Chevrolet 40 60 Series Overhaul Manual
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Chevrolet 40 60 Series Overhaul Manual

Chevrolet 40 60 Series Overhaul Manual

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40-60 SERIES TRUCK
SUPPLEM EN T
ST 334-72

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  • Page 1 40-60 SERIES TRUCK SUPPLEM EN T ST 334-72...
  • Page 2 This manual should be kept in a handy place for ready reference. If properly used, it w ill enable the technician to better service the owners o f Chevrolet built vehicles. A ll information, illustrations and specifications contained in this literature are based on the latest product information avail­...

  • Page 3: Index

    NOTE: It may be necessary to drive this unit from On all axles except 13,500 lb., loosen ring gear thrust carrier. Use brass d rift against pilot end of pinion. pad locknut and remove thrust pad. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 4 Front Pinion Bearing D ifferential Side Gear D iffere ntial Drive Pinion D ifferential C ase-Left C ase-R ight Half Half Rear Pinion Bearing Fig. 1G--11,000 lb. Capacity A xle-C ross Section CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 5 (Left Half) D iffere ntial Case Pinion Bearing Assem bly D ifferential Spider Axle Shaft (Right Half) Fig. 2G--13,5 00, 15 ,000 and 17 ,000 lb. C apacity A xle-C ross Section CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 6 J-6203-six tooth pinion. J-2225-seven tooth pinion. Pinion Inspection Wash all parts in cleaning solvent. Inspect pinion for scored, cracked, chipped or worn Fig. 4G~Pinion Rear Bearing Removal (1 1,000 Lb. Axle) teeth. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 7 . Slide oil seal retainer on pinion shaft, then tap drive flange onto pinion splines. Clamp drive flange in a bench vise and install flange Fig. 8G--Pinion Oil Seal Installation (Typical) CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 8 Lubricate differential side gears, pinions and thrust washers. Place differential pinions and thrust washers on spider. Assemble side gears and pinions and thrust washers to Fig. 12G --Differential Case Line-Up Marks left half of differential case. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 9 .003" loosen the left hand adjusting nut one Install differential assembly in carrier and install ad­ notch and tighten right hand nut one notch. justing nuts. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 10 (fig. 19G). Fig. 1 7G -G ear Tooth N om enclature HEEL CONTACT CORRECT TOE CONTACT TOOTH CONTACT FACE CONTACT FLANK CONTACT Fig. 18G--Gear Tooth C ontact Patterns CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 11: Table Of Contents

    Swing the propeller shaft the upper holes to keep carrier aligned with housing. to one side and tie it to the frame side rail. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 12 Pinion A d ju s tin g Nut Lock D ifferential Side Gear Pinion and Bearing D iffe re n tia l Carrier (Right) (Left) Retainer Fig. 1J-Two-Speed Axle Cross Section CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 13 D ifferential Pinion Sun Gear Pinion Interm e dia te D iffe re n tia l Bearing D iffe re n tia l B aring P inion R etaining Nut D iffe re n tia l and Plane Shaft A d ju s tin g N ut and Oil Cap (Left) and W ashe r Bearing...

  • Page 14: Disassembly

    Remove differential bearing adjusting nut lock from and intermediate bearing cups from the retainer (fig. each nut and remove locks from both sides. 9J). CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 15: Inspection

    W ash all m etal p arts thoroughly in cleaning sol­ Replace defective parts as required. vent and dry with air. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 16: Reassembly

    Tool J-22283 (fig. 17J). Press the seal into the bore until it bottoms against internal Fig. 1 2J--Removing Pinion Interm ediate Bearing Using shoulder. J -2 2 3 0 7 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 17: D Ifferential And P Lanet

    Position pinion rear bearing into carrier bore and install in the same relative position; then remove the sun gear bearing so that it seats against stop, using Tool J-22303 and planet gears. and Driver Handle J-8092 (fig. 18J). CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 18: Inspection

    Replace all damaged or excessively worn parts includ­ (Fig. 21J). ing mating parts where necessary. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 19: Reassembly

    Make sure thrust washer is in position at bottom of case. Align and install the differential and planet support case, using the alignment marks previously scribed in Fig. 2 4 J — Installing D ifferential Bearing Caps disassembly procedures. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 20: Ring Gear And Pinion Adjustment

    Fig. 2 6 J -M e a s u rin g Pinion Rotating Torque Fig. 2 8 J -T ig h te n in g D ifferential Left A d ju s tin g N ut Using D rift CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 21: Checking Pinion D Epth

    . Fill axle with lubricant to a level even with bottom of to-ring gear so that clearance is .03" to. .09"-torque filler hole, using lubricant meeting the requirements retaining bolts to specifications. specified in Section 0 Truck Service Manual. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 22 Inspect splines of pinion shaft for excessive wear. CAUTION: Exercise care that differential side bear­ Inspect pinion for scored, cracked, chipped or worn ing cups (7) are not dropped in removing assembly teeth. from housing. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 23 B olt Flat W asher Cap Screw Shims D ifferential Bearing Pinion Bearing Cage Cone (LH) D ifferential Case Lock W asher (Plain Half) Fig. 1K~Exploded V iew o f Eaton Single-Speed CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 24 This information w ill be used in deter­ Differential Inspection mining the approximate thickness of shim pack to be used w ith the new pinion. Wash all parts thoroughly in cleaning solvent. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 25 Check differential bearings and cups for broken races, run-out exceeds limits listed in "Specifications" discoloration or roughness. remove differential assembly and check for cause. . Inspect differential case for cracks or distortion. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 26 1 . Drain lubricant and remove axle shafts. See Truck Ser­ cover. vice Manual "Axle Shaft Removal and Installation, Ea- Remove two stud nuts retaining shift unit to carrier and ton Single Speed". pull unit from carrier. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 27: Differential C Arrier

    S upport Case Nut Lockw ire Idle r Pinion Pinion Bearing Spacer S h ift Fork S ha ft Bushing High-Speed Clutch Plate Fig. IL -E a to n Two-Speed Axle CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 28: Disassembly

    Clutch Gear and Sh ift Fork-Removal Remove shims (53) noting quantity and thickness for Remove shift fork seal (44) and spring (45). Note that use at assembly. Wire shim pack together. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 29: Repairs

