Page 2 CAUTION To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: Proper service and repair are important to the safety of the service technician and the safe, reliable operation of all motor vehicles. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part.
Page 3 • GMC Truck! Division service manuals are intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others and damage to your vehicle that may cause it not jto operate properly.
Page 4 No part of this publication may be reproduced, stored in any retrieval system, or transmitted, in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the GMC Truck Division of General Motors Corp. This includes all text, illustrations, tables, and charts.
Page 5 TABLE OF CONTENTS The table of contents on this page indicates the sections covered in this manual. At the beginning of each individual section is a table of contents which gives the page number on .which each major subject begins. SECTION SUBJECT ii-M...
Page 6 Date Filled to your vehicle that may cause it not to operate properly. Other GMC Truck Service Publications For Your ’93 TopKick/Kodiak and Medium Duty Forward Control Models: Price Each Form Description FOrm No.
Page 7 GENERAL INFORMATION OA-1 T " ™ “ " " — ^ m m a — — SECTION OA GENERAL INFORMATION CONTENTS SUBJECT PAGE Special Tool Ordering Information OA- 1 Service Parts Identification Label OA- 1 Vehicle Identification Number..OA- 2 Vehicle Certification Label..
Page 8 OA-2 GENERAL INFORMATION 1. Service Parts Label, without Carpeting 2. Seryice Parts Label, ; with Carpeting F8012 Figure 2—Service Parts Label Location VEHICLE IDENTIFICATION V - NUMBER The .VIN is the legal identifier of the vehicle. On :C6H and C7H models, it is located on a plate that is attached to the left top of the instrument panel and can be seen through ithe windshield (figure 3).
Page 9 Brake Chassis Only P6 Model (No Cab) System Range Syatem Range Bus Chassis. B7 Model (No Cab) Chevrolet Hydraulic' 23501-26000 9001-10000 GMC Incomplete. Vehicle 26001-33000 Hydraulic 10001-14000 Hydraulic Chhev. Incomplete Vehicle 14001-16000 Hydraulic 26001-33000 GMC MPV Hydraulic 14001-16000 33001 -40500 Chev.
Page 10 QA-4 GENERAL INFORMATION Figure ^ C a te rp illa r Engine 3116 I.Di Plate Location GASOLINE ENGINES ; AXLE r e a r The 6.0L and 7[.0L engine serial number is located on IDEENTIFIC ATION NUMBER the engine block just in front of the right cylinder head. The engine serial numberis also located at the left rear ROCKWELL corner of the engine block (figure 9).
Page 11 GENERAL INFORMATION OA-5 Figure 10—Rear Axle I.D. Location METRIC FASTENERS EATON All Eaton axles have an identification tag on the side Current model GM vehicles are primarily dimensioned of the differential carrier (figure 10). in the metric system. Many fasteners are metric and are Differential Carrier Tag very close in dimension to well-known customary fas...
Page 12 OA-6 GENERAL INFORMATION Figure 11— Allison Transmission I.D. Location...
Page 13 GENERAL INFORMATION OA-7 L— Ratio Set Forward Speeds Synchronized— — Design Level x 100 Nominal Torque Capacity F9377 Figure 12—Eaton-Fuller Model FS transmission I.D.Location Road ranger---- 1 I— Ratio Set, I— Forward Speeds Twin Countershaft— — Design Level Overdrive- x 100 = Nominal Torque Capacity F9376 Figure 13—...
Page 14 PA-8 GENERAL IN FORMATION Figure 14—Model Identification; (C Models) identifications embossed on each bolt head. Markings correspond; |to two lines less than the actual grade (i.e.gradeij7:bplt will exhibit 5 embossed radial lines on the bolt |.Head). Some metric nuts are marked with a single dipitj lstrength identification number on the nut face.
Page 15 GENERAL INFORMATION OA-9 used as a method of interference between nut and bolt threads (figure 18). A prevailing torque bolt is designed to develop an interference between bolt and nut threads, or the threads of a tapped hole. This is accomplished by dis torting some of the threads or by using a nylon patch or adhesive.
Page 16 PA-10 GENERAL M N FORM AT ION & ® (ED (££) © 1 i • - 2 : ' " ■ ' CED P v j O . . © ;<H> . . , METRIC SIZE FASTENERS FASTENER TORQUE TYPE UNITS 6 &...
Page 17 CONVERSION TABLE to get equivalent to get equivalent number of: Multiply Multiply number of: LENGTH ACCELERATION Inch 25.4 millimeters (mm) Foot/sec2 0.3048 meter/sec2 (m/s2 ) Foot 0.304 8 meters (m) Inch/sec2 0.025 4 : meter/sec2 Yard 0.914 4 meters TORQUE Mile 1.609 kilometers (km)
Page 18 DECIMAL AND METRIC EQUIVALENTS Fractions Decimal In. Metric mm Fractions Decimal In. Metric mm 1/64 0.015625 0.39688 33/64 0.515625 13.09687 1/32 0.03125 0.79375 17/32 0.53125 13.49375 3/64. 0.046875 1,19062 35/64 0.546875 13.89062 1/16 0.0625 1.58750 9/16 0.5625 14.28750 5/64 0.078125 1.98437 37/64 0.578125...
Page 19 GENERAL INFORMATION OA-13 J1930 CONVEIRSION CHART From Absolute Pressure Sensor (APS) Manifold Absolute Pressure Sensor (MAP.Sensor) Accelerator (ACCEL) Accelerator Pedal (AP) l ■ Air Cleaner Assembly Air Cleaner (ACL) Air Cleaner Filter Element Air Cleaner Filter (ACL Filter) Air Induction System Air Intake System Air Injection Reaction System (A.I.R.
Page 20 PA-14 GENERAL INFORMATION J1930 CONVERSION CHART From ■ Electronic Spark Control Circuit (ESC Circuit) Knock Sensor Circuit (KS Circuit) Electronic Spark Control System (ESC System) Knock Sensor System (KS System) Electronic Vacuum Regulator Valve (EVRV) Exhaust Gas Recirculation Electronic Vacuum Regula tor Solenoid Valve Engine Calibration Unit (ECU) Programmable Read Only Memory (PROM)
Page 21: Table Of Contents
HR6-HE AIR CONDITIONING COMPRESSOR 1D2-1 SECTION 1D2 HR6-HE AIR CONDITIONING COMPRESSOR NOTICE: When fasteners are removed, always reinstall them at the same locahon from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is nojf available, a fastener of equal size and strength (or stronger) may be used.
Page 22 1D2-2 HR6-HE AIR CONDITIONING COMPRESSOR 1 — CLUTCH DRIVER 2 — ROTOR BEARING RETAINER 3 — PULLEY BEARING 4 — PULLEY 5 — CLUTCH COIL ASSEMBLY 6 — SHAFT SEAL PARTS 7 — PUMP ASSEMBLY 8 — SWITCH O-RING SYSTEM CONTROL SWITCH HIGH PRESSURE RELIEF VALVE...
Page 23: Metric Thread Size Information
HR6-HE AIR CONDITIONING COMPRESSOR 102^3 METRIC THREAD SIZE INFORMATION and recorded. This oil should then be discarded and an equal amount of new 525 viscosity refrigerant oil added to the Compressor to mounting bracket bolts. compressor. Front MIO x 1.5-6H Rear M8 x 1.25 - 6H The service compressor is shipped with 240 ml (8 oz.) of...
Page 24: Compressor Clutch Rotor And/Or B E A R I N G . I D
1D2-4 HR6-HE AIR CONDITIONING COMPRESSOR i, 1 ' _ ‘ • NOTICE: If the center screw is threaded, fully onto the end of the compressor: shaft, or if the body of the installer is held and the center screw is rotated, the key will wedge and will break the clutch hub.
Page 25 HR6-HE AIR CONDITIONING COMPRESSOR 1D2-5 Fig. 6 Installing-Removing Pulley Rotor & Bearing Assembly Retaining Ring - • [7] PULLEY ROTOR □ J 33020 (LESS FORCING SCREW) "FACEDOWN" INVERTED AND HFI J 9398-A BEARING USED TO SUPPORT REMOVER HUB OF ROTOR FOR BEARING J 29886 DRIVER REMOVAL.
Page 26 1P2-6 HR6-HE AIR CONDITIONING COMPRESSOR |T 1 J 33019 1 BEARING STAKING GUIDE ubber band U 33019-2 BEARING STAKING PIN L~ ~j . j- |i l, ; _ _____ - . • ' ■ ■ _________ G60150-1D2-EK-R1 i ,l • - */ Staking Bearing In Rotor Hub Bore Install or Connect Place the pulley rotor on the J 2 1352-A support block ' t <...
Page 27: Compressor Clutch Coil
HR6-HE AIR CONDITIONING COMPRESSOR 1D2-7 Q ] J 8433-3 SCREW J 33023-A PULLER PILOT J 33026-2 THROUGH BOLTS PULLEY ROTOR J 33017 PULLEY ROTOR AND BEAR- ING INSTALLER J 8433-1 CROSS BAR ____________________________________ ; G60170-1D2-C-R1 Fig. 13 Installing Pulley Rotor and Bearing Assembly COMPRESSOR CLUTCH COIL Remove or Disconnect Perform Steps 1 through 4 of “Clutch Rotor and/or...
Page 28: Major Hr6-He Compressor Repair Procedures
1D2-8 HR6-HE AIR CONDITIONING COMPRESSOR 3-S T A K E IN FRONT CLUTCH COIL HEAD (3 PLACES) D R IF T PUNCH 520020 1D2 Fig. 16; Staking Glutch Coil to Front Head Fig. 17; Details of Stakes in Front Head for Clutch Coil When coil is fully seated on the front head;...
Page 29 HR6-HE AIR CONDITIONING COMPRESSOR 1D2-9 Remove or Disconnect Recover the refrigerant. Loosen and reposition compressor in mounting brackets, if necessary. Remove clutch-.plate and hub assembly from compressor as described in minor repairs. . Remove the shaft seal; retainer ring, using snap ring pliers J 5403 (Fig.
Page 30: Compressor Pressure Relief Valve
1D2-10 HR6-HE AIR CONDITIONING COMPRESSOR Install the, new seal retainer ring with its flat side against the Seal, using Snap-Ring Pliers J 5403. See Figure 21. Use'the sleeve from O-ring installer J 33011 to press in on the seal retainer ring so that it snaps into its groove. To leak test, install compressor leak test fixture J 9625-A on rear head of compressor and connect gage charging'lines and J 38100-C Refrigerant Recovery...
Page 31: Control Switches
HR6-HE AIR CONDITIONING COMPRESSOR 1D2-11 CONTROL SWITCHES If an external leak is present, perform the necessary corrective measures and recheck for leaks to make Figure 20 certain the leak has been Corrected. Recover the refrigerant. Remove or Disconnect Disconnect both gage adapters J 5420 or hoses from the test plate J 9625-A.
Page 32 1D2-12 HR6-HE AIR CONDITIONING COMPRESSOR O i ] 1 — J 5403 SNAP RING PLIERS 14 — J 38100-C REFRIGERANT RECOVERY AND RECYCLING SYSTEM 2 — J 6083 SNAP RING PLIERS 15 — J 33017 PULLEY & BEARING ASSEMBLY INSTALLER; 3 —...
