Chevrolet 1991 Light Duty Truck Repair Manual

Chevrolet 1991 light duty truck unit repair manual

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Summary of Contents for Chevrolet 1991 Light Duty Truck

Page 1 CHEVROLET TRUCKS...
Page 2 --------— ■ * “ .—...
Page 3 Chevrolet Motor Division of General Motors Corp. This includes all text, illustrations, tables and charts.
Page 4 CAUTION To reduce the chance of personal injury and/or property damage, the fol lowing instructions must be carefully observed. Proper service and repair are important to the safety of the service techni cian 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 5 1991 LIGHT TRUCK UNIT REPAIR MANUAL When reference is made in this manual to a brand name, number, or specific tool, an equivalent product may be used in place of the recommended item. All information, illustrations, and specifications contained in this manual are based on the latest product information available at the time of publication approval.
Page 6 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. CONTENTS SECTION SUBJECT...
Page 7: General Information
GENERAL INFORMATION OA-1 SECTION OA GENERAL INFORMATION CONTENTS SUBJECT PAGE 0A- 1 Service Parts Identification Label OA- 1 Vehicle Identification Number 0A- 1 C ertification Label 0A- 2 Engine Identification Number 0A- 3 lla n s m is s io n Identification Number 0A- 3 Model Reference 0A- 3...
Page 8 F Flint, Ml 1991 Chassis Only J Janesville, Wl Hi-Cube/Cutaway Van Code Make S St. Louis, MO Forward Control Chevrolet Bus* V Pontiac, Ml Four-Door Cab/Utility Chevrolet Incomplete Z Fort Wayne, IN Two-Door Cab Chevrolet Truck 0 Pontiac, Ml GMC Incomplete...
Page 9 GENERAL INFORMATION OA-3 TRANSMISSION IDENTIFICATION NUMBER Refer to figures 10 through 13 for determining trans mission identification numbers and code meanings. MODEL REFERENCE Refer to figures 14 through 19 for determining the vehicle model. C, R, and S models are two wheel drive.
Page 10 OA-4 GENERAL INFORMATION 1. Engine I.D. 2. Engine I.D. (Optional Location) F7553 Figure 8—5.0L, 5.7L, 7.4L Engine I.D. Location Figure 9—6.2L Diesel Engine I.D. Location per inch. The thread pitch is in between the customary FASTENER STRENGTH coarse and fine thread pitches. IDENTIFICATION Metric and customary thread notation differ slightly.
Page 11 GENERAL INFORMATION OA-5 JULIAN DATE (OR DAY OF THE YEAR) MODEL YEAR [HYDRA MATIC 4L601 <1 -1991) 1 .YK, M 209 ,A^ SHIFT BUILT MODEL A & B » FIRST SHIFT C 4 H - SECOND SHIFT 1. Transmission I.D. Location BUILD DAY OF MONTH MODEL YEAR 01 .
Page 12 OA-6 GENERAL INFORMATION CALENDAR YEAR I JULIAN DATEl BUILT I MODEL LETTERS I HYDRA-MATIC SERIAL NO. 0*V. OF GEN. MTRS CORP. .9 1 , . ,B C P MODEL MODEL YEAR LETTERS 2. Transmission Identification Tag 1. Transmission I.D. | SERIAL NUMBER [— F9135 I MODEL | p l a n t...
Page 13 GENERAL INFORMATION OA-7 R-V MODELS Suburban Pickup, Bonus/Crew Cab Utility Vehicle Jimmy (Blazer) /q m — — U F7558 Figure 14—R/V Models...
Page 14 OA-8 GENERAL INFORMATION G VAN MODELS Rally (Sportvan) Vandura (Chevy Van) Cutaway Van Magnavan (Hi-Cube Van) Extended Van ~Tl- ** “ g fc / ------------------ — " F7569 Figure 15— G Models...
Page 15 GENERAL INFORMATION 0A P MODELS Motor Home Chassis Value Van (Step Van) (Aluminum) Forward Control Chassis Value Van (Step Van) (Steel) GIP Cutaway Cab F7570 Figure 16—P Models F4481 Figure 17—C/K Models...
Page 16 0A-10 GENERAL INFORMATION S/T UTILITY VEHICLE JIMMY (BLAZER) S/T PICKUP, REGULAR CAB 4 DOOR S/T UTILITY VEHICLE JIMMY (BLAZER) S/T PICKUP, EXTENDED CAB S/T CHASSIS CAB F9136 Figure 18—ST Models...
Page 17 GENERAL INFORMATION OA-11 PASSENGER VAN CARGO VAN 1. Grade 2 (GM 200-M) 2. Grade 5 (GM 280-M) 3. Grade 7 (GM 290-M) 4. Grade 8 (GM 300-M) 5. Manufacturer’s Identification 6. Nut Strength Identification 7. Identification Marks (Posidriv Screw Head) EXTENDED VAN ___________________________________ F0695 Figure 20—Bolt and Nut Identification...
Page 18 OA-12 GENERAL INFORMATION E - External Drive ______________________________________ B2221 Figure 22—Six Lobed Socket Head Fasteners...
