4 0 0)7 A -44 A U TO M A TIC TR A N S M IS S IO N S If the case assem bly requires replacement, rem ove the nam eplate from the old case and re-install it on the new case, using the truss head nam eplate attaching screw that is serviced w ith the case.
  • Page 331 A U T O M A TIC T R A N S M IS S IO N S (400)7A -45 SNAP RING SPEED O M ETER DRIVE G EA R I.D. FLANGE RACE O.D. FLANGE RACE I.D. FLANGE RACE M A I N SHAF T OUT PUT CARRIER ASSEMBLY...
  • Page 332 (4 0 0)7 A -46 A U TO M A TIC TR A N SM IS S IO N S F ig . 7 A -1 4 3 C ~ l n s t a l l i n g R e a r I n t e r n a l G e a r t o S u n G e a r B e a r i n g a n d R a c e s a.
  • Page 333 A U TO M A TIC TR A N S M IS S IO N S (4 0 0 )7 A-47 S U N GEAR SHAFT I.D . FLANGED RACE THRUST BEARING I.D . FLANGED RACE F i g . 7 A - 1 4 6 C - l n s t a l l i n g F r o n t I n t e r n a l G e a r R i n g t o O u t p u t C a r r i e r Fig .
  • Page 334 (400)7A -48 A U TO M A TIC TR A N SM IS S IO N S ROLLER CLUTCH ASSEMBLY F ig . 7 A - 1 5 0 C ~ l n s t a l l i n g R o l l e r C l u t c h t o R e a c t i o n C a r r i e r 18.
  • Page 335 A U T O M A T IC T R A N S M IS S IO N S (400)7A -49 M CENTER SUPPORT S i ■ t o c a s e s p a c e r RETAINING mm i \ i SPRING «...
  • Page 336 (400)7A -50 A U TO M A TIC TR A N S M IS S IO N S SNAP RING BACKING PLATE COMPOSITION PLATES STEEL PLATES F i g . 7 A - 1 5 9 C ~ l n s t a l l i n g C e n t e r S u p p o r t t o C a s e S n a p R in g and locating gap adjacent to band anchor pin.
  • Page 337 A U T O M A T IC T R A N S M IS S IO N S (4 0 0 )7 A-51 F i g . 7 A - 1 6 3 C —I n s t a l l i n g F r o n t B a n d Fig.
  • Page 338 (400)7A -52 A U TO M A TIC TR A N SM IS S IO N S DIAL IN D IC A T O R J -8 0 0 1 Fi g. 7 A - 1 6 9 C - - C h e c k i n g F r o n t U n i t E n d P l a y Fi g.
  • Page 339 A U TO M A TIC T R A N S M IS S IO N S (4 0 0 )7 A -53 Fi g. 7 A - 1 7 3 C - - L o c a t i o n o f C h e c k B a I ls--l n V e h i c l e I n s t a l l a t i o n Fig.
  • Page 340 (400)7A -54 A U TO M A TIC TR A N SM IS S IO N S Locate feeler stock on edge of front servo I GUIDE PINS, piston so front accumulator oiston can enter bore GASKET FRONT # IS SERVO •...
  • Page 341 A U TO M A TIC T R A N S M IS S IO N S (400)7A -55 Fi g. 7 A - 1 7 9 C - C h e c k i n g R e a r B a n d Pin F ig .
  • Page 342 (4 0 0)7 A -56 A U TO M A TIC TR A N SM IS S IO N S G O VERNO R SCREEN ASSY. G OVER NO R FEED PIPE HOLE Fig. 7 A - 1 8 5 C —I n s t a l l i n g D e t e n t R o l l e r a n d S p r i n g A s s e m b l y Fi g.
  • Page 343 A U TO M A TIC TR A N S M IS S IO N S (400)7A -57 M odels CB, C K and CZ use a m odulator that is different than the m odulator used on the other models. Refer to parts catalog book for correct usage.
  • Page 344 (4 0 0)7 A-58 A U TO M A TIC TR A N SM IS S IO N S SPECIFICATIONS TORQUE SPECIFICATIONS Pump Cover B o l t s ........... 18 ft. lbs. Parking Pawl Bracket B o l t s ........18 ft. lbs. Center Support B o lt ..........23 ft.
  • Page 345 A U TO M A T IC TR A N S M IS S IO N S (4 0 0 )7 A-59 J -6 116-01 Rear Unit Holding Fixture J -2 1795-2 Part of Above Holding Tool J-8092 Driver Handle J-5384 Converter Holding Strap J -2 1359...
  • Page 346 (4 0 0)7 A -60 A U TO M A TIC TR A N SM IS S IO N S J-8763 Transmission Holding Fixture J-21664 Clutch Spring Compressor J-3289-14 Holding Fixture Base Adapter Ring J-21427-1 Speedo Gear Remover Clutch Spring Compressor J-4670 J-9539 Side Hammer Bolts (3 /8 "...