Page 33 SP-510 HP AIR CONDITIONING COMPRESSOR 1P6-1 SECTION 1D6 SD-510 HD AIR CONDITIONING COMPRESSOR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 34 1D6-2 SD-510 HD AIR CONDITIONINQ COMPRESSOR MINOR REPAIR TO THE COMPRESSOR CLUTCH PLATE AND HUB Turn the center bolt to the right with the socket ; wrench until the, front plate is loosened. ASSEMBLY REPLACEMENT Shaft key (27) (figure 4). Remove or Disconnect (Figures 1, 2, 3 arid 4) •...
Page 35 SP-510 HP AIR CONDITIONING COMPRESSOR 1P6-3 Figure 2—Removing/lnstalling the Shaft Nut Figure A — Removing/lnstalling the Shaft Key Figure 3—Removing the Clutch Plate and Hub Figure 5—Installing the Clutch Plate and Hub Assembly Assembly Important • Do not drive or pound on the clutch bore of the shaft.
Page 36 1P6-4 SP-510 HP AIR CONDITIONING COMPRESSOR PULLEY AND BEARING ASSEMBLY REPLACEMENT Remove or Disconnect (Figures 7 through 11) Tools Required: J 4245 Internal Snap Ring Pliers J 6435 External Snap Ring Pliers T J 37829 Bearing Remover and Installer !■' J 37827 Puller Pilot J 37828 Puller Fingers 1.
Page 37 SD-510 HP AIR CONDITIONING COMPRESSOR 1P6-5 Figure 11—-Removing the Bearing from the Pulley 7. Retainer 10. Coil F4805 Figure 13—Removing/lnstalling the Clutch Coll Retainer 1. Clutch plate and hub assembly. Refer to "Clutch Plate and Hub Assembly Replacement.” 2. Pulley and bearing assembly. Refer to "Pulley and Bearing Assembly Replacement.”...
Page 38 1D6-6 SD-510 HD AIR CONDITIONING COMPRESSOR " ■ i 25. Felt.Ring Metal Retainer Figure 17—Removing the Shaft Seal Seat F4529 Figure 14—Removing/lnstalling the Felt Ring Metal Retainer Figure 18—Removing the Shaft Seal O-Ring F7520 Figure 19—Removing/lnstalling the Shaft Seal Assembly Figure 16^-Removing/installing the Shaft Seal Seat Retainer...
Page 39 SP-510 HP AIR CONDITIONING COMPRESSOR 106-7 Clean • Seal cavity with R-12 and blow out with dry air. ■M- Install or Connect (Figures 1, 20 through 25) Tools Required: J 4245 InternarSnap Ring Pliers J 9393-A Seal Remover and Installer J 9553-01 O-Ring Remover .
Page 40 1D6-8 SD-510 HD AIR CONDITIONING COMPRESSOR B. Insert the cage over J 29640 and press the .cage into the shaft cavity. 7 C. Twist J 36048 and release the cage. D. Remove J 36048. 3. O-ring (22) (figure 22). ; : V A.
Page 41 SD-510 HD AIR CONDITIONING COMPRESSOR 1D6-9 17. Valve Plate Gasket 18. Valve Plate F4602 Figure 29^-Removing/lnstalling the Valve Plate Figure 30—Removing/lnstalling the Valve Plate Gasket NOTICE: See “Notice” on page 1D6-1. 5. Cylinder head cap screws (11) (figure 27). Tighten &...
Page 42 1P6-10 SP-510 HP AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 4245 J 29886 J 36048 J 6435 J 37825 J 9393-A J 37826 J 9553-01 J 37827 J 29640 .! ■ J 37828 J 37829 1. Internal Snap Ring Pliers 2. External Snap Ring Pliers 3.
Page 43 POWER STEERING GEAR UNIT REPAIR 3B1A-1 SECTION 3B1A POWER STEERING GEAR UNIT REPAIR NOTICE: Repair the steering gear in a clean, dust-free location, using clean tools and equipment. Dirt or grit will damage the machined surfaces and result in leaking or damage to the steering gear assembly. If broken components or foreign materials are found while disassembling the gear, the hydraulic system should be disassembled, inspected, cleaned, and flushed.
Page 44 3B1A-2 POWER STEERING GEAR UNIT REPAIR Figure 1 710 Power Steering Gear...
Page 45: Gear Disassembly
POWER STEERING GEAR UNIT REPAIR 3B1A-3 Key No. Pail Name Key No. Part Name 1 - NUT, PRELOAD ADJUSTER 27 - RING, VALVE BODY 2 - BOLT, HEX HEAD (SIDE COVER) 28 - BODY, VALVE . 3 - COVER ASSEMBLY, HOUSING SIDE 29 - SEAL, O-RING (SPOOL) ,4 - SEAL, O-RING (SIDE COVER) 30 - SPOOL, VALVE...
Page 46 3B1A-4 POWER STEERING GEAR UNIT REPAIR O -ring seal (11). Important • Turn the stub shaft counterclockwise; until the rack piston (50) covers the crossover hole • Do not remove the plug (8) from the rack (see: Figure 4). piston (7) during this procedure. Remove only for replacement.
Page 47 POWER STEERING GEAR UNIT REPAIR 3B1A-6 Rack piston (50) and balls (49). Pitman shaft (5) from housing (6). Tap in end o f shaft. Nut (14) (see Figure 8). Adjuster plug (19). Use tool J 7624 or equivalent (see Figure 9). Valve (28) and worm shaft (33) as an assembly with both races (34) and bearing (35).
Page 48: Adjuster Plug
3B1A-6 POWER STEERING GEAR UNIT REPAIR ADJUSTER PLUG Spacer (24). , Race (23). Figures 1, 10 thru 2 2 Bearing (22). Tools Required: Race (21). J 4245 Internal Snap Ring Pliers, Seal (20). . J 8524-2 Bearing Seal Remover 10. Needle bearing (18), if necessary. Use J 8524-2 J 7079-2 Driver and J 7079-2 (see Figure 13).
Page 49 POWER STEERING GEAR UNIT REPAIR 3B1A-7 Inspect • Spacer (24) for wear or cracks. • Races (23, 21) for wear or scoring. • Adjuster plug (19) threads for wear. • Bearing (22) for wear or scoring. • Needle bearing (18) for wear, pitting, or scoring (see Figure 14).
Page 50 3B1A-8 POWER STEERING GEAR UNIT REPAIR Retaining ring (15), use tool J 4245 (see Figure 17)1 • Lubricate new seal (20) with power steering fluid. New seal (20). : [p • Lubricate the thrust bearing assembly with power steering fluid. Large race;...
Page 51: Valve And Stub Shaft
POWER STEERING GEAR UNIT REPAIR 3B1A-9 VALVE AND STUB SHAFT Figures 2 0 thru 2 5 Important • Valve assembly malfunction is uncommon, except during seal replacement; Do not service the valve unless indicated to do so. Disassemble Seal (32) in the shaft cap end. Stub shaft (31) from the valve body (28) (Figure20)* •...
Page 52: Pitman Shaft And Side Cover
3B1A-10 POWER STEERING GEAR UNIT REPAIR Assemble • Lubricate new rings (27) and seals (26). New seals (26) in the ring grooves. New rings |(27) in the grooves over the seals (26). • Lubricate valve spool seal (29). Seal (29) over the valve spool. •...
Page 53: Primary Rack Piston
POWER STEERING GEAR UNIT REPAIR 3B1A-11 PRIMARY RACK PISTON Figure 1 an d 29 Tool Required: J 21552 Rack Pinion Arbor Inspect Worm (33) and rack piston (50) grooves and all balls (49) for scoring. Replace as a matched assembly. Seal (9) and ring (10) for wear.
Page 54: Steering Gear Connectors
3B1A-12 POWER STEERING GEAR UNIT REPAIR PITMAN SHAFT BEARING AND STEERING GEAR CONNECTORS SEAL REPLACEMENT Figure 1 a n d 29 Figure 30 Tool Required: J 6217 Valve Connector Seat Installer Tools Required: J 4245 Internal Snap Ring Pliers Important , | : J 24655 Bearing Installer and Remover J 8092 Handle •...
Page 55: Gear Reassembly
POWER STEERING GEAR UNIT REPAIR 3B1A-13 GEAR REASSEMBLY Figures 31 thru 39 J 24655 Tool Required: J 6222-A Shaft Seal Protector J 7624 Spanner Wrench J 7754-01 Torque Wrench Assemble £ • Lubricate the worm (33), bearing (35), and races (34) with power steering fluid. Race (34), bearing (35), and race (34) over the end of the worm (33).
Page 56 3B1A-14 POWER STEERING GEAR UNIT REPAIR • Turn the stub shaft (31) clockwise to thread , the rack piston onto the worm (33) while holding tool J 21552 against the end o f the worm. • Remove tool J 21552 after the rack piston is completely threaded on the worm.
Page 57 POWER STEERING GEAR UNIT REPAIR 3B1A-15 Adjust Pitman shaft preload, as follows (see Figure 39): Attach tool J 7754-01 and a 12-point socket on the stub shaft splines. Center the steering gear by: • Counting the number o f turns while turning the stub shaft (31) counter-clockwise until bottomed.
Page 58: Gear Service Adjustments
3B1A-16 POWER STEERING GEAR UNIT REPAIR GEAR SERVICE ADJUSTMENTS Turn stub shaft one half turn (180°) right or left from center. Install torque wrench vertical on stub shaft. Turn torque wrench 20° left or right o f vertical. Tools Required: Take torque reading while turning torque wrench J 7754-01 Torque Wrench back to vertical.
Page 59: Specifications
POWER STEERING GEAR UNIT REPAIR 3B1A-17 SPECIFICATIONS FLUID SPECIFICATION Power Steering Fluid Requirement............GM Power Steering Fluid Part N o. 1050017 or Equivalent m eeting G M S pecification 9 9 85010. FASTENER TIGHTENING SPECIFICATIONS Pitman Shaft Preload Adjuster Screw Jam N u t..........:......90 N*m (66 lb.
Page 60: Special Tools
3B1A-18 POWER STEERING GEAR UNIT REPAIR SPECIAL TOOLS 3. J 24655 4. J 34196-4 5. J 35509 1. J 21552 2. J 22912-01 11. J 7754-01 12. J 8092 13. J 8524-1 14. J 8524-2 1. RACK PINION ARBOR 8. SHAFT SEAL PROTECTOR 2.
Page 61 MEDIUM DUTY TRUCK STEERING PUMP UNIT REPAIR 3B1B-1 SECTION 3B1B STEERING PUMP UNIT REPAIR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. I f a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener o f equal size and strength (or stronger) may be used.
Page 63: Drive Shaft, Drive Shaft Seal, Ball Bearing Assembly
MEDIUM DUTY TRUCK STEERING PUMP UNIT REPAIR 3B1B-3 Key No. Part Name Key No. Part Name 1 - SHAFT, DRIVE 16- ROTOR, PUMP 2 - KEY, WOODRUFF 1 7 - VANE, PUMP (10) • 3 - RING, RETAINING (INTERNAL) 18- RING, PUMP 4 - BEARING ASM., BALL 19 - PLATE, PRESSURE 20 - SPRING, PRESSURE PLATE...
Page 64: Control Valve
3B1&4 MEDIUM DUTY TRUCK STEERING PUMP UNIT REPAIR CONTROL VALVE Install or Connect Figures 1 a n d 2 Magnet (29) to pump housing assembly (9). Remove or Disconnect Lubricate new O-ring seals (8) and (10) with power steering fluid. Pump assembly from vehicle if necessary for access.