Page 19 GENERAL INFORMATION OA-13 ( I° I) 6 & 6.3 In. Lbs. 1,2, 3, 6, 7, 8,9 In. Lbs. .437 .250 .312 .375 .500 .562 .625 .750 In. Lbs. 1,2, 3, 6, In. Lbs. 6. Nylon Strip Or Patch A. Metric Sizes 1.
Page 20 CONVERSION TABLE to get equivalent to get equivalent Multiply number of: Multiply number of: LENGTH ACCELERATION Inch 25.4 millimeters (mm) Foot/sec2 0.304 8 meter/sec2 (m/s2 ) Foot 0.304 8 meters (m) Inch/sec2 0.025 4 meter/sec2 Yard 0.9144 meters TORQUE kilometers (km) Mile 1.609 Pound-inch...
Page 21 GENERAL INFORMATION OA-15 DECIMAL AND METRIC EQUIVALENTS Metric Fractions Decimal In. Metric mm Fractions Decimal In. 13.09687 0.39688 33/64 0.515625 1/64 0.015625 17/32 0.53125 13.49375 1/32 0.03125 0.79375 35/64 13.89062 3/64 0.046875 1.19062 0.546875 1.58750 9/16 0.5625 14.28750 1/16 0.0625 1.98437 37/64 14.68437...
Page 22 OA-16 GENERAL INFORMATION...
Page 23 A-6 AIR CONDITIONING COMPRESSOR 1B1-1 SECTION 1 AIR CONDITIONING CONTENTS SUBJECT PAGE A-6 A ir Conditioning C om pressor........................... 1B1-1 V-5 A ir Conditioning C om pressor........................... 1B2-1 R-4 A ir Conditioning C om pressor........................... 1B3-1 HR-6 HE A ir Conditioning C om pressor........................1B4-1 SD-709 A ir Conditioning C o m pressor........................1B5-1 SECTION 1B1 A-6 AIR CONDITIONING COMPRESSOR...
Page 24 1B1-2 Ar6 AIR CONDITIONING COMPRESSOR viscosity refrigerant oil after repair. Refer to "Specifica They have been prepared in sequence in order of tions.” accessibility of the components (figure 1). For compressor removal and installation, refer to the IDENTIFICATION proper truck service manual. An identification label attached to the compressor Do not kink or place excessive tension on lines or provides the name of the manufacturer, model number...
Page 25 A-6 AIR CONDITIONING COMPRESSOR 1B1-3 1. Nut 2. Clutch 3. Ring 4. Pulley Bearing Ring 5. Bearing 6. Pulley 7. Clutch Coil Ring 8. Coil 9. Shell 10. Sleeve Seal 11. Flat Seal 12. Ring 13. Seat Seal 14. Shaft Seal 15.
Page 26 1B1-4 A-6 AIR CONDITIONING COMPRESSOR 2. Clutch F9137 Figure 3— Removing the Clutch Plate and Hub Assembly 1. Clutch plate and hub assembly (2). 2. Pulley bearing retainer (2) with J 6435 (figure 6). 3. Pulley (6). • Install J 9395 over the end of the compressor shaft (38) (figure 7).
Page 27 Ar6 AIR CONDITIONING COMPRESSOR 1B1-5 | Important • When using J 24092, the puller arms must extend around to the rear side of the pulley. Do not attempt to pull the pulley off by engaging the puller arms in a multi-groove pulley. 4.
Page 28 1B1-6 Ar6 AIR CONDITIONING COMPRESSOR A. Locator Notch 8. Coil 3. Pulley (6) and bearing (5) to shaft (38) with J 8092 B. Locator Hole 16. Front Head and J 9481-A. F1578 4. Retainer ring (4) to pulley (6) and bearing (5). 5.
Page 29 A-6 AIR CONDITIONING COMPRESSOR 1B1-7 3. Coil and housing retainer ring (7) with J 6435. p jjf l Clean • Remove any excess adhesive. 4. Pulley and bearing assembly (5 and 6). 5. Clutch plate and hub assembly (2). MAJOR REPAIR TO THE COMPRESSOR SHAFT SEAL REPLACEMENT \+-*\ Remove or Disconnect (Figures 1, 13, 14 and 12.
Page 30 1B1-8 A-6 AIR CONDITIONING COMPRESSOR J 9392-01 C Straight Edge D. 0.793 mm (0.0313") E. Wire Gage 0.66 mm (0.026") Should “GO” F9143 1.91 mm (0.075") Should “ Not Go” or Should “Just Go” Figure 15 — Removing/installing Shaft Seal 10.
Page 31 A-6 AIR CONDITIONING COMPRESSOR 1B1-9 Push the seal (13) into place with a rotary PRESSURE RELIEF motion. VALVE REPLACEMENT | Important |*“ »| Remove or Disconnect (Figure 1) • Do not dislodge the seal (O-ring) (15). 1. Valve (56). 4. Shaft seal seat retaining ring (12) with J 5403 (fig 2.
Page 32 1B1-10 Ar6 AIR CONDITIONING COMPRESSOR NOTICE: Turning the compressor at less than turns to distribute the oil to the cylinder and piston one revolution per second can result in a low areas. er pump up pressure and disqualify a good 10.