  • Page 347: Manual Transmission

    M A N U A L TR A N S M IS S IO N 7B-1 SECTION 7B MANUAL TRANSMISSION CONTENTS 3-Speed 76m m T ransm ission..........7B-1 4-Speed 117mm T ransm ission........... 7B-35 3-Speed 77m m T ransm ission..........7B-9 Specifications................7B-48 4-Speed 76m m T ransm ission..........7B-17 Special T o o ls ................
  • Page 348 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 Clutch G ear 1st Speed G ear S n ap R in g -B e a rin g C lutch G ear Bearing 3 1 .

  • Page 349: Front And Rear Bearings

    M A N U A L TR A N S M IS S IO N 7B-3 F i g . 7 B - 2 A ~ R e m o v i n g C l u t c h G e a r B e a r i n g R e t a i n i n g R i n g F i g .

  • Page 350: Clutch Bearing Retainer Oil Seal

    7B-4 M A N U A L T R A N S M IS S IO N Fig. 7B-6A-Removing Reverse Idler Shaft Fig. 7B-8A-Rem oving Rear Bearing Retaining Ring R EPA IR S Clutch Keys and Springs Extension Oil Seal or Bushing R ep lacem e nt If bushing in rear o f extension requires replacement, T he clutch hubs and sliding sleeves are a selected...
  • Page 351 M A N U A L TR A N S M IS S IO N 7B-5 J-21426 F i g . 7 B - 1 2 A - l n s t a l l i n g R e a r E x t e n s i o n S e a l F i g .
  • Page 352 7B-6 M A N U A L TR A N S M IS S IO N 8. Install synchronizer hub to mainshaft snap ring. Be sure the notches o f the blocker ring align w ith the keys o f the synchronizer assembly.
  • Page 353 M A N U A L TR A N S M IS S IO N 7B-7 2. Place countergear assembly through case rear 7. Place extension to case gasket at rear o f case holding opening along w ith a tanged thrust washer (tang away from in place with grease and, from the rear o f case, assemble the clutch gear, m ainshaft and extension to case as an assembly.
  • Page 354 7B-8 M A N U A L TR A N SM IS S IO N Snap Ring Bearing Retainer Bolts and Washers (4) Thrust Washer Synchronizer Ring Fro nt Bearing Retainer Countergear Shaft 2-3 S v nch ro n izerSI eeve Bearing Retainer Gasket Countergear Shaft Key Synchronizer Key Spring...
  • Page 355 M A N U A L TR A N S M IS S IO N 7B-9 3 SPEED 7 7 M M TRANSMISSION INDEX Overhaul O perations.............7B-9 R epairs..................7B-14 Transmission D isassem bly..........7B-9 Synchronizer K eys and Spring........7B-14 M ainshaft D isassem b ly............7B-12 Extension Oil Seal or B u sh in g ........7B-14 Cleaning and In sp ection ..........
  • Page 356 7B-10 M A N U A L TR A N SM IS S IO N 1. M AIN SH A FT ROLLER BEARINGS 36. EXTENSION HOUSING TO CASE GASKET 2. 2ND ft 3R D SYNCHRONIZER R ETA IN IN G RING 36.
  • Page 357 M A N U A L TR A N SM IS S IO N 7 B -1 1 N O T E : A L IG N R O L L P IN H O LE W H E N IN S T A L L IN G R E A R F IL L...
  • Page 358 7B-12 M A N U A L TR A N SM IS S IO N T U R N R A IL 9 0 F i g . 7 B - 7 B - R e m o v i n g F r o n t B e a r i n g Fi g .
  • Page 359 M A N U A L TR A N S M IS S IO N 7B -13 SPRING' O - RING FIRST-REVERSE UNDER LIP OF LOCATION SLEEVE AND GEAR K E Y S RETAINING SNAP RING Fig. 7 B -1 1 B— S h ift Fork Shafts FIRST-REVERSE Front and R ear Bearings SYNCHRONIZER...