    Check the support case for run-out. If run-out exceeds screws (14). D iffe re n tia l Thrust W asher Thrust W asher B-SIDE GEAR THRUST WASHER A-SUPPORT CASE THRUST WASHER REMOVAL REMOVAL Fig. 4L— D ifferential Disassem bly CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 30: Differential Assem Bly

    Planetary Unit-Assem bly Place support case thrust washer (11) in right-hand support case; then position differential assembly in case. Fig. 6L-R em oval and Installation of Com panion Flange CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 31 Power Divider Section covering shift fork shaft. Fig. 8L--Bearing A dju stin g Lock Service Replacement Fig. 7L~Checking End Play, Using Dial Ind icator CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 32 Remove Propeller shaft at input and output shafts. carrier, or the cover assembly and differential carrier Hold flanges with holding Tool J-3453 or J-8478, then assembly may be removed as a unit: CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 33 REAR AXLE DIFFERENTIAL CARRIER 4-31 LOCKOUTS AIR-OPERATED VACUUM-OPERATED Fig. lM -F orw ard Rear Axle Assembly-Exploded View (See legend on next page) CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 34: Differential Carrier Cover

    (fig. 4M). Tap cover to loosen and pull removed, lift the sliding clutch and the fork and push cover assembly from dowels on differential carrier. rod assembly out of cover. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 35: Vacuum Operated Differential Lockout

    If lockout shift components have not been removed, slip the sliding clutch out of shift fork and remove clutch from cover. © Fig. 4M--Removing D ifferential Carrier Cover Bolts Fig. 3M ~Rem oving Input S haft Flange Nut CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 36 Fig. 5M~Removing Helical and D ifferential Side Gear and " Fig. 6M -R em oving Input Shaft Assem bly Fig. 7M~Rem oving Inter-Axle Lock Out S h ift Lever Fig. 8M -R em oving S hift Spring, Fork and Clutch CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 37: Air Operated Differential Lockout

    Shift Cylinder B od y Shift Fork Fig. 10M~Removal or Installation of A ir O perated Lockout Piston Fig. 12M ~ A ir O perated Lockout S h ift Com ponents CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 38: Repairs

    Support bearing on split plates and, using brass rod between threaded end of shaft and ram of press as Fig. 14M~Push Rod Oil Seal Installed shown in Figure 17M, press shaft out of bearing. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 39: A Ssem Bly

    "D" washer remains in position, and install wire snap ring (fig. 5M). Fig. 17M ~Removing Inter-Axle D ifferential from Carrier CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 40: Differential C Arrie R

    If rear bearing is to be replaced remove inner race from ing, press bearing tight against back of gear. shaft. Start new bearing inner race straight on shaft and, Fig. 19M--Removing Pinion S haft Helical Gear CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 41: Inter-Axle Differential

    Fig. 2 2 M -ln s ta llin g Pinion Gage Bearing Cup w ith Tool Fig. 2 1 M -ln s ta llin g O utput S haft Bushing Using Tool J-8 4 7 6 J-8479 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 42: Ring Gear And Differential Assembly

    Remove snap ring retaining bearing in cover as shown in Figure 27M, and tap bearing out rear of Fig. 2 4 M ~ ln sta llin g Pinion S haft End Nut cover. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 43 Fig. 29 M ~ ln sta llin g O utput S haft Bearing Race W ith Tool Fig. 27M --Rem oving O utput S haft Bearing Snap Ring J-6419-1 and -2 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 44: Gear Backlash