Page 65 MEDIUM DUTY TRUCK STEERING PUMP UNIT REPAIR 3B1B-5 Inspect z ° Pressure plate (19). Pump ring (18). Pump Vanes (17). Pump rotor (16). Thrust plate (15) for heavy or unusual wear, or scoring. Drive shaft (1) and splines. Ball bearing (4). N eedle bearing (7) for scoring, pitting, or chatter m arks.
Page 66 3B1B-6 MEDIUM DUTY TRUCK STEERING PUMP UNIT REPAIR SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS P Series (Heavy Duty) (28) Connector Fitting Assem bly....................55 N*m (401b. ft.) (26) Reservoir Stud or B o lt......................48 N*m (35 lb. ft.) SPECIAL TOOLS...
Page 67 POWER STEERING COMPONENTS (MIDLAND) 3B2-1 SECTION 3B2 POWER STEERING COMPONENTS (MIDLAND) NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 68 3B2-2 POWER STEERING COMPONENTS (MIPLAWP) A. Remote Reservoir Adapter Venturi B. Remote Reservoir Adapter Bolt 159. Bolt Intake Adapter 183. Carrier 160. Helical Spring Washer Seal 184. Roller Vanes 161. Washer Seal 185. Seal 162. Pulley Return Tube Adapter 186. Pin 163.
Page 69 POWER STEERING COMPONENTS (MIPLAWP) 3B2-3 169. Bushing Body 188. Bushing Cover Figure 2—Removing the Bushing Cover 11. Seals (185 and 187) (figure 3). 12. Roller vanes (184) from the body pockets. Use a clean magnet. Do not use pliers or similar tools that could raise a burr (figure 4).
Page 70 3B2-4 POWER STEERING COMPONENTS (MIDLAND) : 3. Cam (181), locating pin (176), port plate (180), and end plate (.177) by sliding the parts out of the pump body pocket. Leave end plate seals (178 and 179) in the end plate pockets. 4.
Page 71 POWER STEERING COMPONENTS (MIDLAND) 3B2*5 (0.0001 inch). Replacement is required for more severe1 wear. • Seals (178 and 179) for cracking or excessive swelling. • End plate (177) for cracks in the area of the sealing rings. •Control valve (190) assembly. It is difficult to visually determine if internal valve components are faulty.
Page 72 3B2-6 POWER STEERING COMPONENTS (MIDLAND) 2. Carrier (183) and drive pin (182). • Note the direction of the teeth before removing 3. Shaft (166). , the carrier (183). 4. Snap ring (some models). Carrier (183) and drive pin (182). Install or Connect (Figures 1, 8 through 10) Install or Connect (Figures 1, 8 through 10) 1.
Page 73: Specifications
POWER STEERING COMPONENTS (MIDLAND) 3B2-7 •Lubricate new seal (192) with power steering Tighten fluid GM P/N 1050017 or equivalent (meeting GM Spec. No. 9985010). • Bracket mounting bolts to 48 N m (35 ft. lbs.). • Valve cap to 65 N.m (48 ft. lbs.)'. 6.
Page 74 POWER STEERING COMPONENTS TRW ROSS 3B3-1 SECTION 3B3 POWER STEERING COMPONENTS (TRW ROSS) NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 75 3B3-2 POWER STEERING COMPONENTS - TRW ROSS...
Page 76 POWER STEERING COMPONENTS - TRW ROSS 3B3-3 1. Valve Housing Bolts 20. Rack Piston Seal 36. Seal 2. Input Seal 21. Back Up Seal 37. Seal 3. Retaining Ring 22. Poppet Adjuster Seat 38. Spacer 4. Input Shaft Seal Sleeve Assembly 39.
Page 77 3B3-4 POWER STEERING COMPONENTS - TRW ROSS C. Slide J 36452-A Over the- seat Of the poppet • Place the sector shaft firmly in a soft jawed vise and unstake the retainer using a suitable chisel. adjuster seat and sleeve assemblies (22^ (figure •...
Page 78 POWER STEERING COMPONENTS - TRW ROSS 3B3-5 Figure 6—Removing the Roller Bearing Figure 7—Removing the Bearing Adjuster and Jam NOTICE: The sleeve is retained with thread locking compound. A new rack piston and Remove or Disconnect (Figures 1, 2, and 7) poppet assembly will be required if they are damaged while removing the sleeve.
Page 79 3B3-6 POWER STEERING COMPONENTS - TRW ROSS INSPECTION fine-tooth flat file. Do not change the dimensional | y | Inspect characteristics. • Roller bearing (35) in the housing for brinelling or • Rack piston teeth for cracks and wear.. If a step spalling.
Page 80 POWER STEERING COMPONENTS f RW ROSS 3B3-7 • Reverse the assembly in the vise so that the worm • Torque required to rotate the input shaft must be end is down. Use an inch pound torque wrench on between 0.56 to 1/T3 N m (5 to 10 in. lbs.) rnore the input shaft, note the torque required to rotate that the original torque that was noted.
Page 81 3B3-8 POWER STEERING COMPONENTS - TRW ROSS 11. Wqijrrv end of the input shaft to maximum depth rack pistoh. Repeauhis procedure for the other without the valve housing contacting the upper poppet adjuster seat and sleeve assembly. ■ poppet. ; •...
Page 82 POWER STEERING COMPONENTS - TRW ROSS 3B3-9 • The rack piston poppet adjuster seat and Important sleeve assemblies must not be allowed to bot tom against the internal poppet stops in the • If the rack piston is not centered when sec steering gear until it is installed in the vehicle.
Page 83 3B3-10 POWER STEERING COMPONENTS ■ TRW ROSS 33. Seal (37). • Remove tape from the sector shaft. • Pack the end of the housing trunnion area at the sector shaft with clean high temperature grease. • Apply more grease to the seal (37) before installing it.
Page 84: Special Tools
POWER STEERING COMPONENTS - TRW ROSS 3B3-11 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS ITEM Ft. Lbs. Allen or Torx Head Screws......... Auxiliary Cylinder Plug (44)......Bearing Adjuster Jam Nut (18)...... Hex Head Bolts (31 A)......... Manual Bleed Screw (40)........Plug (Auto Bleed) (41)........Poppet Adjuster Seat &...
Page 85 POWER STEERING COMPONENTS (LuK LF 93) 3B4-1 SECTION 3B4 POWER STEERING COMPONENTS (LuK LF 93) NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct p a rt num ber fastener fo r that application. If the correct p art num ber fastener is n ot available, a fastener o f equal size and strength (o r stronger) may be used.
Page 86 3B4-2 POWER STEERING COMPONENTS (LuK LF 93) 1. RING, SNAP 10. RING ; £6: WASHER SEAL, SHAFT . 11! ROTOR 21. SCREW RING, ADJUSTING 12. VANES,10 22. STOP. VALVE 4. SHAFT 13. PLATE, PRESSURE 23. SPRING 5. FLANGE 14! PLATE, SUPPORT 24.
Page 87 POWER STEERING COMPONENTS (LuK LF 93) 3B4-3 2. Check the wearing of body parts, pressure plate, 4. Inspect bearing for wear and looseness. Check for cam ring and rotor and check for scoring. Replace pitting or scoring. If bearing is worn, pitted or scored or badly worn parts with a new replacement scored, replace the pump.
Page 88 BEAR AXLE CONTROLS 4B2-1 SECTION 4B2 REAR AXLE CONTROLS NOTICE: When fasteners are re m o v e d a lw a y s re install them at the same location from which they were removed. If a fastener needs to be replaced, use the correct p art num ber fastener fo r that application. If the correct p a rt num ber fastener is n ot available, a fastener o f equal size and strength (o r stronger) may be used.
Page 89 4B2-2 REAR AXLE CONTROLS Slider block (14) in housing (6). Important A: Lightly lubricate the full length Of the shaft (17). • Do not disturb the switch spring (7). Fill the gear pin slot in the slider block with Clean (Figure 1) lubricant.
Page 90 REAR AXLE CONTROLS 4B2-3 D. Turn the gear so the pin is 90 degrees from the centerline of the sliding block shaft. 5. Slider block (14). Make sure the slot in the block engages with the gear pin. 6. Base housing (15). A.
Page 91 4B2-4 REAR AXLE CONTROLS UNIT REPAIR DISASSEMBLY 1. Housing for damage or cracks. Remove or Disconnect (Figure 5) 2. Cylinder bore for wedr or scoring. 3. Pistpn (19) for wear or hardness. : 1. Plug (11). 4. Felt rings (20) for wear or hardness. 2.
Page 92 REAR AXLE CONTROLS 4B2*5 Tighten [ & l Tighten • Nut to 15.5 N m (135 in. lbs.). • Screws to 11.5 N m (100 in. lbs.). 14. Cylinder cover seal (24). 8. Piston stop (4). 15. Cylinder cover (25). 9.
Page 93 4B2-6 REAR AXLE CONTROLS SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS In. Lbs. Gearshaft Nut.;..................;......8.5 . 75 Housing Screw......!..............;....1 2 ' ‘ Motor to Housing Screw......................V.. Circuit Board Nut......Cover Screw......:..'..................6 ■...
Page 94 MASTER CYLINDER 5A-1 BRAKES CONTENTS SUBJECT PAGE Master Cylinder............................... 5A-1 Hydraulic Booster................. 5D2-1 Air Brake Valves..............................5H-1 Air Foundation Brake............................51-1 Air Compressor and Governor................... SECTION 5A MASTER CYLINDER NOTICE: When fasteners are removed, always re install them at the same location from which they were removed.
Page 95 5A-2 MASTER CYLINDER GENERAL DESCRIPTION These; master cylinders have identifying information The Bendix tandem master cylinder has a primary and secondary hydraulic system. Each system has a stamped on a pad on the left side of the mounting separate piston. One piston delivers pressure to the flange.
Page 96 MASTER CYLINDER 5A-3 1. Caps 2. Diaphragms 3. Reservoir 4. Compensating Valve Seal 5. Compensating Poppets 6. Spring 18. Actuator, Primary 7. Compensating Valve Port 19. Retaining Ring 8. Cylinder Body 20. Piston Return Spring, Primary 9. Piston Return Spring, Secondary 21.
Page 97: Master Cylinder
5A-4 MASTER CYLINDER ed for brake system bleeding after the master cylinder 21. Compensating valve spring (6). is installed; pn the vehicle. If tools are not available for 22. Compensating valve poppets (5). bench bleeding, bleed the master cylinder on the vehi 23.
Page 98: Hydraulic Booster
HYDRAULIC BOOSTER 5D2-1 SECTION 5D2 HYDRAULIC BOOSTER NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct p art num ber fastener fo r that application. If the correct p art num ber fastener is n ot available, a fastener o f equal size and strength (o r stronger) may be used.
Page 99: Unit Repair
5D2-2 HYDRAULIC BOOSTER UNIT REPAIR 13. InStail 'two 10 mm x 1.5 x 80-mm (3-inch) bolts that BOOSTER ASSEMBLY are iftlilly; threaded and, have nuts installed on them, in opposite corners of the master cylinder mounting Remove or Disconnect (Figures 1 through 5) hpjejsj jjfigure 2).
Page 100 HYDRAULIC BOOSTER 5D2-3 1. Return Spring 19. Power Piston 2. Control Valve/Push Rod Assembly 20. Return Spring 3. Snubber (Bumper) 21. Seal Expander 4. Washer 22. Cylinder Seal 5. V-Lip Seal 23. Output Push Rod (Piston Rod) 6. By-Pass Plug 24.