Page 33 A-6 AIR CONDITIONING COMPRESSOR 1B1-11 SPE C IA L TOOLS J S403 J 9625-A J 21352-A J 9392-01 C T T D J 22974-A J 23138-A J 9396 J 24092 & J 9398-A ^ 25030-A J 9399-A J 9401-B J 38505 J 9459 J 33011 J 9553-01...
Page 34 1B1-12 Ar6 AIR CONDITIONING COMPRESSOR...
Page 35 V-5 AIR CONDITIONING COMPRESSOR 1B2-1 SECTION 1B2 V-5 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 36 1B2-2 V-5 AIR CONDITIONING COMPRESSOR removal of the compressor. The parts must be kept clean at all times and any parts to be reassembled should be cleaned with Trichlorethane, naptha, Stod dard solvent, kerosene or equivalent solvent and dried with dry air. Use only lint free cloths to wipe parts. Up to 118 ml (4 fl.oz.) of oil can collect in the crank...
Page 37 V-5 AIR CONDITIONING COMPRESSOR 1B2-3 High Pressure Relief Valve High Side Low Pressure Valve High Side Cut-Off Switch Control Valve Shaft Nut Clutch Plate and Hub Assembly Pulley Bearing Retainer Pulley Bearing Pulley Clutch Coil Assembly Retainer Seal O-ring Bolt Gasket Front Head Shim...
Page 38 1B2-4 V-5 AIR CONDITIONING COMPRESSOR MINOR REPAIR TO THE COMPRESSOR 3. Shaft key (23). CLUTCH PLATE AND HUB • Retain shaft key (21) if usable. ASSEMBLY REPLACEMENT Inspect Clean All parts and replace as necessary. • The compressor assembly with solvent and blow dry with dry air.
Page 39 V-5 AIR CONDITIONING COMPRESSOR 1B2-5 • Measure the air gap between contact surfaces of the clutch plate and hub assembly (22) and the pulley (26). The gap should be 0.38-0.64 mm (0.015-0. 025-inch). • Remove J 33013-B. 3. Shaft nut (21). I f f l Inspect •...
Page 40 1B2-6 V-5 AIR CONDITIONING COMPRESSOR slots in the pulley (26) contact surface. Rotate J 33020 clockwise so the tangs will lock into the segments between the slots (figure 10). • Hold J 33020 in place and tighten the puller screw against J 33023-A puller pilot to remove the pulley (26) (figure 10).
Page 41 V-5 AIR CONDITIONING COMPRESSOR 1B2-7 A. Stake Three Locations, 120° Apart B6546 Figure 14— Bearing Stake Locations in the Pulley Bore 3. Pulley (26) on the front head. • Position J 33017 and J 33023-A over the inner race of the bearing (figure 15). •...
Page 42 1B2-8 V-5 AIR CONDITIONING COMPRESSOR CLUTCH COIL ASSEMBLY REPLACEMENT Remove or Disconnect (Figures 3 and 16) Tools Required: J 8433-1 Puller Bar J 8433-3 Puller Screw J 33023-A Puller Pilot J 33025 Clutch Coil Puller Legs 1. Clutch plate and hub assembly (22). 2.
Page 43 V-5 AIR CONDITIONING COMPRESSOR 1B2^S — Stake size should be one half the area of • When the clutch coil assembly (27) is seated the p u n ch tip and 0 .2 8 -0 .3 5 mm on the front head, use a 3 mm (1/8-inch) diam (0.010-0.015-inch) deep (figure 19).
Page 44 1B2-10 V-5 AIR CONDITIONING COMPRESSOR • Dip the new O-ring seal in clean 525 viscosity refrigerant oil. 1. J 34614 onto the shaft. 2. O-ring seal using J 33011 (figure 24). • Insert J 33011 into the compressor neck until the installer “bottoms.”...
Page 45 V-5 AIR CONDITIONING COMPRESSOR 1B2-11 1. New O-ring. J 5403 Internal Snap Ring Pliers 2 Pressure relief valve (2). 1. O-ring seals (44) to the switch cavity. Tighten • Dip the O-ring seals into clean 525 refrigerant oil. Pressure relief valve (2) to 9 N m (84 in.lbs.). 2 Switches (3) and (4).
Page 46 1B2-12 V-5 AIR CONDITIONING COMPRESSOR • Attach the compressor to J 34992 fixture and tion and/or discharge valves leaking, an internal mount the compressor in a vise so that the com leak, or an inoperative valve. Disassemble the pressor will be in a horizontal position and the compressor and repair as necessary.
Page 47 V-5 AIR CONDITIONING COMPRESSOR 1B2-13 SPECIAL TOOLS J 33022 J 5403 J 23128-A J 33023-A J 21352-A 20 J 33024 J 33011 J 29886 J 8433-1 J 33013-B J 33025 J 8433-3 J 34993 J9398-A J 33017 J 34992 J 33019 J 9481-A J 9553-01 J 33020...
Page 48 1B2-14 V-5 AIR CONDITIONING COMPRESSOR...