    Bearing C ag e Spring Scale Fig. 3 1 M -C h e c k in g Pinion Bearing Pre-Load Fig. 32M ~C hecking Backlash 40-60 CHEVROLET TRUCK SERVICE M A N U A L...
  • Page 45 Pour a liberal quantity of rear axle lubricant on gears and point. Further shim changes may be necessary to obtain the bearings and revolve gears to distribute lubricant to all sur­ correct setting. faces. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 46 Pinion Front Bearing Remover Plate 9. J-6171 Pinion Front Bearing Remover Plate J-1439 Pinion Front Bearing Remover Plate Fig. 1T~Special Tools, 1 1 ,000 Through 1 7 0 0 0 Lb. C apacity Single Speed CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 47 Drive Handle J-3 4 5 3 Pinion Yoke Bar Fig. 2 T -S p e cia l T o o ls -1 5 0 0 0 and 17 00 0 Lb. Two-Speed CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 48 Slide Hammer J -84 79 Bearing Cup Installer J -3 4 5 3 Pinion Flange H olding Bar J-3941 D iffere ntial Case S upport Fixture Fig. 3T -E aton Special Tools CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 49 Fig. ID -B e n d ix Single Diaphragm Hydrovac CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 50 Turn rim of diaphragm back and, still maintaining pres­ sure with your stomach, use both hands and snap ring Fig. 4 D - Disassem bly o f Push Rod and Piston CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 51 If two cups are used, install them on piston assembled, install nut (7) (if nu t is undercut, install back to back. Then assemble piston, washer ( ) and u ndercut side first) and tighten to 160-200 in. lbs., CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 52 S n ap R ing Pliers, rem ove snap ring (2) fro m rod. groove inside bore o f end plate. Slide retainer ring (12) out of groove in piston (10) and CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 53 Diaphragm and Center Sh e ll (Fig. 8D) Clamp nut (12) on end of shaft in vise and remove nut Fig. 8D -D isassem bly of D iaphragm and Center Shell Assem bly CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 54 ) and install end cap, securely tight­ screws up, guide center shells and diaphragm assembly ened, in cylinder. ) onto end of push rod, seating push rod in seat in end CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 55 When air in system reaches maximum pressure for which The air compressor crankshaft turns continously while the governor is set, air passes through governor into unloader engine is running. Actual compression of air, however, is CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 56 35 U nloader S pring Seat 23 P iston Pin L ockw ire 11 Oil Seal Ring 24 Piston 12 T h ru s t W asher Fig. 1G~Air Com pressor (Typical) CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 57 Remove two cap screws securing the air strainer to All of these parts should be marked before disassembling, to compressor. assure proper positioning at assembly. Refer to figure 1G for Remove air strainer assembly. cross-section of complete compressor assembly. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 58 C ylin d e r Head R em oval and D isa sse m b ly Remove all cylinder head cap screws, then lift off cylin­ Fig. 6G ~Unloader Assem bly Com ponents CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 59 T h r u s t Remove cap screws securing cylinder block to crankcase, then remove cylinder block and cylinder block gasket. Dis­ Fig. 8G ~Crankshaft Bushing Installed (Gear Drive) card gasket. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 60 Insp ectio n Cylinder Head Inspect cylinder head for cracks or breaks. Replace with new head if cracked or damaged. Fig. 9G -M ea surin g C ylinder Bore Diam eter CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 61 If looseness is evident, replace connecting rod bushings as directed under "Compressor Repair." Discard Fig. 12G--Piston Ring A rrangem ent and clearances 7 1 /4 cu. all piston pin lock wires. ft. Com pressor CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 62 0.145", nor be second is not permissible. If leakage is excessive, leave less than ". air pressure applied. Using a fiber or a hardwood dowel 1 0 1 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 63 Insert crankshaft through end cover opening in crank­ bearing cap from N o.l connecting rod. case. Position rear thrust washer on crankshaft with oil grooves toward shoulder on shaft. NOTE: Stagger ring gaps 120 degrees from each other CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 64 57 In se rt Bearing Discharge Valve Seat Tube A ssem bly G asket 52 Main In sert Bearing 58 Connecting Rod Fig. 15 G -A ir Com pressor Com ponents CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 65 Make certain that saddle rests squarely on top of plunger guides, and make sure top of spring engages spring seat pressed into cylinder block. Fig. 17G ~A lignm ent of Piston Pin and Piston Lockw ire Holes CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 66 Carefully align inlet valve springs with inlet valve guides in cylinder head. Align marks made before disas- Fig. 2 1 G -ln s ta lla tio n of Lockw asher and B olt on Connecting Rod and Cap CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 67 Refer to Fig. 2 5 G with these compressors, has a piston upon which air pressure Reservoir air pressure enters the governor at one of its acts to overcome the pressure setting spring and control the CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 68 Use a suita­ ble sleeve; press new filters in governor body ports. . Inspect all air passages in ports for obstructions Fig. 25 G -T yp e D-2 G overnor C utaw ay CHEVROLET OVERHAUL M AN U AL...
  • Page 69 Operating Test Start the engine and build up air pressure in system. Fig. 2 7 G -A d ju s tin g Screw M easurem ent CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 70 If compressor is to be tested after overhaul, then DO NOT During the above test the compressor should be checked install air strainer until after compressor test. for oil leakage and noisy operation. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 71 To test governor setting on the service floor, run the vacuum connections or passages behind the slave engine up to governor specifications Adjust governor unit. as necessary. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 72 • Remove pump diaphragm screws and lift cleaning purposes. If part replacement is required, pump housing, diaphragm and spring from fuel bowl. proceed as follows: CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 73 Inspect holes in all operating levers and castings for excessive wear. Inspect bearing surfaces of all shafts for excessive clear­ ance. It is not necessary to remove shafts and plate to inspect. Fig. H1~H olley 4150G Carburetor CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 74 ID L E A IR B L E E D I ID L E FE E D RESTRIC TIO N I RESTR IC TIO N < 1 W E L L ID L E TRANSFER PASSAGE ID L E DISCHARGE PASSAGE ID L E ADJUSTING/T| JfO A...
  • Page 75 Check filter element for restriction by blowing on cone Inspect all mating surfaces of fuel bowl, carburetor CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 76 Install idle speed screw and spring. Install accelerator pump cam on throttle lever. Invert fuel bowl allowing float to drop to the fully Assemble and install pump operating lever assembly. closed position. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 77 Seat-Fuel Valve, Assem bly S pring-A ctuating Rod " 0 " Ring-Fuel Valve Seat Screen-Filter Fuel Inlet Retainer-Actuating Rod Spring Fig. H5~Fuel Bowl and M etering B lock-E xploded V iew CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 78 T H R O T T L E P L A T E S C L O S E D ) C H A M B E R Fig. H8--Secondary Control Valve O peration (at Governed Speed) CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 79 NEEDLE PUMP DISCHARGE SECONDARY NOZZLE OPERATING COVER GASKETS SCREW Fig. H10~Pum p Discharge Needle Assembly Fig. H 9-S eco nda ry T h ro ttle O perating and Control Assem bly CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 80 119 TH R U 123, SERVICED SEPARATELY (UNLESS OTHERW ISE NOTED). # SERVICEABLE ONLY AS PART OF A CO M PLETE ASSEM BLY Fig. H 1 1--Holley Model 4 150G--Exploded View CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 81 Retainer-Vent Valve Rod Spring Shaft-Throttle 130. A ir Cleaner-Control Valve B ushing-Throttle Shaft Not Shown. (a) Serviceable Only as Part of a Complete Assembly - (b) Serviceable Only as Part of a Complete Assembly. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 82 Any movement of spring, then install fuel bowl retaining screws with new the throttle lever should be noticed at operating lever gaskets under heads and tighten securely. spring end, indicating correct pump tip-in. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 83 L O C K S C R E W THROTTLE OPERATING HOUSING PLATE PRIMARY THROTTLE THROTTLE CONNECTING THROTTLE SHAFT SHAFT Fig. H 16--Secondary T hrottle Stop Screw Fig. H 1 4--Governor Control Linkage CHEVROLET OVERHAUL M A N L A L SUPPLEMENT...