  • Page 360: A Ssem Bly O F M Ainsh Aft

    7B-14 M A N U A L TR A N SM IS S IO N Fi g . 7 B - 1 5 B - l n s t a l l i n g E x t e n s i o n H o u s i n g B u s h i n g Fi g .
  • Page 361 M A N U A L T R A N S M IS S IO N 7B-15 TABBED THRUST WASHER (SHARP EDGE MUST FACE OUT) Fig. 7B-1 8 B -ln s ta llin g T abbed T hrust W asher Fig.
  • Page 362 7B-16 M A N U A L TR A N SM IS S IO N J-2 44 33 Fig. 7 B -2 1 B -ln s ta lla tio n Sequence - Detent Plugs and Fig. 7 B -2 2 B -ln s ta llin g Front Bearing S prings 6.
  • Page 363 M A N U A L TR A N S M IS S IO N 7B-1 7 23. Install large snap ring on front bearing. 24. Install front bearing on clutch gear shaft by hand drive bearing on clutch gear shaft using tool J-24433 (Fig. 7B-22B).
  • Page 364 D r i v e G e a r 2 n d S p e e d B l o c k e r E x t e n s i o n 2 7 . C o u n t e r g e a r T h r u s t W a s h e r - F r o n t B e a r i n g R e t a i n e r R in g...