Page 101 5P2-4 HYDRAULIC BOOSTER Figure 5—Removing the Seal Plug Figure 3—Removing the End Cover Assembly ;...
Page 102 HYDRAULIC BOOSTER 5D2-5 Inspect • Studs (10) and (35) for thread damage. • All rubber parts for nicks or cuts. • Parts for cracks, distortion, or any evidence of structural damage. • Machined surfaces for scoring, burrs, or corrosion. • Replace any damaged parts. [■►...
Page 103 5D2-6 HYDRAULIC BOOSTER 8. Booster Head Body 1 8. Power Piston Seal 26. Seal 19. Power Piston 25. End Plate A. Valve Seat •B5741 B5739 Figure 9—Installing the Piston Assembly Figure 10—Piston Rod Seal and End Cover 16. Seal (26) into the end cover (25). . 2.
Page 104: Master Cylinder
HYDRAULIC BOOSTER 5D2-7 27. Rubber boot (9). 28. Piston push rod (23). • Refer to "Gaging Procedure." GAGING PROCEDURE After rebuilding the booster, particularly after replacing the piston assembly or control valve, it is necessary to check the piston rod extension. Replacement rods are available in various lengths.
Page 105 502-8 HYDRAULIC BOOSTER SPECIAL TOOLS J 2 4 8 6 6 ■ . . ■ -V '.'/V • , fl— ------“ ------- J 2 6 2 4 3 - , i . ■ i ;, J 2 8 6 6 1 c S = g J 8 0 9 2 1.
Page 106 AIR BRAKE VALVES 5H-1 SECTION 5H AIR BRAKE VALVES NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct p a rt num ber fastener fo r that application. If the correct p art num ber fastener is n ot available, a fastener o f equal size and strength (o r stronger) may be used.
Page 107 5H-2 AIR BRAKE VALVES AIR DRYERS CPI BRAKEMASTER 5. Packing ring gasket (14) in body (1). 6. Filter (17) in cup (18). 7. Strainer (16). Remove or Disconnect (Figure 1) • The safety valve (22) cannot be serviced and should, not be removed from the top cap., T.
Page 108: Bendix
A IR BRAKE VALUES 5H-3 8. V-spring (15). iceable. If the heater and thermostat are inoper 9. Filter cup (18) in body. ative, replace the purge valve assembly. ) ■ 10. Spring (19). 6. Bolts (6 and 24), nuts (2), and washers (3 and 11.
Page 109 5H-4 AIR BRAKE VALVES 1. HOUSING 2. NUT 3. WASHER 4. COVER, END 5. WASHER 6. BOLT 7. O-RING 8. O-RING 9. O-RING 10. BOLT 1 1 .0 -R IN G 12. O-RING 13. PISTON, PURGE 14. SPRING 15. COVER, EXHAUST 16.
Page 110 BENDIX PP-1 • Use only new seals from the repair kit. 2. O-ring (2) on plunger (1). 3. Spring (3) and plunger (1) in body (4). Remove or Disconnect (figure 4) 4. Mounting nut (12). 5. Valve (5). 1. Bolts (8) and washers (9). 6.
Page 111 5H-6 AIR BRAKE VALVES 52. End Plate 53. Bolt 54. Seal Ring Return Spring 55. Plunger Nut Control Inlet Exhaust Valve 56. Washer Valve Body 57. Plunger ValVe 47. Piston Return Spring 58. Upper Body A. Identifying Information 48. Piston O-Ring 59.
Page 112: Dual Application Valve
AIR BRAKE VALVES 5H-7 A. Identifying Informatior 21. Bolt 22. Washer 23. Cover 24. Nut 25. Washer 26. Valve " 27. O-Ring 28. Body 29. Plunger 30. O-Ring F4854 Figure 6—Bendix PP-8 Air Supply Valve 4. Valve (26). Install or Connect (Figure 6) 5.
Page 113 5H-8 AIR BRAKE VALVES , 1. Diaphragm Washer Screw 21. Relay Piston Spring 2. Diaphragm Washer 22. No. 1 Inlet ^Exhaust Valve Assembly Retaining Ring 3. Diaphragm 23. No. 1 Inlet & Exhaust Valve Retaining Ring 4. Exhaust Cover Screw 24.
Page 114 AIR BRAKE VALVES SH-9 Figure 11—Installing the Rubber Washer CAUTION: Before proceeding with the assem 1. Lubricate all O-rings, O-ring grooves, piston bores, bly, refer to Figure 10 and note that the and metal-to-metal moving surfaces with a barium nylon-insert nut and stem are used to contain base lubricant.
Page 115: Front Axle Limiting (Ratio) Valve
5H-10 AIR BRAKE VALVES ,14. Compress the No. 1 piston piston spring (42), {39), and relay piston (18) in upper body (43) (figures 12 and 13). 15. Stem (17). 16. Stem spring (35). ■17. Spring guide (34). 18. Nylon insert nut (33). Tighten >...
Page 116: Check Valves
AIR BRAKE VALVES 5H-11 3. Valve (10). 4. Spring (9). 5. Washer (8). 6. Retaining ring (7). 7. O-ring (4) on upper piston (5). 8. Press the piston assembly (11) in piston (5) 9. Piston spring (13) in body (14). 10.
Page 117: Bendix Dc-4 Double Check Valve
5H-12 AIR BRAKE VALVES 14. O-ring 11. Screw 15. Shuttle 1. Body .12. Split Washer 16. Guide5 2. Washer 13. Cap 17. Body 3. Valve Seat B6613 4. Disc Valve 5. . Spring Figure 16— Bendix DC-4 Double Check Valve 6.
Page 118: Pressure Protection Valve
AIR BRAKE VALVES 5H-1 a • Use only new rubber seals from the repair kit. 7. O-ring (4). 2. Filter retainer (8). 8. Cover (3). 3. Filter (9). 4. Adapter (10). N O T IC E : S e e “N o tic e ” o n p a g e 5 H -1 . 5.
Page 119: Quick Release Valve
5H-14 AIR BRAKE VALVES QUICK RELEASE VALVE BENDIX QR-N Remove or Disconnect (Figure 19) 1. Bolts (6) and lower body (7). 2. Seal (5). 3. Diaphragm follower (3). 4. Diaphragm (2). Clean • Body parts in mineral spirits or another suitable solvent.
Page 120: Bendix Proportioning Relay Valve Bp-R1
AIR BRAKE VALVES 5H-15 Figure 20—Bendix R-14 Relay Valve 8. Sealing ring (86) and O-ring (62). Piston (8). 9. Relay piston (63) and relay piston spring (65). 10. Seal (O-ring) (9). 11. Cover (10). • The relay piston spring (65) is not used in all •...
Page 121 5H-16 AIR BRAKE VALVES Figure 21— Bendix Proportioning Relay Valve Components...
Page 122 • • AIR BRAKE VALVES 5H-17 51. Valve Main Body 70. Exhaust Diaphragm 52. Valve Cover 71. Service Piston. 53. Retaining Ring Service Piston O-Ring 54. Exhaust Cover 73. Spring 55. O-Ring 74. Spring Cage 56. O-Ring 75. Blend Back Piston 57.
Page 123: Safety Valve
! ! l I 5H-18 AIR BRAKE VALVES 25. 0 -n n g s (55 arid 56) inexhaust'cover (54). 30. O-ring ;(64) on relay piston (63): 26. Exhaust cover (54) in valve main body (51). 31. Relay;piston (63) in valve main body (51). 27.
Page 124 AIR BRAKE VALVES 5H-19 . ■ ... ■ .!■ : 1. Cover Screw and Washer 2. Cover - - 3. Outer Piston Spring 4. Inner Piston Spring 5. Piston 6. O-Ring 7.
Page 125 5H-20 AIR BRAKE VALVES screws: 6. Outer piston spring (3). 7. Cover (2). 16. Four cover screws (1), washers, and Cover (2). 8. Four cover screws (1) and washers. 17. Outer piston spring (3). 18. Inner piston spring (4). Tighten 19.
Page 126: Tractor Protection Valve
AIR BRAKE VALVES 5H-21 TRACTOR PROTECTION VALVE BENDIX TP-5 17. Shuttle (20), 18. Screws (27) and washers (28). 19. Exhaust plate (24). Remove or Disconnect (Figure 25) 20. Diaphragm (23). 21. O-rings (22). 1. TP cap (1). 22. O-ring (21). 2.
Page 127: Bendix
5H-22 AIR BRAKE VALVES 2. O-ring (21) and seals (22) in exhaust plate (figure : 26)....3. Diaphragm (23). 4. Exhaust plate (24). N O T IC E : S e e “N o tic e ” o n p a g e 5H -1 . 5.
Page 128: Two-Way Control Valve
AIR BRAKE VALVES 5H-23 Tighten • Screws (62) to 9.6 N-m (85 in. lbs). 15. Lock ring (47) in notch on cover. 16. Seal (46). 17. Head (45). 18. O-ring (43) on handle (42). 19. Handle (42). 20. Pin (44). Adjustment The standard TC-2 brake valve should deliver full res...
Page 129: Specifications
5H-24 AIR BRAKE VALVES 2. Valve disc (4). 3. Valve spring (3). 4. Seal (2). 5. Cap nut (1). 6. Plunger spring (7). 7. O-ring (8) on plunger (9). 8. Plunger (9). 9. Control lever (10). ; Fulcrum pin (6). SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS In.
Page 130 AIR FOUNDATION BRAKES 51-1 SECTION 51 AIR FOUNDATION BRAKES N O T IC E : W hen fa s te n e rs a re re m o v e d , a lw a y s re in s ta ll th em a t th e s a m e lo c a tio n fro m w h ich th e y w ere rem o v e d .
Page 131 51-2 AIR FOUNDATION BRAKES Identifying Information Clamp Boot Actuator Rod Spiral Ring Piston Pin Piston Actuator (Adjusting Sleeve] Housing Seal Thrust Washer Retaining Ring Worm Gear Snap Ring Grease Seal Lube Fitting Gear Pressure Relief Capscrew Gasket Spring Pawl F4850 Figure 1—Rockwell jAutomatic Slack Adjuster 7.
Page 132: Lubrication
AIR FOUNDATION BRAKES 51-3 LUBRICATION Using a conventional type grease gun and a high temperature waterproof grease, fill the adjuster until grease begins to flow from the pressure relief cap screw. ; The Rockwell grease specification is 0-616-A and the following grease is suitable: Texaco Termotex EP#1 , .
Page 133: Torque Check
51-4 AIR FOUNDATION BRAKES TORQUE CHECK 1. Attach a torque wrench to the adjusting nut end of the worm. While observing the torque scale, rotate the worm counterclockwise until the gear turns 360 degrees (figure 7). 2. If the torque wrench is below 16 N;m (25 in. lbs.) the unit is satisfactory.
Page 134: Service Brake Chambers
AIR FOUNDATION BRAKES 51-5 7. Bushing 1. Rivet 2. Button (Plug) 8. Body 3. Cover 9. Lock Pin 4. Gear 10. Worm Shaft 5. Worm 11. Lock Sleeve 6. Plug 12. Lock Spring F4924 Figure 8—Manual Slack Adjuster Components Figure 11—Removing the Worm Shaft SERVICE BRAKE CHAMBERS ANCHORLOK (Standard) 3: Nuts (28) and bolts (27).