Page 49 R-4 AIR CONDITIONING COMPRESSOR 1B3-1 SECTION 1B3 R-4 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 50 1B3-2 R-4 AIR CONDITIONING COMPRESSOR Figure 2—R-4 Compressor, Poly-Groove Pulley ly p e with 4 Pole Clutch and Driver Shown with a 6 Pole Clutch and Driver Shown 1. Shaft Nut 13. Seal 2. Clutch Hub Key 14. Bolt 3. Clutch Drive Hub 15.
Page 51 R-4 AIR CONDITIONING COMPRESSOR 1B3-3 MINOR REPAIR TO THE COMPRESSOR CLUTCH PLATE AND HUB REPLACEMENT Remove or Disconnect (Figures 3, 4, 5 and 6) Tools Required: J 9399-AThin Wall Socket J 33027-A Clutch Hub Holding Tool J 33013-B Hub and Drive Plate Remover J 25008-A Compressor Holding Fixture •...
Page 52 1B3-4 R-4 AIR CONDITIONING COMPRESSOR 1. Clutch plate and hub assembly (3). 2. Snap ring (4) with J 6083 (figure 9). A. Air Gap (.020-040-inch) 3. Clutch Plate and Hub • Mark the location of the clutch coil terminals. Assembly Important 9401 -B •...
Page 53 R-4 AIR CONDITIONING COMPRESSOR 1B3-5 Install or Connect (Figures 3, 13, 14 and 15) Tools Required: J 6083 External Snap Ring Pliers J 29886 Universal Drive Handle J 9481-A Pulley and Bearing Installer J 26271-A Rotor and Bearing Installer • Place the rotor and hub assembly face down on a clean, flat surface.
Page 54 1B3-6 R-4 AIR CONDITIONING COMPRESSOR CLUTCH ROTOR ANDj/OR BEARING REPLACEMENT POLY-GROOVE TYPE Remove or Disconnect (Figures 3, 6, 9 and 16) Tools Required: J 6083 External Snap Rings Pliers J 29886 Universal Driver Handle J 9398-A Rotor Bearing Remover J 25031 Rotor and Bearing Puller J 33020 Pulley Puller 1.
Page 55 R-4 AIR CONDITIONING COMPRESSOR 1B3-7 Figure 18—Bearing Installation Figure 17— Bearing Removal I ? I Important • It is not necessary to remove the staking in front of the bearing. However, it will be neces sary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be dam...
Page 56 1B3-8 R-4 AIR CONDITIONING COMPRESSOR the staking pin location. A heavy duty rubber band 2. Pulley rim mounting screws and discard. may be used to hold the stake pin in the guide, 3. Slide the pulley rim off the rotor and hub assem and the stake pin should be properly positioned in bly.
Page 57 R-4 AIR CONDITIONING COMPRESSOR 1B3-9 • Align the three protrusions on the rear of the f+ + | Install or Connect (Figures 3 and 19) clutch coil housing with the locator holes in the front head. Tool Required: J 26271-A Rotor and Bearing Installer 3.
Page 58 1B3-10 R-4 AIR CONDITIONING COMPRESSOR Install or Connect (Figures 22, 24 and 25) Tools Required: J 33011 O-Ring Installer J 23128-A Seal Seat Remover and Installer J 34614 Shaft Seal Protector J 5403 External Snap Ring Pliers J 9625-A Pressure Test Fixture 1.
Page 59 R-4 AIR CONDITIONING COMPRESSOR 1B3-11 vapor to equalize pressure to the drum pres FRONT HEAD AND O-RING sure. Temporarily install the shaft nut and with REPLACEMENT the compressor in a horizontal position and using a wrench, rotate the compressor shaft in normal direction of rotation several times by Remove or Disconnect (Figures 26 and 27) hand.
Page 60 1B3-12 R-4 AIR CONDITIONING COMPRESSOR K \ | Tighten • Front head mounting screws to 27 N-m (20 ft.lbs.). 4. New shaft seal. 5. Clutch Rotor and Bearing, Clutch Coil and Pulley Rim assembly to the front head using J 26271-A. •...
Page 61 R-4 AIR CONDITIONING COMPRESSOR 1B3-13 18. On the R-4 compressor, tilt the compressor so that If further assembly or processing is required, a ship ping plate or J 9625-A should be installed to keep out the compressor suction and discharge ports are air, dirt and moisture until the compressor is installed.
Page 62: Special Tools
1B3-14 R-4 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 29886 J 5403 9m / * . J 9625-A J 33011 J 21352-A J 5420 J 23128-A J 6083 J 33013-B J 9398-A J 25008-A J 33019 J 9399-A J 33020 J 25031 J 9401 -B J 25287 J 33027-A...
Page 63 HR-6 HE AIR CONDITIONING COMPRESSOR 1B4-1 SECTION 1B4 HR-6 HE 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 64 1B4-2 H IM HE AIR CONDITIONING COMPRESSOR or cylinder repair is needed, replace the internal cylin der assembly. All clutch parts, valve mechanisms, and head assemblies are serviceable, plus seals and gas kets. Refrigerant oil, dispersed in the refrigerant vapor, lubricates the system.