  • Page 365: Transmission Case

    M A N U A L T R A N S M IS S IO N 7B-19 PULL MAIN DRIVE GEAR f o r w a r d F i g . 7 B - 4 J - - R e m o v i n g E x t e n s i o n t o R e a r B e a r i n g S n a p R i n g F ig .
  • Page 366 7B-20 M A N U A L TR A N S M IS S IO N F i g . 7 B - 6 J - R e m o v i n g R e v e r s e I d l e r G e a r S h a f t Gears 1.
  • Page 367 M A N U A L TR A N SM IS S IO N 7B-21 Fig. 7B-10J--Rem oving 1st and 2nd Synchronizer Snap Ring Fig. 7B-1 2 J-E x te n sio n Bushing R eplacem ent for the synchronizer, the groove is at the same end as the fork slot.
  • Page 368 7B-22 M A N U A L TR A N SM IS S IO N . Install synchronizer hub to mainshaft snap ring (Fig. 7B-10J). SCREWDRIVER 9. Install a blocker ring with notches downward so they align with the keys of the synchronizer assembly.
  • Page 369 M A N U A L TR A N S M IS S IO N 7B-23 Drive Gear Bearing F irst Speed Gear Drive Gear T hrust Washer M ainshaft P ilot S pring Washer Bearings Rear Bearing 3-4 Synchronizer Speedo Drive Gear AssenL»ly M ainshaft...
  • Page 370 B earing R etainer T hrust W asher-Front 3rd Speed B lo cker Gasket-Extension to D etent S pring G asket-R etainer to Gear 3-4 D etent Cam Ring Case 1-2 D etent Cam Case Needle Retainer 3rd Speed Gear Snap Ring-Extension 3-4 S h ifte r S haft Oil Seal...
  • Page 371 M A N U A L T R A N S M IS S IO N 7B-25 MAIN DRIVE GEAR Fig. 7 B -2 0 J -L o a d in g M ainsh aft Bearings Fig. 7B-1 9 J -lo a d in g C ountergear Bearing 4-SPEED 8 3 M M T R A N S M IS S IO N IN D E X Disassembly of Transmission........
  • Page 372 14 15 16 1 Clutch G ear Bearing Retainer 12 1st & 2nd Speed Clutch Assy. 23 Thrust W asher 2 Retainer Lip Seal 13 1st Speed Synochronizer Ring 2 4 Thrust W asher 3 Snap Ring and W asher 1 st Speed G ea r 25 Idler Shaft Roll Pin 4 Clutch G ear Bearing...
  • Page 373 M A N U A L TR A N SM IS S IO N 7B-27 23. First and Second Speed 6 3 . C o u n tersh aft 4 4 . Rear B earing R etainer To 1. B earing R etainer Clutch Sliding Sleeve 6 4 .
  • Page 374 7B-28 M A N U A L TR A N SM IS S IO N Fig, 7B -3K -R em oving Reverse S hifte r S ha ft Lock Pin Fig. 7B -5K -R em oving Reverse Gear 13. Shift first-second and third-fourth clutch sliding and synchronizer assembly, and the second gear (Fig.
  • Page 375 M A N U A L TR A N SM IS S IO N 7B-29 2. Blow out bearings with compressed air. NOTICE: Do not allow the bearings to spin. Turn them slowly by hand. Spinning bearings may damage the race and balls. REPA IRS S ynchronizer Keys and Springs R eplacem ent...
  • Page 376 7B-30 M A N U A L TR A N SM IS S IO N Fig. 7B -9K -R em oving 3-4 Clutch A ssem bly Retainer Fig. 7B-1 1K -R em oving Rear Bearing Snap Ring Coat I.D . of bushing and seal with transmission 4.
  • Page 377 M A N U A L TR A N SM IS S IO N 7B-31 SPRING SLEEVE 7B-1 3 K -S yn ch ro n ize r Assem bly F ig . Reverse Idler Shaft Replacement J—21 1. Place a small punch into hole in extension’s reverse idler shaft boss and drive the welch plug and pin into the shaft (Fig.
  • Page 378 7B-32 M A N U A L TR A N SM IS S IO N SLEEVE O-RING O-RING f lW W I SPRING 1-2 SH IFTER SHAFT ! ^ K B A L L B A L L 3.4 SH|F T E R SHAFT F ig .
  • Page 379 M A N U A L T R A N S M IS S IO N 7B-33 1ST GEAR R E A R BEARING F ig . 7 B - 2 2 K ~ l n s t a l l i n g R e a r B e a r in g F ig .
  • Page 380 7B-34 M A N U A L TR A N SM IS S IO N USE SEALER O N THIS BOLT F ig . 7 B - 2 3 K ~ l n s t a l l i n g F r o n t M a in B e a r in g F ig .
  • Page 381 M A N U A L T R A N S M IS S IO N 7B-35 4-SPEED 1 1 7 M M T R A N S M IS S IO N IN D E X Drive Gear Bearing Retainer Oil Seal..... 7B-39 Disassembly of Transmission........
  • Page 382 7B-36 M A N U A L TR A N SM IS S IO N M a in D riv e G e a r R e v e rs e D riv e n G e a r M a in s h a f t R e a r 3 7 .
  • Page 383 R ear R e ta in e r G asket 1 st-2nd Speed 2 6 . 2 n d Speed Gear 3 7 . S nap R ing 4 8 . D rive Gear Bearing S y n c h ro n iz e r H u b 3 rd Gear Bushing 3 8 .
  • Page 384 7B-38 M A N U A L TR A N SM IS S IO N R E V E R SE 3RD/4TH 1 S T /2 N D F ig . 7 B - 5 L - - C o v e r A s s e m b ly 5.
  • Page 385 M A N U A L TR A N S M IS S IO N 7B-39 Transm ission Cover 3rd -4th S hifter Fork Interlock Plunger Interlock Balls ”C" Ring Lock Clip Spring 3rd -4th S hifter S haft Reverse S hifter Fork Reverse In terlo ck Reverse S hifter S haft S hifter S haft Hole...
  • Page 386 7B-40 M A N U A L TR A N SM IS S IO N nd speed synchronizer hub. Split 2nd speed gear bushing with chisel and remove bushing from shaft. Exercise care not to damage mainshaft. Inspection 1. Wash all parts in cleaning solvent. REVERSE 2.
  • Page 387 M A N U A L TR A N SM IS S IO N 7B-41 F ig . 7 B - 1 0 L - R e m o v i n g D riv e G e a r B e a r in g 5.