Page 135: Anchorlok (Gold Seal Type)
51-6 AIR FOUNDATION BRAKES Inspect • The diaphragm and return spring for wear. • The inside of the brake chamber for corrosion. Replace if corroded. • The pushrod assembly for damaged threads. Install or Connect (Figure 12) 1. Return spring (23) into the housing assembly (22). 2.
Page 136 AIR FOUNDATION BRAKES 51-7 A. Removing Release Tool from Pocket Figure 16—Caged Anchorlok Spring Brake B. Inserting Release Tool in Keyhole Chamber 51. Release Tool Washer 52. Release Tool Nut 2. Pushrod assembly (4). F9572 • Compress the return spring and clamp it in place Figure 14—...
Page 137: Specifications
50-8 AIR FOUNDATION BRAKES 6. Release the locking pliers. 7. Uncage the compression spring and reassemble the release tool in the pocket of the adapter. 8. Install the rubber cap in the release tool keyhole. Figure 18—Anchorlok Gold Seal Spring Brake Chamber Components SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS...
Page 138 SECTION 5J N O T IC E : W h en fa s te n e rs a re re m o v e d , a lw a y s re in s ta ll th e m a t th e s a m e lo c a tio n fro m w h ic h th e y w ere re m o v e d .
Page 139: Bendix Tu-Flo 550 Air Compressor Disassembly
5J-2 AIR COMPRESSOR ANO GOVERNOR BENDIX TU-FLO 550 AIR COMPRESSOR DISASSEMBLY • If the unloader bushing is damaged or worn Remove road dirt and grease from the compressor with a cleaning solvent. Before disassembling the com ^excessively, replace the cylinder head or com pressor, mark the following items to show their relation...
Page 140 AIR COMPRESSOR AND GOVERNOR 5J-3 1. BOLT 23; RING, EXPANDER 2. BOLT 24. BUTTON, W R IS t PIN 3. WASHER 25. PIN, WRIST 4. PLATE, UNLOADER 26. PISTON 5. GASKET 27. BUSHING 6. O-RING 28. ROD, CONNECTING 7. UNLOADER 29.
Page 141: Crankcase Base Plate Or Adapter
5J-4 AIR COMPRESSOR AND GOVERNOR Inlet valve stops (14) using J 25447-A (figure 5). ' Inlet valve springs (13) and valves (12). CRANKCASE BASE PLATE OR ADAPTER Remove or Disconnect (Figure 3) Bolts (41). • Tap base plate or base adapter with a soft faced mallet to break the gasket seal.
Page 142: Cleaning And Inspection
AIR COMPRESSOR AND GOVERNOR 5J-5 )))i \\V Y iu JiL fs . 33. CRANKSHAFT 44. ADAPTER V3018 Figure 8—Crankshaft Drive Adapter BENDIX TU-FLO 550 CLEANING, INSPECTION, AND REPAIR CLEANING AND INSPECTION • Apply compressed air to one coolant port with the others plugged.
Page 143 5J-6 AIR COMPRESSOR AND GOVERNOR Figure 10-—Measuring the Connecting Rod Journal — Standard crankshaft connecting rod journals are 1.1242 to 1.1252 inch in diameter. If the, crankshaft journals are scored, worn, or Figure 12—Checking the Piston to Cylinder Fit out-of-round and cannot be reground, replace the crankshaft.
Page 144: Repair
AIR COMPRESSOR AND GOVERNOR 5J-7 D. Install the connecting rod caps (35) and bolts (36). Tighten • Bolts to 15 N m (11 ft. lbs.) Important • Do not move the connecting rod or crankcase to avoid a false reading. E.
Page 145: Inlet Valves And Seats
5J-8 AIR COMPRESSOR AND GOVERNOR INLET VALVES AND SEATS 1. Replace valves and springs. 2. If the seats are scratched or nicked, dress with fine emery cloth or lap with a lapping stone or grinding stone and grinding tool. Replace if damaged. BENDIX TU-FLO 550 AIR COMPRESSOR ASSEMBLY CRANKSHAFT N O T IC E : F o r s te p s 11 a n d 13, s e e “N o tic e ”...
Page 146: Cylinder Head
AIR COMPRESSOR AND GOVERNOR 5J-9 Bolts (41). 6. Unloader springs (8) and unloaders (7). 7. Gasket (5). Tighten 8. Plate (4). 9. Bolts (2) and washers (3). • Bolts (41) to 23 N-m (17 ft. lbs.). Tighten CYLINDER HEAD -►+ Install or Connect (Figure 3) •...
Page 147 5J-10 AIR COMPRESSOR AND (GOVERNOR F9051 Figure 18— Bendix BX-2150 Compressor Components !!' i" ! ,...
Page 148: Bendix Bx-2150 Cleaning, Inspection, And Repair
AIR COMPRESSOR AND GOVERNOR 5J-11 260. Unloader Piston Stop 280. End Cover Assembly 261. Hex Head Screw 281. Thrust Washer 262. O-Ring 282. Identification Plate 263. Cylinder Head 283. Connecting Rod Cap 264. Gasket 284. Connecting Rod Bolt Locks 265. Discharge Valve Stop 285.
Page 149 5J-12 AIR COMPRESSOR AND GOVERNOR 2. Crankcase (288). ■ • the main bearing and the main bearing crankshaft journals. • Dirt from the interior. — Use compressed air to remove dirt. • Clean and oil passages. 3. Oil passages. 5. Cylinder bore (288). •...
Page 150: Discharge Valve, Valve Stop, And Seat
AIR COMPRESSOR AND GOVERNOR 5J-13 Tighten Bolts to 15 N-m (11 ft. lbs.). Important • Do not move the connecting rod or crankcase, or a false reading may be obtained. D. Check the measurement bn the gaging material scale (figure 22). E.
Page 151: Inlet Valve And Seat
5J-14 AIR COMPRESSOR AND GOVERNOR INLET VALVE AND SEAT If excessive leakage is found, leave the air pressure applied and with a fiber or hardwood dowel and ham 1. Replace valve and spring. mer, tap the discharge valves off their seats to reduce 2.
Page 152: Governor
AIR COMPRESSOR AND GOVERNOR 5J-15 3. Unloader piston (295) and O-ring (296) so the short 10. Bolts (261). stem of the piston rests on the unloader stop (260). 4. Unloader spring (294) small end first, on the stem Tighten of the unloader piston (295). 5.
Page 153: Assembly
5J-16 AIR COMPRESSOR AND GOVERNOR 300. Rubber Cover 301. Cover Retaining Ring 302. Jam Nut 303. Upper Spring Seat 304. Adjuster Screw Spring 305. Lower Spring Seat 306. Spring Guide 308. Adjuster Screw 316. Valve Spring 309. Piston Grommet : ; 317. Piston Grommet 310.
Page 154: Specifications
AIR COMPRESSOR AND GOVERNOR 5J-17 Leakage Test • In the cut-out position, check the exhaust port To make a leakage check, apply a soap solution at for leakage at the exhaust valve seat or stem the exhaust port in the cut-in and cut-out positions. grommet and the upper piston grommet.
Page 155: Bendix Air Compressor (Bx-2150)
5J-18 AIRCOM PRESSORANPGOVERNOR SPECIFICATIONS BENDIX AIR COMPRESSOR (BX-2150) Capacity (At 1250 rpm)..:..:......................•,..9.5 bu! Ft. Cylinder Bore................................!; 3.375” Stroke...!..:......................:....;......1.468” Inlet Valve Diameter........ ;;....................1.301 ”± 0.022” Inlet Valve Spring: : ;...
Page 156: Bendix "D2" Governor
AIR COMPRESSOR AND GOVERNOR 5J-19 BENDIX “D2” GOVERNOR Model................................... D-2 Cut-Out Pressure..................;........,.862 kPa (125 psi) Cut-In Pressure............................724 kPa (105 psi) Springs Free Length..............................21 mm (0.83") Solid Length..
Page 157 V 8 ENGINES, GASOLINE 6A2-1 SECTION 6A2 V8 ENGINES, GASOLINE 6.0L RPO LSO, VIN P 7.0L RPO LRO, VIN M N O T IC E : W h en fa s te n e rs a re re m o v e d , a lw a y s re in s ta ll th e m a t th e s a m e lo c a tio n fro m w h ic h th e y w e re re m o v e d .
Page 158: Subject Page
6A2-2 V8 ENGINES, GASOLINE CONTENTS (cont’d) SUBJECT PAGE Oil Pan and Rocker Arm Covers Oil Pump......... Valve Train Components Pushrods, Rocker Arms, Balls, and Bolts ....... Hydraulic Lifters......Cylinder Head..... .
Page 159 V8 ENGINES, GASOLINE 6A2-3 F9478 Figure 1—Lubrication Diagram The gear type oil pump is driven through an exten ENGINE IDENTIFICATION sion shaft from the distributor drive shaft that is gear One basic type of engine, with two different displace driven from the camshaft. The oil is drawn from the ments, is covered in this section, the 6.0L (366 CID) engine oil pan through a pickup screen and tube.
Page 160: Cleaning
6A2-4 V 8 ENGINES, GASOLINE Diagrams of emission and vacuum hose routings, wir ing harness routing, accessory drive belt layout, etc., (should be made before removing accessories. • Block drain plugs to 12 N-m (112 in. lbs.). CLEANING EXHAUST MANIFOLD REMOVAL Remove the engine accessories before cleaning to provide better access to engine exterior surfaces.
Page 161: Rocker Arm Cover Removal
V8 ENGINES, GASOLINE 6A2-5 • Pull the intake manifold up. 3. Gaskets (22). 4. Seals (23). ROCKER ARM COVER REMOVAL 1. Bolts (30), supports (31). 2. Rocker arm covers (32). • If the rocker arm cover adheres to the cylinder head, bump the end of the cover with a rubber mallet.
Page 162: Cylinder Head Removal
6A2-6 V8 ENGINES, GASOLINE — Hydraulic lifters (44). • Remove the lifters one at a time, using a mag net. Place the lifters in the organizer rack, or tag them in some way to ensure they can be returned to the valve lifter bore from which they were removed.
Page 163 V8 ENGINES, GASOLINE 6A2-7 40. Bolt 41. Ball 42. Rocker Arm 43. Pushrod 44. Hydraulic Lifter 46. Cylinder Head 260. Pushrod Guide - — l i n — OIL PAN REMOVAL A. 22 mm (7/s-lnch) B. 55 mm (21 /4-inch) ■...
Page 164: Oil Pump Removal
6A2-8 V8 ENGINES, GASOLINE — l i c — OIL PUMP REMOVAL 1. Oil pump retaining bolt. 2. Oil pump, with drive shaft and connector, FRONT COVER REMOVAL 1. Bolts (93). 2. Front cover (91). 3. Gasket (90).
Page 165: Timing Chain And Camshaft Sprocket Removal
V8 ENGINES, GASOLINE 6A2-9 TIMING CHAIN AND CAMSHAFT SPROCKET REMOVAL Timing^chain free play. If the chain can be moved back and forth in excess of 16 mm (5/8 inch), make a note to replace the timing chain during assembly. 1. Bolts (100). 2.
Page 166: Flywheel Removal
6A2-10 V8 ENGINES, GASOLINE C. To avoid mismatching the connecting rbds and connecting rod cap, remove only one connect ing rod cap at a time. Place the piston at the bottom of its stroke. D. Remove the connecting rod cap. E.