Page 65 HR-6 HE AIR CONDITIONING COMPRESSOR 1B4-3 cedures require that the system be discharged of refrig and an equal amount of new 525 viscosity refrigerant erant. oil added to the compressor. Note: The service compressor is shipped with 236 ml IDENTIFICATION (8 fl.oz.) of 525 viscosity refrigerant oil.
Page 66 1B4-4 HR-6 HE AIR CONDITIONING COMPRESSOR 2. Clutch Plate And Hub Assembly 2. Clutch Plate and Hub Assembly 5. Pulley (Rotor) 21. Key 35. Keyway (Shaft) ________________________________________ B6574 F4459 Figure 6— Removing the Clutch Plate and Figure 7— Positioning the Shaft Key, Clutch Plate, Hub Assembly and Hub Assembly J 33013-B and check that the shaft key (21) is...
Page 67 HR-6 HE AIR CONDITIONING COMPRESSOR 1B4-5 ROTOR AND/OR BEARING ASSEMBLY REPLACEMENT Remove or Disconnect (Figures 4, 9, 10, 11 and 12) Tools Required: J 6083 External Snap Ring Pliers J 29886 Driver Handle J 9398-A Pulley Bearing Remover J 33020 Pulley Puller J 33023-A Puller Pilot 1.
Page 68 1B4-6 HR-6 HE AIR CONDITIONING COMPRESSOR 5. Pulley Rotor "Face Down" F7096 Figure 12 —Removing the Pulley Bearing Figure 13— Installing the Pulley Rotor Bearing — The staked metal should not contact the outer race of the bearing to prevent the pos sibility of bending the outer race.
Page 69 HR-6 HE AIR CONDITIONING COMPRESSOR 1B4-7 E 5 l Tighten • J 8433-1 forcing screw against J 33025. • Clutch coil assembly ( ). Replace as necessary. Install or Connect (Figures 4, 18, 19 and 20) Tools Required: J 8433-1 Puller Bar J 33024 Clutch Coil Installer Adapter J 33026 Compressor Holding Fixture 1.
Page 70 1B4-8 HR-6 HE AIR CONDITIONING COMPRESSOR Stake size should be one half the area of the p un ch tip and 0 .2 8 -0 .3 5 mm (0.010-0.015-inch) deep (figure 20). . Clutch Coil Assembly A. Drift Punch 3 mm (1 /s inch) B.
Page 71 HR-6 HE AIR CONDITIONING COMPRESSOR 1B4-9 MAJOR REPAIR TO THE COMPRESSOR • Dip the shaft lip seal in clean 525 viscosity refrig SHAFT SEAL REPLACEMENT erant oil and install shaft lip seal on J 23128-A. • Bottom the shaft lip seal into the compressor neck Remove or Disconnect (Figures 4, 21, 22, 23 area using J 23128-A.
Page 72 1B4-10 HR-6 HE AIR CONDITIONING COMPRESSOR 9. One-Piece Seal A. J 23128-A Seal Remover and Installer B. J 34614 Shaft Seal Protector F6507 Figure 23— Removing or Installing Shaft Lip Seal £\| Tighten • High pressure relief valve (32) to 9 N m (84 in.lbs.).
Page 73 HR-6 HE AIR CONDITIONING COMPRESSOR 1B4-11 Figure 25—Installing the Seal Seat O-Ring Figure 26—HR-6 HE Compressor Rear Head Detail LEAK TESTING • Disconnect both gage adapters or hoses from Tools Required: J 9625-A Pressure Test Plate J 9625-A. J 23500-01 Portable Charging Station •...
Page 74 1B4-12 HR-6 HE AIR CONDITIONING COMPRESSOR and repair as necessary. Reassemble and repeat • Allow a 10-minute drain period and then charge the pump-up test. the compressor with the proper amount of oil. Pour the new 525 viscosity refrigerant oil into the suc •...
Page 75 HR-6 HE AIR CONDITIONING COMPRESSOR 1B4-13 SPE C IA L TOOLS J 21352-A J 5403 J 33023-A 10 . 23128-A J 6083 J 33024 J 33025 J 8433-1 J 8433-3 J 23500-01 29086 J 9398-A J 33013-B J 9481-A J 34614 J 33019 J 9553-01 J 5420...
Page 76 1B4-14 HR-6 HE AIR CONDITIONING COMPRESSOR . Snap Ring Pliers 9. Support Block Point 13mm Socket 2. Snap Ring Pliers 10. Seal Remover and Installer 17. Puller Pilot 3. Puller Bar 11. Portable Charging Station 18. Clutch Coil Installer Adapter 4.
Page 77 SD-709 AIR CONDITIONING COMPRESSOR 1B5-1 SECTION 1B5 SD-709 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 78 1B5-2 SD-709 AIR CONDITIONING COMPRESSOR 4. Oil around the filler hole. If the O-ring is damaged, Hex nut using a 19 mm socket. it can be replaced. If the threads are stripped, 2 Clutch front plate using J 37825 (figure 4). replace the compressor.
Page 79 SD-709 AIR CONDITIONING COMPRESSOR 1B5-3 7. Field coil (10). • Loosen the coil lead wire from the clip on top of the compressor front housing. • Remove the snap ring (7) (figure 9). • Remove the coil. Figure 8— Removing the Rotor Pulley (Cont.) SHAFT SEAL Always replace the shaft seal assembly if it is disas...