  • Page 388: A Ssem Bly O F T Ransm Ission

    7B-42 M A N U A L TR A N SM IS S IO N C O U N T E R S H A F T A S S E M B L Y Disassembly 1. Remove front countergear retaining ring and thrust washer.
  • Page 389 M A N U A L TR A N S M IS S IO N 7B-43 2 n d S p e e d B lo c k e r 1 3 . 4 t h S p e e d B lo c k e r 1 s t S p e e d G e a r 1 0 .
  • Page 390 7 8 4 4 M A N U A L TR A N SM IS S IO N J-22873 1ST GEAR BUSHING I F ig . 7 B -1 5 L - - D is a s s e m b ly o f M a i n s h a f t J-22873 2ND GEAR BUSHING...
  • Page 391 M A N U A L TR A N S M IS S IO N 7B-45 J - 2 2 8 3 2 F ig . 7 B -1 L—In s t a llin g 3 r d S p e e d G e a r B u s h in g SPA CER F ig .
  • Page 392 7B-46 M A N U A L TR A N SM IS S IO N J-22873 J-22830 SNAP RING F ig . 7 B - 2 1 L—In s t a llin g C o u n t e r G e a r S n a p R in g F ig .
  • Page 393 M A N U A L TR A N S M IS S IO N 7B-47 J-23070 F ig . 7 B - 2 6 L - - ln s t a ll in g M a in s h a f t R e a r B e a r in g L o c k N u t ( 4 - W h e e l D riv e o n ly ) F ig .
  • Page 394 7B-48 M A N U A L TR A N SM IS S IO N SPECIFICATIONS T H R E E SPEED 76mm T H R E E SPEED 77mm C lutch G ear R e ta in e r to Case B o l t s ....15 ft.
  • Page 395 M A N U A L TR A N S M IS S IO N 7B-49 SPECIAL TOOLS 1. J -1 1 2 6 Transm ission G uid e Pins 7. J -1 45 3-01 S p eedo m eter D rive G ear Press Plates and R etainer Snap Ring Pliers 2.
  • Page 396 7B-50 M A N U A L TR A N SM IS S IO N J 2 3 4 3 2 1 S n a p R ing Picks J 2 3 4 3 2 S n a p R ing Pliers. J 8 0 9 2 H an d le .
  • Page 397 CLUTCHES 7C-1 S E C T IO N 7C CLUTCHES C O N T E N T S Single Plate Diaphragm Spring Clutch..........7C-1 Single Plate Coil Spring Clutch............7C-3 Special Tools..................7C-7 SINGLE PLATE D IA P H R A G M CLUTCH IN D E X Disassembly..................
  • Page 398 7C-2 CLUTCHES Fig. 7C-2A-Retracting Spring Location (Typical) D IS A S S E M B L Y (FIG. 7C -2A ) Fig. 7 C -3A-Clutch Pilot Bearing Removal (Typical) N O TIC E: When disassembling, mark edge of pressure plate and cover. These marks must be aligned in .
  • Page 399 CLUTCHES 7C-3 SINGLE PLATE COIL SPRING CLUTCH IN D E X Disassembly..................7C-3 Inspection..................... 7C-3 Assembly....................7C-3 Adjusting Levers.................. 7C-4 arrangement of springs. See Fig. 7C-3E. D IS A S S E M B L Y 4.
  • Page 400 7C-4 CLUTCHES F ig . 7 C - 3 E - D i s a s s e m b l y o f C lu t c h F ig . 7 C - 5 E - R e m o v i n g o r In s t a ll in g L e v e r into the groove in the lever, as shown in Fig.
  • Page 401 CLUTCHES 7C-5 EYEBOLT RELEASE LEVER STRUT F ig . 7 C - 7 E - l n s t a l l i n g L e v e r . Loosen the cover to flywheel bolts a turn or two at a time and in rotation until spring pressure is relieved to allow clutch and gauge plate to be removed.
  • Page 402 7C-6 CLUTCHES F ig . 7 C - 1 2 E - D e p r e s s i n g L e v e r F ig . 7 C -1 4 E - S t a k i n g N u t...
  • Page 403 CLUTCHES 7C-7 SPECIAL TOOLS 1. J-6456-01 Height Gauge 2. J-1048 Gauge Plate 3. J -1522 Pilot Bearing Driver 4. J-2 37 20 Clutch Pilot Tool 5. J-1448 Pilot Bearing Puller F ig . 7 C -1 S T - C l u t c h S p e c ia l T o o ls O VE R H A U L M A N U A L...