  • Page 84 SCREW Fig. H 17 - A ir V en t Valve A djustm en t Fig. H18~Fast Idle A djustm en t Fig. H 19~A ccelerator Pump A djustm en t CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 85 J-1 0 1 7 6 Fast Idle W rench bbl.) J-2 2 9 7 3 Ther-Mac Therm om eter J-5 1 9 7 U nloader Bending Fig. H20~Engine Fuel Special Tools CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 87 Be sure testing equipment is in good working order an assembly. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 88 Fig. 3C --6.2” Series 2D D e lc o tro n Brush H o ld e r Assem bly Fig. 2C --6 .2 ” Series 2 D D e lc o tro n Assem bly CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 89 If lamp lights in windings are open. both directions or fails to light at all, the diode is defective. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 90 CAUTION: Do not heat excessively, and avoid bend­ ble, if not previously done during disassembly. ing or moving diode stem as excessive heat and CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 91 Remove pin and attach terminal cover with two screws, Install retainer plate. Use new retainer plate if felt seal making sure leads are not caught underneath the cover. is hardened or excessively worn. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 92 FRAM E ASSEMBLY RO TOR ASSEMBLY DIODES SLIP RINGS GREASE RESERVOIR BALL BEARIN G DRIVE SLIP RING STATOR DIODES END FRAME FRAME ASSEMBLY Fig. 10C--130 Am p Series 4D, Type 150 Delcotron CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 93 Connect the ohmmeter leads at each diode as previously Refer to Specifications or appropriate service bulletin. described using a test lamp first in one direction and then the CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 94 DIODE LEAD CAUTION: Use only 60% tin, 40% lead rosin core solder or equivalent with 360 degrees F. melting point. Do not hold soldering iron on diode lead Fig. 14C--Cutting Diode Lead CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 95 CAUTION: To prevent damage to brush units, physi­ cally lift brushes away from the slip rings. NOTE: Torque shaft nut to 60 lb. ft. Install the four frame through bolts. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 96 >47- - k > u "■ •, ■ ■ m . i < »i i iin I'll ......II . I...
  • Page 97 Anti-R attle Spring Driven Discs C lutch Cover Release Yoke A d ju s tin g Nut Front Pressure Plate Coil S pring Release Lever l-B olt Fig. 1E-2-Plate Clutch C ross-S ection CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 98 Inspect pressure plate and flywheel for scores on the Release Lever Eyebolt S trut Fig. 5E-R em oving Levers (Step 2) Fig. 3E--Disassembly o f Clutch CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 99 10E) being sure that the anti-rattle springs are in correct position and also that the punch marks made before Release Lever Eyebolt S trut Fig. 7E— Installing Lever Fig. 9E --lnstalling Anti-R attle Spring CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 100 Turn adjusting nut until lever is flush with proper step of height gauge. Adjust remaining levers in same man­ ner. The height gauge (insert) has three steps for use Fig. 11E --D rive S trap Assem bly Fig. 13E--Depressing Lever CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 101 Countershaft ..............7-11 Subassembly Operations..........Disassembly..............7-11 Transmission Cover............. Assem bly.................7-11 Disassembly..............Reverse Idler Gear B ushings.........7-11 Assem bly..............Assembly of Transm ission..........7-11 Clutch Gear and Bearing.......... Disassembly..............Transmission Cover Installation........7-12 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 102 Remove countershaft front bearing outer retainer and Place transmission in two gears at once to lock main­ gasket, cut inner bearing retainer bolt lock wire and CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 103 Step 2. pressed into position. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 104 . Depress lock pin into recess in mainshaft, turn thrust SHIFTER FORK washer to clear splines on washer on mainshaft (fig. 2ND AND 3RD SHIFTER FORK Fig. 4N P-Rem oving Retaining r in Fig. 3NP~Removing Reverse Idler Shaft CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 105 NOTE: 2nd and 3rd sliding clutch must be posi­ tioned on mainshaft w ith the longer hub of the clutch rings internal gear toward the front end of Fig. 5NP--Shifter S haft Installation the mainshaft. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 106 Fig. 9NP~Removing T hrust W asher and 2nd Gear Fig. 7N P~M ainshaft Pilot Bearing CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 107 Install mainshaft rear bearing outer retainer snap ring on bearing and install bearing on mainshaft and in bore in case. Install clutch bearing outer retainer snap ring on clutch Fig. 10NP~Selecting Proper Retainer Ring CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 108 Remove cotter pin and nut from rear of out of case. Remove snap ring, and using Tool J-1619, mainshaft and pull brake drum and flange from shaft. pull bearing from shaft as shown in Figure 3R. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 109 Reverse Idler Gear Bearing 2nd and 3rd S hift Speedom eter Drive T hrust W asher Snap Ring Gear Fork Main Drive Gear Bearing Cap Oil Seal Fig. 1R~Spicer 5-Speed Transm ission CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 110 Slush bearings in solvent until all old lubricant is loos­ ened. Hold bearing races so bearings will not rotate; Fig. 3R~Remove Idler Gear Shaft then brush bearing with a soft bristled brush until all CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 111 Remove inner plunger pin from first-and-reverse shifter lever (fig. 7R) and, if control lever housing of first-and- reverse shifter lever is to be replaced, remove nut and Fig. 5R~Spicer Hopping Guard CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 112 C O N T R O L L E V E R H O U S I N G S T U D Fig. 7R~Removing Inner Plunger Pin Fig. 9R ~Shifter S haft and Fork Installation CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 113 Remove synchronizer hub snap ring from shaft. 4th & 5th SHIFTER FORK 4th & 5th SHIFTER SHAFT Fig. 1 1 R-Removing Interlock Pin Fig. 13R --lnstalling 4th and 5th S hifter Fork CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 114 4th & 5th 2n d S P E E D SPEED G E A R SYNCHRONIZER 1st & REVERSE GEAR MAINSHAFT Fig. 15R --M ainshaft Assem bly Fig. 17R--Removing Synchronizer Hub (Step 1) CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 115 2nd and 3rd gear spacer. Align 4th speed gear (4) with key and press gear on the countershaft. Install 4th gear snap ring (3) in groove of Fig. 20R --lnstalling 4th Speed Gear Sleeve countershaft. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 116 Place thrust washer on forward end of countershaft assembly and lower assembly into case, with rear of shaft through rear bore in case. J-5740 J-358-1 Fig. 22R ~lnstalling C ountershaft Drive Gear Fig. 23R~Removing Clutch Gear Bearing CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 117 Install transmission cover gasket and cover assembly. NOTE: When assembling a close ratio model, the Install propeller shaft brake band and levers. clutch gear can not be installed from the front of the CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 118 Fig. 25R -5-S peed Transm ission Gear Details and Relative Parts Fig. 2 6 R ~ lnstallin g C ountershaft Front Bearing Spacer Fig. 2 7 R— Installing C ountershaft Rear Bearing CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 119 (fig. 5N). Remove bolt and lock washer assemblies; then remove R em oval (Fig. 2N) countershaft rear bearing cap and gasket. Discard gas­ Remove control top or remote control assembly. ket. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 120 (fig. Raise front end of mainshaft to clear case, then remove Pry countershaft to the rear to expose rear bearing and the mainshaft assembly. remove snap ring from bearing. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 121 Remove 3rd speed gear retainer ring, 3rd speed gear and locating washer. Remove 2nd and 3rd synchronizer assembly, 2nd and 3rd shift hub sleeve retainer ring and hub sleeve (fig. 14N). Fig. 2N--Cover Explode CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 122 7-26 T R A N SM ISSIO N A N D CLUTCH Fig. 3N~Transm ission A ssem bly-E xploded View CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 123 Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry Remove 4th and 5th shift fork roll pin, shaft rod and bearings using moisture- free compressed air. Be careful to fork. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 124 Parts should remain in solution cleaners. Fig. 5N~Removing Rear Bearing Cap Fig. 7N--Removing M ain Drive Gear CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 125 Replacement of all parts show­ cloth or paper to protect them until installed. Fig. 1 1N -Rem oving C ountershaft Rear Bearing Fig. 9N~Rem oving Reverse Idle r Shaft CHEVROLET OVERHAUL M A N U A L SUPPLEMJNT...