Page 167 V 8 ENGINES, GASOLINE 6A2-11 f r t 4 Ffiy 110A; FLYWHEEL, MANUAL TRANSMISSION 11 OB. FLYWHEEL, AUTOMATIC TRANSMISSION 111. BOLT 112. PLATE, FLYWHEEL FLEX 113. RETAINER 200. PIN, ENGINE BALANCING GROOVE V3911 Figure 18— Flywheel and Components...
Page 168: Block
6A2-12 VS ENGINES, GASOLINE ; 134 130. Crankshaft 131. Rear Seal 132. Rear Main Bearing Cap 133. Main Bearing' Cap 134. Bolt 135. Lower Main Bearing Insert 136. Upper Main Bearing Insert F9332 CLEANING, INSPECTION^ A NDItEm UR ; parts, will be needed along with various bristle, brushes 5.
Page 169 V8 ENGINES, GASOLINE 6A2-13 210. PLUG, ENGINE BLOCK COOLANT DRAIN 220. PLUG, OIL FEED HOLE 221. PLUG, OIL GALLERY HOLE 222. PLUG; OIL GALLERY HOLE 223. PLUG, OIL GALLERY HOLE 224. PLUG, OIL GALLERY HOLE . 225. PLUG, OIL GALLERY HOLE 226.
Page 170 6A2-14 V8 ENGINES, GASOLINE • Cylinder out-of-round and taper as follows: N O T IC E : H a n d le th e p is to n s w ith c a re a n d d o n o t a tte h ip t to fo rc e th e m th ro u g h th e c y lin 1.
Page 171 VS ENGINES, GASOLINE 6A2-15 • Piston rings (if necessary). If the rings are to be reused, they must not be bent dr damaged. •Connecting rod bearing inserts for scratches or deep pitting. Measure (Figures 25 and 26) 4086-8 1. Piston pin diameter (figure 25). Check against “Specifications.”...
Page 172 6A2-16 V8 ENGINES, GASOLINE •, 2. Piston pin. A. insert the piston pin into the piston pin hole. B. Place the assembly on the support fixture (fig ure 31). C. Adjust the piston pin installer (J 24086-9) to the correct length, using the letter-number scale on the installer adjuster (figure 31).
Page 173 V8 ENGINES, GASOLINE 6A2-17 Important Each connecting rod and bearing cap should be marked, beginning at the front of the engine. Cylin ders 1, 3, 5, and 7 are the left bank and 2, 4, 6, and 8 are tlie right bank. The numbers On the connecting rod and bearing cap must be on the same side when installed in the cylinder bore.
Page 174 6A2-18 V8 ENGINES, GASOLINE Figure 33—Checking Ring Fit Figure 34—Measuring Ring Clearance Assemble (Figure 23) • All compression rings are marked on the upper , side of the ring. When installing the compression rings, make sure the MARKED SIDE IS TOWARD THE TOP OF THE PISTON.
Page 175: Camshaft Searings
V8 ENGINES, GASOLINE 6A2-19 Measure (Figures 36 and 37) Tool Required: J 7872 Dial Indicator (or equivalent) • Camshaft (75) runout (figure 36). Mount the cam shaft in V-blocks or between centers. Using J 7872, check the intermediate camshaft journal. If runout exceeds 0.0015 inch, the camshaft is excessively bent and should be replaced along with the cam...
Page 176: Timing Chain And Sprockets
6A2-20 V8 ENGINES, GASOLINE F. Repeat this procedure to remove the remaining TIM ING CHAIN AND innpr parnshaft bearings. Note that the rear SPROCKETS v* inner tearing, must be removed with the, pilot fitted into the rear camshaft tearing. Inspect 3.
Page 177: Front Cover
V8 ENGINES, GASOLINE 6A2-21 Assemble (Figure 40) Inspect Tools Required: • Coolant pump shaft for rotation and end play. The J 22102 Crankshaft Sprocket Installer shaft and fan hub should turn straight and smooth 1. Key, if removed; ly. If the hub wobbles or the shaft is noisy or feels 2.
Page 178: Valve Train Components
6A2-22 V8 ENGINES, GASOLINE N O T IC E : B e c a re fu l o f tw is tin g , s h e a rin g o r c o lla p s in g th e p ip e w h ile in s ta llin g i t In 179 180 p u m p .
Page 179: Cylinder Head
V8 ENGINES, GASOLINE 6A2-23 40. BOLT 41. BALL 42. ROCKER ARM 46. CYLINDER HEAD 47. GASKET 251. VALVE KEEPERS 253. CAP ‘ 254. ROTATOR 256. SPRING WITH DAMPER 257. SEAL 258. EXHAUST VALVE 259. INTAKE VALVE 260. PUSHROD GUIDE F9346 Figure 45-—Cylinder Head and Components CYLINDER HEAD DISASSEMBLY...
Page 180: Cleaning And Inspection
6A2-24 y a ENGINES, GASOLINE Caps (253), shields (255), springs with dampers • Valve guides using J 8101 (figure 48). . (256) and rotators (254). • Valve stems and heads on a wire wheel. 3; O-ring Seals (252) Or seals (257). •...
Page 181: Valve Grinding
V 8E N G IN E S , GASOLINE 6A2-25 Several different types of equipment are available for refacing valves. The recommendation of the manufac turer of the equipment being used should be carefully followed to attain proper results: The correct valve face angle is 45 degrees.
Page 182: Assembly
6A2-26 V8 ENGINES, GASOLINE 1 r • j ■ “ r 1 ' ■ . A. Grind out this portion. B5248 Figure 54—Cutaway Scale ASSEMBLY Assemble (Figures 45 and 46) Figure 55^Measuring Valve Spring Installed Height Tools Required: ■ >] B.
Page 183: Torsional Damper
V8 ENGINES, GASOUNE 6A2-27 • Crankpins, main bearing journals and thrust sur faces for scoring, nicks, or damage caused by lack of lubrication. • Main bearing inserts for scoring or other damage. In general, the lower inserts (except the #1 bearing) show greater wear and the mbSt distress from fatigue.
Page 184: Crankshaft Grinding
6A2-28 V8 ENGINES, GASOLINE B, Use a dial indicator as shown. Important C. If the main journals are misaligned, the crank shaft is bent and must be replaced, along with •A fter heat treating, the crankshaft should be » ; the main bearing.
Page 185 V8 ENGINES, GASOLINE 6A2-29 2. On the edge of the gaging plastic envelope there is a graduated scale. Without removing the gaging plastic, measure its compressed width (at the widest point) with the graduations oh the gaging plastic envelope (figure 61). .3.
Page 186: Crankshaft Rear Oil Seal Installation
6A2-30 V8 ENGINES, GASOLINE 1. Rear main bearing cap (132). Apply anaerobic Inspect .: sealing compound to the rear bearing cap sealing face or to the rear bearing cap channel of the Crarikshaft for binding, Try turning the crankshaft to engine block, from the corner of the rear thrust check for binding.
Page 187: Camshaft, Timing Chain, And Sprocket Installation
V8 ENGINES, GASOLINE 6A2-31 E. Tighten the screws securely with a screwdriver. This will ensure the seal is installed squarely over the crankshaft. • Timing chain free play. The free play should not F. Turn the handle until it bottoms. .
Page 188 6A2-32 V 8 ENGINES, GASOLINE Figure 67—Installing the Torsional Damper. 2. Installation stud (item A, figure 67) into the tapped end of the crankshaft. The stud is part of J 39Q46. 3. Torsional damper over the installation stud. Align the sjot in the torsional damper hub with the key. 4.
Page 189: Connecting Rod Bearing Selection
V8 ENGINES, GASOLINE 6A2-33 B. Locate the piston ring end gaps as shown in Clean (Figure 71) figure 68. Lubricate the piston and rings with engine oil. • Oil from crankshaft journal and the connecting rod C. Without disturbing the ring end gap Ipcation, bearing inserts.
Page 190: Final Assembly
6A2-34 V8 ENGINES, GASOLINE A. Measure Widest Point of Gaging Plastic with Graduated Scale B4997 Figure 72—Measuring the Gaging Plastic FINAL ASSEMBLY Install or Connect • Apply engine oil to the connecting rod bearing inserts and crankshaft journal. 1. Connecting rod cap with the lower connecting rod bearing inserts.
Page 191: Cylinder Head Installation
V8 ENGINES, GASOLINE 6A2-35 ^SQ Tighten • Bolts to 18 N-m (160 in. lbs.). CYLINDER HEAD INSTALLATION pi|y| Clean • Gasket Surfaces on block and cylinder head. Install or Connect (Figures 75, 76, and 77) 1. Head gasket. • Use no sealer on composite gaskets. •...
Page 192: Valve Train Component Installation
6A2-36 V8 ENGINES, GASOLINE Figure 77—Cylinder Head Bolt Tightening A. Timing Marks Sequence 120. Torsional Damper 123v[ Timing Tab VALVE TRAIN COMPONENT F9358 in s t a l l a t io n Figure 78—Timing Marks I { | Important 2.
Page 193: Intake Manifold Installation
V8 ENGINES, GASOLINE 6A2-37 2. Seals (23) to the block. 3. Intake manifold (21), NOTICE: See “ N o tice ” on page 6A2-1. 4. Bolts (20). . Tighten • Bolts (20) to 54 N-m (40 ft. lbs.). Use the tight ening sequence shown in figure 80.
Page 194: Exhaust Manifold Installation
6A2-38 V8 ENGINES, GASOLINE 1. Exhaust Manifold 4. Bolt/Stud 6. Heat Stove Assembly F9329 — i f o EXHAUST MANIFOLD FLYWHEEL INSTALLATION INSTALLATION • ■ 1. Retainer (113), AT 545 transmission only. 1. Exhaust manifold (1). 2. Flywheel (110) and flexplate (112). FI expiate (112) applies to automatic transmission only.
Page 195 V8 ENGINES, GASOLINE 6A2-39 2. Fill the crankcase with the proper quantity and grade of oil. • If a hew camshaft or hydraulic lifters were installed, add Engine Oil Supplement (GM P/N 1051396) or equivalent to the engine oil. 3. Fill the cooling system with the proper coolant. 4.
Page 196 6A2-40 VS ENGINES, GASOLINE 110A. FLYWHEEL, MANUAL TRANSMISSION 11 OB: f l y w h e e l a u t o m a t ic t r a n s m is s io n 111. BOLT 112. PLATE, FLYWHEEL FLEX 113.
Page 197: Thread Repair
V8 ENGINES, GASOLINE 6A2-41 H O L E V1195 — THREAD REPAIR 3. Tap hole. Lubricate tap with light‘engine oil. Clean Damaged threads may be reconditioned by drilling the thread. out, rethreading and installing a suitable thread insert. Tools Required: General purpose thread repair kits are available commercially.
Page 198: Specifications
6A2-42 V 8 ENGINES, GASOLINE SPECIFICATIONS ENGINE SPECIFICATIONS (6.0L AND 7.0L ENGINES) Ail Specifications are in INCHES unless, otherwise noted. GENERAL DATA: Type ■ ■. • •" - : ; \ r v s • ■ 7.0L (427 Cu. In .). Displacement 6.0L (366 Cu.
Page 199: Engine Specifications
V 8 ENGINES, GASOLINE 6A2-43 SPECIFICATIONS (CONT.) ENGINE SPECIFICATIONS (6.0L AND 7.0L ENGINES) All Specifications are in INCHES unless otherwise noted. DISPLACEMENT: 6.0L (366 Cu. In.) 7.0L (427 Cu. In.) CRANKSHAFT Diameter #1, #2, #3, #4, #5 2.7482-2.7489 Production 0.0004 (Maximum) 0.0005 (Maximum) Main Service Limit...