  • Page 405: Transfer Case

    TRANSFER CASE 7E-1 S E C T IO N 7E TRANSFER CASE C O N T E N T S Model 205 (Part Time) Transfer Case......... 7E-1 Specifications................... 7E-8 Special Tools................... 7E-9 MODEL 2 0 5 (PART T IM E )T R A N S F E R CASE IN D E X Disassembly of Transfer Case..
  • Page 406 7E-2 TRANSFER CASE . Remove shift forks and sliding clutch from case. POPPET NUTS 7. Remove the front output high gear, wahser, and SHIFT RAIL bearing from the case. Remove the shift rail cup plugs and LINK pins from the case. Inpu t S h a ft Assem bly .
  • Page 407 TRANSFER CASE 7E-3 45 44 43 414241 In p u t S h a ft R e a r B e a rin g Id le r G e a r S h a ft B e a rin g 4 3 .
  • Page 408 7E-4 TRANSFER CASE RANGE SHIFT RAIL 4-WHEEL SHIFT RAIL S N A P R IN G SHIFT RAIL F ig . 7 E - 7 R - - S h if t R a il R e m o v a l F ig .
  • Page 409 TRANSFER CASE 7E-5 S lid in g C lutch C o ve r G aske t Rear O u t p u t S h a ft L o c k n u t Rear C ov er W a s h e r In p u t S ha ft T r a n s fe r Case F r o n t O u t p u t S h a ft L o c k n u t...
  • Page 410 7E-6 TRANSFER CASE FRO NT O U TP U T BORE J-8092 J-9276-2 IDLER G EAR ASSEMBLY F ig . 7 E - 1 0 R--I n s ta 1 1 i n g N e w B e a r in g C u p s F ig .
  • Page 411 TRANSFER CASE 7E-7 F ig . 7 E - 1 4 R - - ln s t a ll in g Id le r S h a f t R e a r C o v e r 9. Install yoke, washer, and lock nut output shaft. Position range rail in ’high’...

  • Page 412: Specifications

    7E-8 TRANSFER CASE SPEEDOMETER GEAR SPACER REAR OUTPUT LOW GEAR CLUTCH GEAR F ig . 7 E -1 R -- ln s ta llin g R e a r O u t p u t S h a f t S p a c e r a n d S p e e d o m e t e r G e a r F ig .
  • Page 413 TRANSFER CASE 7E-9 SPECIAL TOOLS 1. J - 2 2 8 3 6 - F ro n t O u tp u t S h a ft Bearing R eta in er Seal In staller 2. J -2 2 3 8 8 - Rear O u tp u t S h a ft Seal In staller 3.
  • Page 415 METRIC AND FASTENER IN FO R M A TIO N 10-1 S E C T IO N 10 METRIC & FASTENER INFORMATION USE OF METRIC AND CUSTOMARY NUTS, BOLTS AND SCREWS Some of the 1980 model cars present special service requirements to the technician due to the use of both metric and customary (inch) type nuts, bolts and screws on the same car.
  • Page 416 10-2 METRIC A N D FASTENER INFO RM A TIO N REUSE OF PREVAILING TORQUE NUT(S) A N D BOLT(S) PREVAILING TORQUE BOLTS ARE THOSE BOLTS WHICH PREVAILING TORQUE NUTS THOSE NUTS WHICH INCORPORATE A SYSTEM TO DEVELOP AN INTERFERENCE INCORPORATE A SYSTEM TO DEVELOP AN INTERFERENCE BETWEEN BOLT AND NUT OR TAPPED HOLE THREADS.
  • Page 417 METRIC A N D FASTENER IN FO R M A TIO N 10-3 M E T R IC B O LT A N D N U T ID E N T IF IC A T IO N Common metric fastener strength property classes are 9.8 and 10.9 w ith the class identification embossed on the head of each bolt.
  • Page 418 SI METRIC-CUSTOMARY CONVERSION TABLE to get equivalent to get equivalent Multiply Multiply number of: number of: ACCELERATION LENGTH meter/sec2 (m/s2) millimeters (mm) 0.304 8 Foot/sec2 Inch 25.4 0.025 4 meter/sec2 meters (m) Inch/sec2 Foot 0.304 8 meters 0.914 * Yard TORQUE kilometers (km)
  • Page 419 METRIC A N D FASTENER IN FO R M A TIO N 10-5 D E C IM A L A N D M E T R IC E Q U IV A L E N T S Metric Decimal Metric Fractions Decimal Fractions...
  • Page 425 UNITED STATES BUSINESS REPLY CARD FIRST CLASS PERMIT N O . 30 2 WARREN, M ICHIGAN POSTAGE WILL BE PAID BY ADDRESSEE CHEVROLET MOTOR DIVISION GENERAL MOTORS CORPORATION 30007 VAN DYKE AVE. WARREN, MICHIGAN 48090 NO POSTAGE NECESSARY IF MAILED...
  • Page 426 1980 CHEVROLET SERVICE MANUAL (PLEASE TYPE OR PRINT CLEARLY) □ Suggestion □ Error Date_ M anual No. a n d Title Section an d Page No. Name. .Title. Dealership Company_ .Zone. Address. .City & State. _Zip Code. 1980 CHEVROLET SERVICE MANUAL...

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