  • Page 126 Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks, or scores. If gear teeth show spots Fig. 13N~Removing 4th and 5th S hift Hub Sleeve Retainer Ring Fig. 15N-Rem oving 2nd Gear Retainer Ring CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 127 Fig. 19 N— I nsta 1 1 i ng 4th and 5th S hift Fork Rod Roll Pin Fig. 17N--Removing 2nd and 3rd S h ift Fork Roll Pin CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 128 3rd shift rods (fig. 20N). to prevent loosening (fig. 16N). Fig. 2 1 N— Installing C ountershaft Front Bearing Fig. 2 3 N ~ lnstallin g 3rd Speed Gear and W asher CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 129 Tip rear of countershaft down and into transmission retainer ring. Fig. 26 N ~ ln sta llin g C ountershaft Rear Bearing Fig. 24 N ~ lnstallin g 4th and 5th S hift Hub Sleeve CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 130 NOTE: Countershaft drive gear must be supported Fig. 28 N —Insta llin g Pilot Bearing Fig. 3 0 N -M a in s h a ft Rear Bearing Installation CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 131 Reverse Idler Gear Installation ........ Main Drive Gear and B earing........741 Mainshaft Installation..........Cleaning and Inspection...........741 Cleaning................741 Shifter Bar Housing Installation ......74 7 Inspection .................743 Control Tower Installation........7 4 7 Repairs..................743 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 132 49. 2nd Speed Gear Retainer Washer 16. Poppet Spring 33. Reverse Idler Gear 50. 2nd Speed Gear Snap Ring 17. Poppet Ball 34. Reverse Idler Gear Bearings Fig. 1 P-Transm ission Cross-Section CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 133 M ainsha ft 2nd Speed M ainsha ft 4th and 5th Speed Gear Gear Reverse Idle r Gear S ynchronizer Assy. M ainsha ft 3rd Speed Gear Fig. 2P ~Transm ission~Shift Bar Removed CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 134 Dust Cover S up po rt S pring Control Tow er Top G earshift Lever Pivot Pins Fig. 4P~Removing Reverse Idler Shaft Fig. 6P~Control T ow e r and G earshift Lever CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 135 Plunger S pring 1st-3rd S h ift Rod Interlo ck Balls Lock Screws 1 st-Reverse Rocker W elch Plugs Interlo ck Cross Pin Fig. 7 P—Shift Bar H ousing-Exploded V iew CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 136 Remove gearshift lever support spring and support spring washer. Push gearshift lever out through bottom of control Fig. 9P--1st and Reverse S h ift Lug and Latch Plunger tower top. Remove Shift Lever pivot pins. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 137 4th speed gear locating washer from shaft. When this manual; then wrap each bearing in clean paper bushing is removed the locating pin will come off shaft. until ready to install in transmission. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 138 7-42 T R A N SM ISSIO N A N D CLUTCH Fig. lO P -T ransm ission Exploded View CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 139 Check keys and key ways for condition. lowed: Inspect shift forks for wear, distortion, or other dam­ Install main drive gear and bearing assembly in transmission case. age. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 140 Slide bearing rollers and cage from plas­ To insure a proper tight stack-up between the 4th speed tic sleeve into bearing pocket. gear locating washer, 4th speed gear bushing sleeve, 4th CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 141 Move shift rod into "Neutral" position. Install 2nd and 3rd shift rod, shift fork, and shift lug in Fig. 12P~Slecting 4th Speed Gear V ariable Thickness Retainer housing as follows: W asher CHEVROLET OVERHAUL M A N U A L...
  • Page 142 IMPORTANT: Oil return hole in bearing cap must Position dust cover on gearshift lever. line up w ith oil hole in transmission case. Install gearshift lever knob. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 143 Remove countershaft front bearing cup from case. seal and speedometer driven gear in cap, then remove Remove power take-off covers, and filler plug from oil seal and speedometer driven gear from cap and case. sleeve. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 144 C ountershaft 2nd S h ift Housing (Cover) M ainshaft Rear Speed Gear Snap Bearing Cone Retainer Cap Assy. Rings Seal Cap Fig. 1 F -A u x ilia ry Transm ission Cross-Section CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 145 A S S E M B L Y OF S U B A S S E M B L IE S Handle Countershaft Gears and Bearings Drive gear keys in countershaft slots, then using arbor Fig. 2F~Pressing M ainshaft O ut of Case CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 146 . Install mainshaft rear bearing cap and gasket on rear of bottom hole of cover, being careful not to damage oil case with cap screws and washers. Tighten cap screws seal. firmly. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 147 Remove shift rods and apply a light coat of grease to tate drive gear and check shifting of both rods to make all case bores and rods as they are assembled. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 148 . Remove mainshaft and gear assembly by lifting front of Move drive gear bearing spacer (9) aside and use drift shaft upward and out through top of case. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 149 (29) bearing cones. Remove countershaft drive gear snap ring (30). Support Wash all parts dry and examine thoroughly before as­ countershaft drive gear (31) with parallel bars as close sembly. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 150 . Assemble snap ring (9) to lock drive gear in place. When in doubt about which end of the hub to assemble on Observe note following Step 4. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 151 Use a soft hammer to tap front (12) and rear (13) roller around 2nd and 4th speed gear. bearing cups into bearing bores of case and over cones After adjustment is made, remove rear bearing cap and on countershaft. CHEVROLET OVERHAUL M A N U A L...
  • Page 152 Bearing Spacer S linger Flange Drive Gear Rear Bearing Snap Drive Gear Front Bearing Drive Gear Bearing Cap Ring G asket Figure 8 F -M a in Drive Gear and Bearing Details CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 153 Drive Gear (Figure 8F) Install shift rods, shift forks and cover as outlined under shift controls assembly. Position drive gear bearing cap (1) in press, rear bearing CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 154 Valve, Control - Install ........7-100 7-85 Valve, Control - O verhaul........7-73 Roller Clutch ........ 7-85 Valve, Control - Remove ........7-61 Output Carrier ......7-87 Valve, Modulator - Install ........7-101 Major Units ........CHEVROLET OVERHAUL M A N U A L...
  • Page 155 OUTPUT CARRIER AND FORWARD CLUTCH GEAR UNITS DIRECT CLUTCH INTERMEDIATE CLUTCH OUTPUT SHAFT REAR BAND MAINSHAFT REAR SERVO UNIT PUMP FRONT SERVO UNIT TURBINE SHAFT CONTROL VALVE Figure — Transmission Cross Section CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 156 DiscardO -ring. Figure 3 — R em oving M o d u la to r R etainer Figure — R em oving G o ve rn o r C over CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 157 Figure 7 — R em oving O il Pan A tta c h in g Screw s Figure 10— R em oving C ontrol V alve and G o v e rn o r Pipes CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 158 Figure 12— R e m o v in g R ear S e rv o C o v e r CHEVROLET OV ERH A U L M A N U A L SUPPLEMENT...
  • Page 159 Figure 15— R em oving D etent Solenoid and Gasket Figure 16— R e m o v in g Electrical Connector a n d O -R in g CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 160 SERVO SPRING RETAINER SPRING Figure 18— Rem oving Front Servo Piston R etainer Ring a n d Pin Figure 2 0 — C ose Extension a n d Sea l CHEVROLET O VERHAU L M A N U A L SUPPLEMENT...
  • Page 161 Black .126 - .130 Purple Figure 2 2 — R em oving Pump Assem bly Figure 2 4 — R em o vin g Direct Clutch A sse m b ly CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 162 Figure 2 6 — R e m o v in g Detent L e ve r an d Jam N ut lected from the following chart: from M a n u a l Shaft CHEVROLET O VERHAU L M A N U A L SUPPLEMENT...