Page 200: Fastener Tightening Specifications
6A2-44 V8 ENGINES, GASOLINE SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS (6.0L and 7.0L ENGINES) Item In. Lbi Ft. Lbs. ■ — - • Camshaft Sprocket Bolts....' — ; Connecting Rod Bolt Nuts......— Coolant Pump Bolts... — ^ Coolant Outlet Bolts....
Page 201 V8 ENGINES, GASOLINE 6A2-45 SPECIAL TOOLS J 8001M J 39046 J 7872 J 38841 J 8062 J 7049 J 22102 J 8087 J 8037 J 8101 8089 J 5239 F9526...
Page 202 MODEL 295 TBI UNIT 6C1-1 SECTION 6C1 MODEL 295 TBI UNIT N O T IC E : W h en fa s te n e rs a re re m o v e d , a lw a y s re in s ta ll th e m a t th e s a m e lo c a tio n fro m w h ic h th e y w ere re m o v e d .
Page 203 1. Air Cleaner Gasket 200. Throttle Body Assembly 5. Fuel Line Inlet Nut O-ring 205. Idle Stop Plug 6. Fuel Line Outlet Nut 0-ring * . - 207. Screw Assembly (Idle Stop) 10. Gasket 208. Idle Stop Screw Spring 20. Fuel Meter Body Assembly 230.
Page 204 MODEL 295 TBI UNIT 6C1-3 F7973 Figure 3— Model 295 TBL Unit...
Page 205: General Description
6C1-4 MODEL 295 TBI UNIT GENERAL DESCRIPTION The fuel control system has an electric fuel pump is delivered under one of several conditions called “modes.” All modes are controlled by the ECM. located in the fuel tank with the gage sending unit. The The DC governor motor is electronically actuated and pump delivers fuel to the throttle body injection (TBI) controlled ! by the ECM through the governor control...
Page 206: Pressure Regulator
MODEL 295 TBI UNIT 6C1-5 PRESSURE REGULATOR |+ -»| Remove or Disconnect (Figure 6) CAUTION: To reduce the risk of fire and per sonal injury that may result from a fuel leak, A. Screwdriver Blade always replace the pressure regulator dia B.
Page 207: Cleaning
6C1-6 MODEL 295 TBI UNIT CLEANING 1. Metal throttle body parts in cold immersion type GOVERNOR DRIVE MOTOR cleaner. Carbon X (X-55) or equivalent. + + I Remove or Disconnect (Figures 8 and 9) N O T IC E : D o n o t im m e rs e I A C valve, th ro ttle 1.
Page 208: Governor Lubrication And Cleaning
MODEL 295 TBI UNIT 6C1-7 350 7 A. Lubrication Points 345. Lever and Bearing Assembly 300. Throttle Drive Assembly (Cover Plate) 350. Throttle to Motor Link 353. Drive Lever 310. Shock Absorber F9241 Figure 10—Governor Lubrication GOVERNOR LUBRICATION AND Remove or Disconnect (Figures 11 and 12) CLEANING Only If Worn The governor throttle drive assembly was prelubri...
Page 209: Throttle Body Reassembly
6C1 -8 MODEL 295 TB I UNIT Important Clean • Do not remove shock absorber from support pin : pn • Throttle drive assembly with a spray type cleaner lever and bearing assembly, to avoid having to (GM X66-A or equivalent) following package replace the shock absorber.
Page 210: Idle Air Control (Iac) Valve
MODEL 295 TBI UNIT 6Cjh9 2. Two TP sensor attaching screw assemblies. Tighten • Screw assemblies to 2 N-m (18 in. lbs.), 3. Electrical connector. 4. Check for TP sensor output. IDLE AIR CONTROL (IAC) VALVE N O T IC E : S in c e th e IA C v a lv e w a s re m o v e d d u rin g s e rv ic e , its o p e ra tio n s h o u ld b e te s te d >...
Page 211: Governor Drive Motor
6C1-10 MODEL 295 TBI UNIT Lubrication Requirements OOV£RNOR-DRIVE MOTOR Certain parts housed in the throttle body assembly Install or Connect (Figures 8 and 9) - ► that interface with the governor throttle drive assembly require special synthetic grease. The parts that require 1.
Page 212: 21-Si 200 Generator
21 -S I 200 GENERATOR 6P1 -1 SECTION 6D ENGINE ELECTRICAL CONTENTS SUBJECT PAGE 21-SI 200 Generator....................V.......... 6D1-1 CS-144 Generator........ ‘......................6D2-1 SD Starter Motors........................'..... 6D3-1 37-MT Starter Motors..
Page 213: Delco Remy 21-Si 200 Generator
6P1 -2 21 -SI 200 GENERATOR DELCO REMY 21-SI 200 GENERATOR GENERAL DESCRIPTION The rptoiri bearings Contain enough grease to elimi nate periodic lubrication. Two brushes carry current This generator has a solid-state regulator with a , through two slip rings to the field coil. two-terminal connector mounted inside the slip ring end The Stator windings are assembled on the inside of a frame (figure 1).
Page 214: Slip Ring End Frame
21-SI 200 GENERATOR 6P1-3 8. Operate the generator at moderate speed and adjust the carbon pile as required to obtain maxi mum output. 9. If the output is within 15 amperes of the rated out put, replace the regulator and check the field wind ing.
Page 215 6D1-4 21-SI 200 GENERATOR 1. TERMINAL AND SHIELD,“BAT”, , 23. SCREW , 4. BEARING,- REAR ,, . 24.. RETAINER .5. FRAME, SLIP .RING.END 25. BEARING, FRONT ■ 6. REGULATOR ‘ 26. FRAME, DRIVE 10. BRUSH HOLDER AND BRUSHES 29. FAN 13.
Page 216: Drive End Frame
21-SI 200 GENERATOR 6D1-5 6. Regulator , 8. Nut 10. Brush Holder . 11. Ground Screw 12. Insulated Screw' 17. Diode Trio 45. “ I” Terminal Attaching Strap F9218 Figure 6—21 -SI End Frame Assembly •Remove the nut by placing a 5/16-inch hex INSPECTION AND REPAIR wrench in the end'of the shaft to hold it;...
Page 217: Electrical Tests
6P1-6 21-SI 200 GENERATOR Open Circuit To check for opens, connect the test lamp or ohmme ter to each slip ring. If the lamp fails to light, or if the ohmmeter reading is high (infinite) the winding is open. Short Circuit or Resistance Check The winding is checked for Short-circuits or excessive resistance by connecting 12-volt battery and ammeter...
Page 218: Diode Trio Check
21 -SI 200 GENERATOR 601 -7 DIODE TRIO CHECK STATOR CHECKS Use an ohmmeter with a 1.5-volt cell and set it to the The stator windings may be checked with a 110-volt lowest range scale. Place the negative ohmmeter lead test lamp or an ohmmeter (figure 11).
Page 219: Assembly
6P1-8 21-SI 200 GENERATOR ASSEMBLY 4. Turn on the fast charger and slowly increase the charge rate. Observe the voltmeter. The lamp should go out at the voltage regulator setting. The Assemble (Figure 5) voltage regulator setting should be a minimum of 13.5 volts and a maximum of 15.5 volts.
Page 220 21 -$l 2 0 0 GENERATOR 6D1 -9 5. Fan (29). 6. Pulley (30). 7. Washer (19). 8. Pulley nut (32). N O T IC E : Too m u c h p re s s u re a p p lie d a g a in s t th e r o to r w ill d is to rt it.
Page 221: Specifications
6P1 -10 21 -SI 200 GENERATOR SPECIFICATIONS GENERATOR SPECIFICATIONS Field Current Rotation Cold Output 27°C (80T) Field-Ohms Output Part No. Series Viewing Dr. End 27°C (80°F) AMPS AMPS AMPS AMPS VOLTS 6.3-7.1 1600 6500 Either 1.7-1.8 1117903 21-SI 200 6.3-7.1 1600;...
Page 222 CS-144 GENERATOR 6P2-1 SECTION 6D2 CS-144 GENERATOR W h en fa s te n e rs a re re m o v e d , a lw a y s re in s ta ll th e m a t th e s a m e lo c a tio n fro m w h ic h th e y w e re re m o v e d a fa s te n e r n e e d s to b e re p la c e d , u s e th e c o rre c t p a r t n u m b e r fa s te n e r f o r th a t a p p lic a tio n .
Page 223 6P2-2 CS-144 GENERATOR nally, the regulator uses internal regulator voltage for control. Both the “L” and “I” terminals serve to turn on the regulator and allow field current to flow when the switch is closed. The “I” terminal may be connected either directly to the switch, or through a resistor.
Page 224 CS-144 GENERATOR 6D2-3 A. CONNECT RESISTOR TO “L” TERMINAL 1. GENERATOR 30. RESISTOR 31. VOLTMETER 32. AMMETER 33. BATTERY 34. CARBON PILE Figure 3—Connections for Generator Output Test DISASSEMBLY DRIVE END FRAME 3. Nut (28) and the washer (27) from the shaft. 4.
Page 225 6D2-4 CS-144 GENERATOR 2. TERMINAL, BATTERY 11. ROTOR 21. BEARING, DRIVE END 3. FRAME, SLIP RING 12. SCREW, BRIDGE AND 22. FRAME, DRIVE END CAPACITOR ATTACHING 23. COLLAR, BEARING 4. BEARING, SLIP RING 13. SCREW, REGULATOR (OUTSIDE) ATTACHING 24. FAN 5.
Page 226 CS-144 GENERATOR 6D2-5 Figure 6—Removing the Slip Ring End Bearing (Some Models) Figure 8—Rectifier Bridge in End Frame (Early Models) 9. BRUSH KIT, WITH HOLDER 10. CONNECTOR, RECTIFIER BRIDGE 12. SCREW, REGULATOR ATTACHING (INSULATED) 13. SCREW, RECTIFIER BRIDGE AND CAPACITOR ATTACHING (INSULATED) 15.
Page 227 6D2-6 CS-144 GENERATOR 13. Screw and, terminal insulator (40) from the outside of the slip ring end frame (figure 10). 14. BAT terminal nut and washer. 15. BAT terminal from the rectifier bridge. Figure 10—BAT Terminal Insulator on End Frame (Later Models) REPAIR AND TESTING 2.
Page 228 CS-144 GENERATOR 6P2-7 Remember that the winding resistance and ammeter ELECTRICAL TESTS readings will vary slightly with winding temperature Except as stated, make the following tests with an changes. If the rotor is not defective, but the generator ohmmeter on the low range scale. fails to supply rated output, the problem is in the rectifi...
Page 229 6D2-8 CS-144 GENERATOR one low reading. If both readings are the same, replace the rectifier bridge. Repeat this same test between the grounded heat sink and the other two terminals* and between the insulated heat sink and each of the three terminals.
Page 230 CS-144 GENERATOR 6D2-9 9. Capacitor. • Make sure the side with the insulator material is placed against the end frame (ground). 10. Two bolts (6) through the rectifier bridge (figure 9). 11. Two insulated screws (38) through the rectifier bridge. ALL MODELS: •...
Page 231 6D2-10 CS-144 GENERATOR SPECIFICATIONS GENERATOR SPECIFICATIONS Series Rotor Field-Ohms Field Current @ 12 Ampere r'ari no* Volts 27°C (80 F) AMPS Rating (Type 100) 27 Q (80°F) 2.1-2.4 5.0-5.7 10480022 CS-144 CS-144 2.1-2.4 5.0-5.7 10480023 FASTENER TIGHTENING SPECIFICATIONS...