Page 80 1B5-4 SD-709 AIR CONDITIONING COMPRESSOR Figure 9— Removing the Coil Snap Ring Remove or Disconnect (Figures 2 and 10 through 12) Tools Required: J 4245 Internal Snap Ring Pliers J 9553-01 O-Ring Remover J 38468 Shaft Seal Remover and Installer J 38479 Seal Seat Remover and Installer 1.
Page 81 SD-709 AIR CONDITIONING COMPRESSOR 1B5-5 tinct change of sound during the tapping pro Clean cess. • Seal cavity thoroughly. 3. Internal bearing snap ring with J 4245. a Use R-12 refrigerant. Blow dry. 4. External front housing snap ring with J 6435. b.
Page 82 1B5-6 SD-709 AIR CONDITIONING COMPRESSOR DISASSEMBLY OF THE CYLINDER HEAD AND VALVE PLATE |» + | Remove or Disconnect (Figures 2 and 15) 1. Six cylinder head cap screws with a 13 mm wrench. 2. Cylinder head from the valve plate. •...
Page 83 SD-709 AIR CONDITIONING COMPRESSOR 1B5-7 SPECIFICATIONS COMPRESSOR Sanden SD 709........................P/N 15573115 Application........................... 7.4L Engine, P Truck Rotation..........................Clockwise O il............................500 Viscosity Suniso 5GS or Equivalent Capacity..........................Approx. 135 cc (4.6 oz.) Clutch Hub Air Gap......................0.49 to 0.79 mm (0.016 to 0.031 in.) TORQUE SPECIFICATIONS Shaft Nut........
Page 84 1B5-8 SD-709 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 37828 J 8433 J 9553-01 J 38479 J 38468 J 29640 J 29886 J 38467 J 37825 11 . J 37827 J 37872 1. Puller Set 2. O-Ring Remover 3. Seal Protector 4.
Page 85 MANUAL STEERIN G GEAR 3B2-1 SECTION 3B2 MANUAL STEERING GEAR NOTICE: When fasteners 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 86 362-2 MANUAL STEERING GEAR 1. Worm Bearing Adjuster Locknut 2. Worm Bearing Adjuster Lower Worm Bearing Cup Lower Worm Bearing Lower Bearing Retainer Ball Nut Worm Shaft Upper Worm Bearing Upper worm Bearing Cup Pitman Shaft Seal Housing Worm Shaft Seal Side Cover Gasket Pitman Shaft Needle Bearing Pitman Shaft...
Page 87 MANUAL STEERIN G GEAR 3B2-3 1. REMOVE AND INSTALL WORM SHAFT SEAL GEAR ASSEMBLED INSTALL REMOVE 1. Install parts as shown. 1. Wrap 0.1 mm to 0.2 mm (.005" to .008") shim stock around shaft and insert between shaft and seal. 1' SOCKET Pry seal out.
Page 88 3B2-4 MANUAL STEERING GEAR 3. REMOVE AND INSTALL WORMSHAFT 4. DISASSEMBLE AND ASSEMBLE WORM AND BALL NUT BEARING ADJUSTER REMOVE DISASSEMBLE INSTALL ASSEMBLE 1. Loosen lock nut. Use punch 1. Install parts as shown. Pry low er bearing retainer Press cup into adjust against edge of slot.
Page 89 MANUAL STEERIN G GEAR 3B2-5 6. REMOVE AND INSTALL PITMAN SHAFT 7. ADJUST WORM BEARING PRELOAD SEALS AND BEARING 1. Tighten worm bearing adjuster until it bottoms then REMOVE INSTALL loosen one-quarter turn. 2. Carefully turn the wormshaft all the way to end of travel 1.
Page 90 362-6 MANUAL STEERING GEAR SPECIFICATIONS ADJUSTMENT Adjustment Torque to Hirn Worm Shaft In. Lbs. Worm Bearing......................0.6-1.0 Over Center Preload....................0.5-1.2 4-10 In Excess of Worm Bearing Preload Total Steering Gear Preload..................16 max. FASTENER TORQUE SAGINAW MODEL 535 Manual Steering Gear Ft.
Page 91 POWER STEERIN G 3B3-1 SECTION 3B3 POWER STEERING NOTICE: When fasteners 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 92 3B3-2 POWER STEERIN G A. RV, G, P , ST, M B. CK, L 202. Nut 203. Spring Washer 204. Retaining Ring 205. Washer 206. Double Lip Seal 207. Single Lip Seal 208. Bearing 209. Screw 210. Clamp . Ball Guide 2 1 1 212.
Page 93 POWER STEERIN G 3B3-3 SAGINAW INTEGRAL POWER STEERING GEAR NOTICE: Repair the steering gear in a clean, DISASSEMBLY dust-free location, using clean tools and equipment. Dirt or grit will damage the Remove or Disconnect (Figures 2 through 11) machined surfaces resulting in leakage or damage to the steering gear assembly.