  • Page 163 Figure 2 9 — R em oving C enter S upp ort to Case B olt Figure 31— R em o vin g Center Support to C ase Sn ap Ring CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 164 NOTE: One race may have been removed with center support. Figure 3 5 — R em o vin g Center Supp ort Thrust W asher Figure — R em oving S elective W asher CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 165 Install speedometer gear removing tool Figure 3 7 — R em oving Sun G e a r Figure 3 9 — R em o ving Speedom eter D rive G e a r CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 166 2. Inspect governor sleeve for nicks, burrs, scoring or galling. 3. Check governor sleeve for free operation in bore of transm ission case. 4. Inspect governor valve for nicks, burrs, CHEVROLET OVERHAU L M A N U A L SUPPLEMENT...
  • Page 167 Figure 4 5 — R e m o v in g G o ve rn o r G e a r Retaining Pin CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 168 3. Remove rear servo piston and seal from band apply pin (fig. 49). 4. Remove washer, spring and retainer. Figure 4 8 — R em oving R etainer fro m R ear S ervo Pin CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 169 Figure 5 0 — Installing Tool to R e m o v e Front tor piston valve and remove retaining ring (fig. 50). A ccum u la to r Piston Retainer CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 170 17 2-3 Shift Valve 26 Bore Plug 1-2 Detent Valve 18 3-2 Intermediate Spring 27 Retaining Pin Figure 5 2 — C ontrol V a lve A ssem bly Components CHEVROLET O VERHAU L M A N U A L SUPPLEMENT...
  • Page 171 Figure 5 7 — Installing Pressure R egulator Figure 5 5 — R e m o v in g R egulator V a lv e S n a p Ring Retaining Pin a n d Bore Plug CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 172 15. Inspect selective washer thrust face for wear or damage. Figure 5 9 — Identification o f O il P assag e s in P um p B o d y CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 173 Figure 6 2 — Installing Pump C o v e r to Pump B ody Figure 6 4 — R e m o v in g Fo rw a rd Clutch H u b a n d Thrust Washers CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 174 (green) into pockets in piston. SNAP RING R ETA IN ER 4. Place spring retainer and snap ring on springs. Figure 6 6 — Rem oving F o rw a rd Clutch Spring Snap Ring CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 175 8. Place forward clutch hub into forward clutch Figure 7 0 — Installing F o rw a rd Clutch Composition an d Steel Plates Figure 6 9 — Installing F o rw a rd Clutch Piston CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 176 Figure 7 3 — R em oving D ire ct C lutch B acking Plate Snap Ring Figure 7 5 — R em o vin g Direct Clutch Piston A sse m b ly CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 177 Install a new inner clutch piston seal on piston with lip facing away from spring pockets (fig. 77). Figure 7 9 — Installing Direct Clutch Center Sea l Figure 7 7 — Installing D irect Clutch Inner Seal CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 178 (fig. 85). DIRECT CLUTCH FORWARD CLUTCH Figure 81— F o rw a rd and D irect Piston Identification Figure 8 3 — Installing Intermediate S p ra g to Direct Clutch CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 179 Figure 8 5 — Installing Intermediate Clutch Retainer Figure 8 8 — Center Supp ort O il S e a l Rings Figure 8 6 — Installing R etainer Snap Ring CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 180 TEFLON OIL SEAL RING INTERMEDIATE CLUTCH OUTER SEAL INTERMEDIATE CLUTCH PISTON INTERMEDIATE CLUTCH SPRING RETAINER CAST IRON OIL SEAL RINGS Figure 9 0 — C enter S upp ort Assem bly Components CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 181 C LU TC H P IS T O N CENTER SUPPORT Figure 9 5 — C hecking Pinion End P lay Figure 9 3 — Installing Interm e diate Clutch Piston CHEVROLET OVERHAU L M A N U A L SUPPLEMENT...
  • Page 182 . Figure 9 7 — R em oving Planet Pinion Pin Figure 9 9 — Installing Planet Pinion Pin CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 183 3. Inspect ground bushing journals for damage. Modulator and Valve Inspect modulator assembly for any signs 4. Inspect snap ring groove for damage. of bending or distortion (fig. 101). 5. Be sure oil lubrication holes are open. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 184 2. Make sure intermediate clutch cup plug hole (fig. 103) is free of foreign material such as dirt, chips, etc. Figure 102— M a n u a l Shaft Components CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 185 (J-21465-8) with driver CAUTION: D r ill only to the depth of handle (J-8092). 2. Installation. Using installer tool (J-21465-8) the o rig in a l hole. adapter ring (J-21465-9), driver handle (J-8092), CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 186 21/64 5/16-18 UNC-2B 5/16-18 STI-NC Valve Body to Case A - l l 17/64 1/4-20 UNC-2B 1/4-20 STI-NC Solenoid to Case A-12 and A-13 17/64 1/4-20 UNC-2B 1/4-20 STI-NC CHEVROLET O VERHAU L M A N U A L SUPPLEMENT...
  • Page 187 Install dial indicator (J-8001) and set it at zero, while its plunger rests on the cap nut of tool (J-21381-8) (fig. 104B). Figure 1 0 5 — A ir C hecking Converter CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 188 CARRIER ASSEM BLY S U N G EAR ASSEM BLY S U N GEAR SHAFT I.D. FLA N G E RACE Figure 106— R ear Unit Assem bly Components CHEVROLET O VERHAU L M A N U A I, SUPPLEMENT...
  • Page 189 Figure 1 0 8 — Installing R e a r Internal G e ars to Sun G e a r Figure 110— Installing Output Shaft B ea rin g an d R a ce s CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 190 Figure 113— Installing Center Supp o rt to Sun G e a r Figure 116— Installing Center Supp ort to Reaction Thrust B ea rin g a n d R aces C arrier Thrust W asher CHEVROLET O VERHAU L M A N U A L SUPPLEMENT...
  • Page 191 BAND ANCHOR PIN Figure 1 2 0 — Positioning Center Support to C o se S p a ce r Figure 118— Installing Case to O u tp u t Shaft Thrust Washer CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 192 X" Dia. rod to seat seal. b. Install manual shaft through case and detent lever. Figure 122— Installing Case to C enter S upp ort Bolt CHEVROLET O VERHAU L M A N U A L SUPPLEMENT...
  • Page 193 Set dial indicator to zero. f. Pull turbine shaft forward. Read resulting travel or end play which should be 0.003''-0.024”. Selective washer controlling this Figure 125— Checking Front U nit End Play CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 194 7. Install front servo spring and spring re ­ tainer into transm ission case. Figure 12 8 — Installing Control V a lv e S p a c e r Plate a n d G asket CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 195 FE E LE R S T O C K — L/se Figure 130 o f F e eler Stock to Retain Front Servo G ro up Figure 131— Checking Rear B and Pin CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 196 Figure 133— Installing R ear S ervo C over and Gasket Figure 1 3 6 — Installing Control V a lv e a n d G o ve rn o r Pipes CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 197 1. Install speedometer driven gear (fig. 138). attach pan to case with attaching screw s. Torque 2. Install speedometer driven gear retainer and attaching bolt. Torque bolt to 6-8 foot-pounds. to 11-13 foot-pounds. CHEVROLET OVERHAU L M A N U A L SUPPLEMENT...
  • Page 198 Clutch Pilot Tool J-1 4 4 8 J-7 8 1 6 Release Lever A djusting Tool Pilot Bearing Puller J -5 8 2 2 Ball Type Pilot Bearing Remover Fig. 1ST-C lutch Special Tools CHEVROLET OVERHAUL M A N U A L...
  • Page 199 J-0 3 5 8 (J-358-1) Press Plate Holder J-2671 T hird Speed Gear Bushing J-1 4 8 8 Rear Bearing Retainer Oil Seal Installer Driver J-77 85 Oil Seal Installer Fig. 2ST--New Process Transmission CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 200 Bearing Installer J-0 9 9 6 J -81 07 (TR-278-R) D ifferential Side (J-996) Bearing Remover Bearing Remover J -5 7 4 0 Bearing Remover Fig. 3ST--Spicer Transm ission Special Tools CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 201 J -1 6 1 9 M ainshaft Bearing Remover J -6 3 8 2 Reverse Idler Gear Shaft Remover J -6 4 1 9 Bearing Installer Set Fig. 4ST~Clark Transm ission Special Tools CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 202 Converter Air Checking Tool and Installer J-21369-6 J-22182 Case Extension Bushing Remover J-21370-6 Band Apply Pin Selection Gauge and Installer J-21370-9 J-22619 Speedometer Drive Gear Remover J-21371-3 Converter End Play Checking Fixture J-21'371-8 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 203 Slide counter-clockwise a few turns. the adjuster screw and shim out of the slot in the end Place a pan under the assembly to catch the lubricant of the pitman shaft. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 204: Steering G Ear