Page 232 SP STARTER MOTORS 6P3-1 SECTION 6D3 SD STARTER MOTORS N O T IC E : W h en fa s te n e rs a re re m o v e d , a lw a y s re in s ta ll th e m a t th e s a m e lo c a tio n fro m w h ic h th e y w e re re m o v e d .
Page 233 6D3-2 SD STARTER MOTORS GENERAL DESCRIPTION DELCO REMY SB-260 AND coils. On the SD-300, one of the pole shoe screws has a grounding stud on it. SD-300 STARTER MOTORS The starter motor has the drive end housing extended to enclose the shift lever and solenoid plunger. The SD-260 and SD-300 are straight drive starters The starter motor bearings are lubricated during with the pinion driven directly by the armature shaft...
Page 234 SP STARTER MOTORS 6P3-3 DIAGNOSIS series with a fully charged 12-volt battery, and a switch STARTER MOTOR TESTS in the open position. Close the switch and compare the Before disassembling the starter motor for repair, the rpm, current, and voltage readings with the specifica following tests should be made.
Page 235 6D3-4 SD STARTER MOTORS DISASSEMBLY ' 1 > i ’ ■ DISASSEMBLY OF THE SD-300 6. Field frame (57) from the drive housing (31) and the armature assembly (9). STARTER MOTOR DRIVE END If the motor does, not perform to specifications, it may need to be disassembled for further testing Of the com...
Page 236 SP STARTER MOTORS 6D3-5 Figure 5—Starter Motor Figure 7— Retaining Ring on Armature Retaining Ring 5. Shift lever (1) and the attached solenoid plunger SOLENOID (2) from the drive housing. First perform the electrical tests on the solenoid 6. Roll pin (40) in order to separate the shift lever described under “Inspection and Repair”...
Page 237 6D3-6 SD STARTER MOTORS 33. Brush 49. Grounded Brush Holder 23. “S” Terminal 50. Insulated Brush Holder 24. Motor Terminal 63. Pivot Pin 66. Contact Disc Assembly 64. Brush Holder Spring 67. Cover 65. Brush Holder Support F4220 ■ F4219 Figure 9—Replacing Brushes on the SD-300 Figure 10—Solenoid Disassembled Models with Solenoid Shield:...
Page 238 SD STARTER MOTORS 6D3-7 1. LEVER, SHIFT 2. PLUNGER 3. SOLENOID 5. SPRING 7. FRAME, DRIVE END 9. ASSEMBLY, ARMATURE 11. GROMMET 13. BEARING COMMUTATOR END 37. RING, PINION STOP 14. WASHER, BRAKE RETAINING 15. PLUG 39. COLLAR, PINION STOP 16.
Page 239 6D3-8 SD STARTER MOTORS REPAIR AND TESTING • Look for loose connections where the conduc INSPECTION AND REPAIR tors join the commutator bars. Poor connections cause arcing and burning Of the commutator. Clean 6. Armature for grounds by using a test lamp (figure ■...
Page 240 SP STARTER MOTORS 6 P M 7. Brushes for wear. If the brushes are worn to half the size of a new brush, replace the brushes. On the SD-260, the brushes and brush holders are an integral part of the frame and field assembly, so the assembly must be replaced.
Page 241 603-10 SD STARTER MOTORS 3. Solenoid 22. Battery 23. “S” Terminal 24. “M ” Terminal 25. “BAT” Terminal 26. Voltmeter 27. Ammeter 29. Switch 30. Carbon Pile A. Checking Solenoid Pull-in Winding B. Checking Solenoid Hold-in Winding F4222 Figure 17—Solenoid Test Connections...
Page 242 _________ SD STARTER MOTORS 6P3-11 ASSEMBLY ASSEMBLY OF THE • Lightly lubricate the shaft underneath the drive assembly with a silicone grease, such as Del- SD-300 STARTER MOTOR co-Remy lubricant No. 1960954. The drive assembly does not require lubrication. SOLENOID ;...
Page 243 6P3-12 SP STARTER MOTORS 1. Drive assembly onto the armature shaft. 2. Pinion stop collar (39) with the flat side of the collar toward the drive pinion (figure 20). 3. New retaining ring (37) onto the armature shaft. • Slide the ring down the shaft until it seats in the shaft groove.
Page 244 SD STARTER MOTORS 6D3-13 6. Shift lever (1) to the drive assembly by spreading PINION CLEARANCE CHECK the arms slightly to snap it onto the buttons on the The pinion clearance cannot be adjusted but should drive collar. be checked after reassembly of the motor. Improper 7.
Page 245 6D3-14 SD STARTER MOTORS 4. Push the pinion back toward the commutator end 3. Momentarily flash a jumper lead from the solenoid motor terminal to the solenoid frame. This will shift to eliminate stack movement. the pinion into cranking position and it will remain 5.
Page 246 __________ ________ 37-MT STARTER MOTORS 6P4-1 SECTION 6D4 37-MT STARTER MOTORS N O T IC E : W h en fa s te n e rs a re re m o v e d ] a lw a y s re in s ta ll th e m a t th e s a m e lo c a tio n fro m w h ic h th e y w e re re m o v e d .
Page 247 6D4-2 37-MT STARTER MOTORS 8: WICK, OIL 9. FRAME, END (REMOVABLE) 9 ‘ 24. BRUSH 27. BOOT, SEALING 126 43 43. O-RING 54. WICK, OIL 58. STRAP, CONNECTOR . 79. GASKET 101. HOUSING, TWO-PIECE 102. SHIFT MECHANISM, TOTALLY ENCLOSED 126. SEAL, SHAFT 127.
Page 248 37-MT STARTER MOTORS 6P4-3 107. YEAR 108. MONTH 109. DAY OF MONTH Figure 3—Identification Label Figure 4— Armature Identification lever housing and the commutator end frame are attached to the field frame by screws entering threaded holes in the field frame. IDENTIFICATION Starter Motor (Figure 3) T|he build date uses the format of year, month, and...
Page 249 6D4-4 37-MT STARTER MOTORS • If the armature does rotate freely, the motor Make disconnections only with the switch open. Test results may be interpreted as follows: should be given a no-load test before disas sembly. 1. Rated current draw and no-load speed indicate normal condition of the starter motor.
Page 250 37-MT STARTER MOTORS 6D4-5 just far enough to rest the spring against the side SOLENOID BOOT of the brush (figure 11). Disassemble (Figures 8 and 9) 6. Brush attaching screws (23) from the positive (insu lated) brushes and field coil leads: 1.
Page 251 6D4-6 37-MT STARTER MOTORS V3022 Figure 8—37-MT Components...
Page 252 37-MT STARTER MOTORS 6P4-7 COMPONENTS IN SHADED AREA ARE PART OF OVERCRANK PROTECTION OPTION. 2. NUT, TERMINAL MOUNTING 24. BRUSH 48. HOUSING, LEVER 3. WASHER, TERMINAL MOUNTING 25. SPRING, BRUSH 49. SEAL, OIL 4. WASHER, TERMINAL MOUNTING 26. WASHER 50. O-RING 5.
Page 253 6D4 8 37-MT STARTER MOTORS Figure 13—Removing or Installing the Lever Housing 22. ASSEMBLY, PLATE 24. BRUSH. 25. SPRING, BRUSH V3062 Figure 11—Retracting the Brushes on the Plate Assembly 18. ARMATURE 113. BLADE, SAW 114. GROWLER V3034 Figure 14—Testing the Armature for Short Circuits 5.
Page 254 37-M T STARTER MOTORS 6D4-9 section. A high reading indicates a shorted or grounded winding, and a low reading indicates excessive resistance. — The winding resistance can be read directly using a digital ohmmeter that can measure tenths of an ohm. 16.
Page 255 6D4-10 37-MT STARTER MOTORS 1 1 8 1 1 9 A. CHECKING HOLD-IN WINDING (TYPE 300) B. CHECKING HOLD-IN WINDING (TYPE 350) C. CHECKING PULL-IN WINDING (BOTH) 115. TERMINAL, “BAT” 116. TERMINAL, "M ” 117. TERMINAL, “S" 118. VOLTMETER 119. AMMETER 120.
Page 256 37-MT STARTER MOTORS 6D4-11 3. Oil wicks (54, 54, and 8) prior to installation by, MAIN ASSEMBLIES soaking new wicks for at least one hour in SAE 20 Install or Connect (Figures 8 and 9) non-detergent oil. The same type oil may be added to previously installed wicks at other times if desired.
Page 257 6P4-12 37-MT STARTER MOTORS 15. Drive housing to the lever housing, aligning the marks made during disassembly. 16. Drive housing mounting screws (38). V Screws to 24 N-m (18 ft. lbs.), 17. Thrust washer (20) onto the armature shaft at the commutator end.
Page 258 37-MT STARTER MOTORS 6D4-13 4. Push the pinion Or drive back toward the com mutator^end to eliminateslack movement. | • Screws to 5.6 N-m (50 in. lbs,). 5. Measure clearance as shown if figure 21. Com 26. Solenoid (62) to the lever housjng with three sole pare the reading to that given in “Specifica- noid mounting screws (61).
Page 259 6D4-14 37-MT STARTER MOTORS SPECIFICATIONS STARTER MOTOR 1993947* 37MT 6000 8700 7104 7104 1993963* 37MT 6000 8700 ; 160 6000 8700 1993964* 37MT 7104 Pinion Clearance: * 0.25 to 1.78 mm (0.01 to 0.07-lnch) SOLENOID SWITCH u l - l n .
Page 260 DISTRIBUTORS 6D5-1 SECTION 6D5 DISTRIBUTORS N O T IC E : W h en fa s te n e rs a re re m o v e d ', a lw a y s r e ln s ta llth e m a t th e s a m e lo c a tio n fro m w h ic h th e y w e re re m o v e d .
Page 261 6P5-2 DISTRIBUTORS B. Drive out the roll pin with a small punch (figure • 5. Driven gear (29), washer or .spring (31), or tang washer (33)..Shaft (26) with the timer core from the housing (30): 7.
Page 262 DISTRIBUTORS 6D5-3 _____; _________J F9230 Figure 3—Distributor Components . Shield (50). INSPECTION AND 9. Pickup coil connector from the module (14). ELECTRICAL TESTS j • Lift the locking tab with a screwdriver. 10. Pickup coil (11). Inspect 11. Two screws holding the ignition control module to the housing.
Page 263 6D5-4 DISTRIBUTORS • Connect an ohmmeter to either pickup coil lead ASSEMBLY and the housing as shown in figure 5, step;ij. The reading should be infinite. If hot, replace -► the'coil. - • Connect an ohmmeter to both pickup coil leads as shown in figure 5, step 2.
Page 264 DISTRIBUTORS 6DS-5 Use a small hammer to tap the retainer evenly | down onto the center bushing. When installing ! the square retainer, make sure both teeth are ; seated in the groove on the bushing. • The retainer should hold the shield, pickup coil, and pole piece firmly.

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Brakes

Air Brake Valves 5H-1 Section 5H Air Brake Valves

Air Foundation Brakes 51-1 Section 51 Air Foundation Brakes

Section 5J

L Rpo Lro, Vin M

Model 295 Tbi Unit 6C1-1 Section 6C1 Model 295 Tbi Unit

Section 6D1 21-Si 200 Generator

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