Page 94 3B3-4 POWER STEERIN G Figure 8—Removing the Needle Bearing from Adjuster Plug 12. Adjuster plug locknut (245). 13. Adjuster plug valve assembly (240) using J 7624 (figure • Retaining ring (244) using J 4245. . Sector shaft assembly ( , 224, 225, 227). 2 2 1 •...
Page 95 POWER STEERIN G 3B3-5 Bearing (247) and races (246) for scoring and 15. Stub shaft (251) from valve body (250) (figure excessive wear. • Hold the assembly and lightly tap the stub shaft against the bench until the shaft cap is Rack piston (214) teeth and external machined surfaces for scoring or excessive wear.
Page 96 3B3-6 POWER STEERIN G • Valve spool inside the valve body (250). The valve spool, when lubricated with steering fluid, must rotate without binding. If binding occurs, replace the complete valve and shaft assembly. ASSEMBLY Install or Connect (Figures 1, 4, and 10 through 16) Tools Required: J 4245 Snap Ring Pliers...
Page 97 POWER STEERIN G 3B3-7 | Assemble (Figure 15) • Adjuster plug assembly. • Lubricate seal (239) before installing on adjuster plug. • Seat needle bearing (241) in the adjuster plug using J 8524-1 and J 7079-2. • Seal (242), washer (243), and retaining ring (244), into the adjuster plug.
Page 98 3B3-8 POWER STEERIN G • Bearing preload: • Use tool J 7624. Turn the adjuster plug (240) to the left until the plug assembly is firmly bot tomed (30 N.m (22 ft. lbs.) (figure 16). • Mark the housing in line with one of the holes in the adjuster plug (figure 17).
Page 99 POWER STEERIN G 3B3-9 Tighten • Nut (227) to 27 N-m (20 ft.lbs.). . Re-check the preload after tightening the nut (227). SAGINAW (1C SERIES) POWER STEERING PUMP NOTICE: Repair the pump only in a clean, Before beginning disassembly of the pump, remove dust-free location, using clean tools and the reservoir filler cap (when used) and drain the oil equipm ent.
Page 100 3B3-10 POWER STEERING E. Note the position of the large lug. 17. Drive Shaft 19. Retaining Ring F1879 Figure 28— Removing and Installing Retaining Ring F . Press G. Support Ring 17. Drive Shaft 18. Bearing F1880 Figure 29— Removing and Installing Driveshaft Bearing 2.
Page 101 POWER STEERIN G 3B3-11 REMOVING SEAL INSTALLING SEAL F. Press 16. Drive Shaft Seal K. Bar Stock H. Suitable Socket and a Press 12. O-Ring Seal 13. Thust Plate F1881 F2151 Figure 33— Removing the Thrust Plate Figure 31— Removing and Installing Driveshaft Seal 14.
Page 102 3B3-12 POWER STEERIN G 3. Dowel Pin 4. O-Ring Seal 5. Pressure Plate Spring F2156 Figure 38—Installation of the Pin, Seal and Pressure Plate Spring L. Mark Top of Pressure Plate . O-Ring Seal 7. Pressure Plate Remove return tube. Install return tube.
Page 103 POWER STEERIN G 3B3-13 4. Control valve (15). It must move smoothly in the valve bore. ASSEMBLY Install or Connect (Figures 24, 36 through 42) 1. Sleeve ( ) (figure 37). • Press sleeve into housing using a suitable socket. 2 Dowel pin (3) (figure 38).
Page 104 3B3-14 POWER STEERIN G CLEANING AND INSPECTION ASSEMBLY | Clean Install or Connect (Figure 43, 44, 46) All parts with solvent and blow dry. Tool Required: J 7728 Seal Installer Inspect (Figure 43, 44, 46) Important 1. Rotating group components (figure 46). —...
Page 105 POWER STEERIN G 3B3-15 A. Pressed In Return Tube B. Treaded Return Tube 74. Housing 75. Return Tube Identification 76. O-Ring Seal arrow on top 77. Return Tube edge of pump F9272 50. Drive Shaft r'ng Figure 44— Power Steering Pump— Model N 53.
Page 106 3B3-16 POWER STEERIN G Model P Power Steering Pump 1. Seal (69). 2. Reservoir (70). 3. Bolt (71). 4. Fitting (73). Model N Power Steering Pump 1. Pressed return tube (75) (figure 47). 2. O-ring seal (76) (figure 48). 3. Threaded return tube (77). 74.
Page 107 POWER STEERIN G 3B3-17 SPECIFICATIONS FASTENER TORQUE Integral Power Steering Gear Pitman Shaft Over Center Preload..................0.6-1.2 N-m (6-10 in. lbs.) Pitman Shaft Preload Adjuster Screw Jam Nut..............27 N-m (20 in. lbs.) Side Cover Bolts........................60 N-m (40 ft. lbs.) Pitman Shaft Nut.........................
Page 108 3B3-18 POWER STEERING...
Page 109 7 1/2 AND 7 5/8-INCH RING GEAR A XLES 4B1-1 SECTION 4B REAR AXLE CONTENTS SUBJECT PAGE 7 1/2 and 7 5/8-inch Ring G ear..........................4B1-1 8 1/2-inch Ring Gear A xle ............................4B2-1 9 1/2-inch Ring Gear A xle ............................4B3-1 10 1/2-inch Ring Gear A xle ............................4B4-1 Dana Rear A x le s ................................4B5-1 12 Inch Ring Gear (Rockwell)...........................4B6-1...