    C O V E R SEAL SHIM LASH ADJUSTER S C R EW Fig. 2-S te e rin g G ear-T A 50-60 M odels w ith 7 0 0 0 Lb. Axle CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 205: Repairs

    On all except Tilt models with 9000 lb. axle, check fit of the pitman shaft in the housing and side cover bushings. The housing bushings can be replaced; however, if the side cover Fig. 4--Removing Pitman Shaft A ssem bly-Typical CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 206: Pitman Shaft Bushing Replacement

    Figures 1 and 2. against the stamped identification side of the bearing. SIDE C O V E R NEEDLE PULLER Fig. 6-R eplacing Needle Bearing in Housing Fig. 7-R em oving Side Cover Needle Bearing CHEVROLET OVERHAUL MANUAL SUPPLEMENT...

  • Page 207: Wormshaft Bearing Replacement

    The lash adjuster retainer is tack-welded in the end of the adjuster plug. Fig. 8-R em oving Expansion Plug and Lower Bearing C u p -T yp ica l Fig. 10-Lash A djuster Screw Installation CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 208: Ball Nut Servicing

    Fig. 1 2—Filling Ball Guides Fig. 13-R em oving and Replacing Ball Guide CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 209: Assem Bly

    A djuster Plug Balls Lash A djuster Ball Nut Fig. 14--Steering G ea r-T ypical o f 40-60 Series (Except T ilt M odels w ith 9 0 0 0 lb. Axle) CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...

  • Page 210: Adjustment On Bench

    Tighten the locknut to 30 ft. lbs. torque Screw the adjuster in until it bottoms, back it off 1/8 and again check torque reading through center of to 1/4 turn and tighten the locknut. travel. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 211 Thrust Plate 7. End Plate 23. Shaft Seal Dowel Pins 8. Springs 24. Shaft End Plate “ O " Ring Fig. 15 -P o w e r Steering Pump Exploded View CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 212 (fig. 19). driver, pry out the pitman shaft seal, being careful not Remove the top cover bolts and carefully withdraw the to damage the housing bore. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 213 2 0 . V a lv e B o d y R in g Fig. 1 7~Power Steering Gear and Valve (Typical) Fig. 18~Removing A d ju ste r Plug Assem bly Using Tool J -7 6 2 4 Fig. 19--Removing Valve Assem bly CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 214 Remove the thrust bearing as ou- RETAINING RING NEEDLE BEARING BACK-UP WASHER ADJUSTER PLUG SEAL Fig. 21-R em oving A d ju ste r Plug Seal Retaining Ring Fig. 23--Removing Needle Bearing and Seal CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 215 Slide the spring off the stub shaft. Remove the valve spool with extreme care. CAUTION: The diametral clearance between the Fig. 25-R em oving Valve Spool CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 216 A slight polish is normal on the valve surfaces. Examine the valve body for nicks, burrs, or bad wear spots. If any are found, the entire valve assembly should Fig. 2 7 — Installing Valve Body Rings CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 217 Rotate the ball nut on the wormshaft; it must rotate CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 218 .063", .065", .067" and .069" thick. holes while turning the worm gradually away from the Start the adjuster into the side cover bushing, then with CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 219 MUST BE FULLY UNCOVERED VALVE ASSEMBLY I Fig. 3 4 -V a lv e Assem bly Properly Installed in Housing Fig. 3 2 —Installing Top Cover, W orm and Ball Nut CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 220 Clean and inspect the components using cleaning solvent posite end of the cylinder. and compressed air. Replace scraper assembly, "O" ring and Loosen the clamp on the outside of the socket and then seal with new parts. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 221 Install the ball seats at both ends of the power cylinder Install the scraper and "O" ring assembly in the guide and then thread the adjuster screws into the sockets. ("O" ring towards guide opening), being careful not to CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 222 ---------------------------- — — --------- ------------ ■ • >...
  • Page 223 7 / i 6 " - 2 0 ............ 1 1-1 8 Cap S c r e w - 5 / i6 " -2 4 6" - 1 8 ...............................130 -170 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 224 A D J U S T I N G NUT FT. LBS. A ll A xles Except C orp. H - 1 1 0 ............................50 C orp. H - 1 1 0 ................................... 75-100 L O C K NUT CHEVROLET OVERHAUL M A N U A L SUPPLEMENT ■[...
  • Page 225 Y O K E U - B O L T T O F R O N T A N D R E A R D I F F E R E N T I A L ( N U T ) ......................................40-55 ft. lbs. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 226 O p t........... 13 A " * A I I M odels w ith Optional S p lit B ra ke System have a M aster C ylin d er Bore. CHEVROLET OVERHAU L M A N U A L SUPPLEMENT...
  • Page 227 Lin in g T h ic k n e s s ............................5 / ie " 5 /l6 " / " Total Lin in g Area (S q . I n .) ........................ 67.5 85.0 4 1 .7 5 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 228 2 No. 59 Accelerator Pump Discharge Jet ......... No. 70 No. 70 Float Level ..................... 0.190 0.190 Accelerator Pump Travel ............. 0.420-0.450 0.420-0.450 * Excluding California Vehicles. * * California Vehicles Only. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 229 CS-40 With L6-292 Engine and Manual T ransm ission....1108360 CE/SE-50 With V8-366 Engine ............1108369 TE-50 With V8-366 Engine ............... 1108487 CE-60 (03-13); ME/TE-60 With V8-427 E n g in e......1108484 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 230 1114356_____________ 1114359_____________ 1114356_____________ 1115518 Rated Voltage ........ Current Consumption Pull-In Winding Amps..........13-15.5 13-15.5 13-15.5 26-29 V o lts ..........Hold-ln Winding Amps..........14.5-16.5 14.5-16.5 14.5-16.5 18-20 V o lts ..........CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 231 IGNITION SYSTEM SPECIFICATIONS 351 C ENGINE DISTRIBUTOR 250282 Delco-Remy Delco-Remy Delco-Remy Make ....................Delco-Remy Delco-Remy Delco-Remy 1110478 1111364 1112048 1111365 Model No..................1110489 1110486 Clockwise Rotation (Viewed at Roto r)..........Clockwise Clockwise Clockwise Clockwise Clockwise Point Opening (In.) 0.019 0.019 N e w ....................
  • Page 232 (b ) If Generator O u tp u t is checked w itho u t a Regulator, the O u tp u t should be 5 -1 0 % higher than the value given. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 233 0.010 (M in .) P oint O p en ing ( I n . ) ................0.015-0.025 Closing Voltage Range ........... Sealing V o ltag e..................1 1.0 M a x. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 234 (b ) Voltm eter not needed for Cold O u tp u t Check. Load Battery w ith a Carbon Pile to obtain M axim u m O u tp u t. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 235 Bottom Pan Attaching S crew s........12 ± 1 Neutralizer Switch Screws..........25 ± 10 Filter Retainer B o l t ............8 ± 2 Converter Dust Shield Screws........34 ± 15 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 236 ( 1 ) N O T E : A ll tapered ball studs m u st be clean and d ry. (2 ) Tighten as indicated, then tighten to next notch to insert cotter pin. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 237 1 7 0 ° F . W hen O p erating Pu m p at Idle Speed Against 665/735 P .S .I . Pressure. Pressure Relief Valve M in im u m P .S .I ....................................................................900 M a xim u m P .S .I ....................................................................1000 CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 238 150-180 (2) F-0 9 0 ; F - 1 1 0 ; F -1 2 0 Fro n t A x l e .......................... N u t 125 -15 0 (2) CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 239 ( 1 ) N O T E : All Tapered Ball Studs must be Clean and D ry . (2 ) Tighten N u t to Specified To rq u e , then Advance to N e xt Aligning Slot and Install a N e w Cotter Pin. CHEVROLET OVERHAUL M A N U A L SUPPLEMENT...
  • Page 240 — I jgv- p v p S l l b ' ■ ' ■ • «i' v • "• *;*v /*k V * " * ♦ . • ,< . 'bsXSv : ’ ■ • s • ’ * . < ' - •...

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