Page 110: Rear Axle
These shims are also used to preload A. Axle Code the bearings which are pressed onto the differential B. 71 /2" (190 mm) Chevrolet St. Catherines case. Two bearing caps are used to hold the differential C Day Built into the rear axle housing.
Page 111 7 1/2 AND 7 5/8-INCH RING GEAR A XLES 4B1-3 27 ^ § > ^ 2 6 21 22 25 U \ J @ ® @ c ^ k i i / I 19. Shim . Brake Drum . Pinion and Ring Gear Set .
Page 112 4B1-4 7 1/2 AND 7 5/8-INCH RING GEAR A XLES . Axle Shaft 3. “ C” Lock 30. Pinion Shaft Lock Bolt F9400 Figure 3— Pinion Shaft Lock Bolt 15. Ring gear (20) from the differential. • Drive the ring gear off with a brass drift if nec 13.
Page 113 7 1/2 AND 7 5/8-INCH RING GEAR A XLES 4B1-5 Figure 9—Checking Pinion Preload Figure 10—Pinion Collapsible Spacer 18. Pinion (20) from the axle housing. • Thread the pinion nut halfway onto the pinion. • Replace the differential cover (34) with two bolts (35) to keep the pinion from falling to the floor.
Page 114 4B1-6 7 1/2 AND 7 5/8-INCH RING GEAR A XLES • Pinion flange splines for wear. • The fit of the pinion gear splines on the pinion flange. • The sealing surface of the pinion flange for nicks, burrs, or rough tool marks which would cause damage to the seals’...
Page 115 7 1/2 AND 7 5/8-INCH RING GEAR A XLES 4B1-7 16. Record the actual number on the dial indicator and |^ Q Tighten not the number which represents how far the need le travels. This is the nominal pinion setting. •...
Page 116 4B1-8 7 1/2 AND 7 5/8-INCH RING GEAR AXLES • Place one pinion gear onto the side gears and rotate the gears until the pinion is exactly oppo site from the differential opening. • Place the second pinion gear onto the side gears so that the pinion gear holes line up.
Page 117 7 1/2 AND 7 5/8-INCH RING GEAR A XLES 4B1-9 . Place the case with the bearing cups installed into the axle housing (figure • Lubricate the axle bearings with axle lubricant. • Support the case to keep it from falling into the axle housing.
Page 118 4B1-10 7 1/2 AND 7 5/8 i ^CH RING GEAR A XLES 5. Pinion oil seal (14) using J 23911. . The pinion flange (13) to the pinion by tapping it with a rawhide hammer until a few threads show through the pinion flange.
Page 119 7 1/2 AND 7 5/8-INCH RING GEAR A XLES 4B1-11 3. Axle shafts (2) into the axle housing (9). 11. Install the left bearing cap and bolts. • Be careful not to damage the oil seal. • Do not tighten. •...
Page 120 4831-12 7 1/2 AND 7 5/8-INCH RING GEAR AXLES 1. Wipe all oil out of the carrier, and carefully clean each tooth of the ring gear (figure 29). 2. Use gear marking compound 1052351 or equiva lent and apply this mixture sparingly to all ring gear teeth, using a medium-stiff brush.
Page 121 7 1/2 AND 7 5/8-INCH RING GEAR A XLES 4B1-13 The backlash will decrease if the left shim thickness is increased (along with a decrease in right shim thick ness). SPECIFICATIONS 7 1/2 AND 7 5/8-INCH RING GEAR AXLE Fastener Ft.
Page 122 4B1-14 7 1/2 AND 7 5/8-INCH RING GEAR A XLES SPECIAL TOOLS J 7817 £ | J 22813-01 J 23911 J 7818 J 25299 J 8107-2 11 . J 25320 J 8614-02 J 8614-02 J 8001 —I J 22888 J 23771 J 5590 1.
Page 123 8 1/2-INCH RING GEAR 4B2-1 SECTION 4B2 8 1/2-INCH RING GEAR 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 124 4B2-2 8 1/2-INCH RING GEAR 13. Differential side bearings ( ) using J 8107-4 and 2. The case for metal chips and shavings. Determine J 22888 (figure 4). where these chips and shavings come from, such as a broken gear or bearing cage. •...
Page 125 8 1/2-INCH RING GEAR 4B2-3 1. Axle Housing 21. Pinion Gear 2. Air Vent 22. Side Gear 3. Plug 23. Ring Gear Bolt 4. Collapsable Spacer 24. Differential Case 5. Inner Pinion Bearing 25. Nut . Shim 26. Washer 7. Ring and Pinion Gear Set 27.
Page 126 4 B 2 4 8 1/2-INCH RING GEAR 2. Axle Shaft 3. “ C” Lock 30. Pinion Shaft Lock Bolt F9400 Figure 2—Pinion Shaft Lock Bolt F4690 Figure 3—Prying the Differential Case AXLE HOUSING [ j y | Inspect • The carrier bore for nicks or burrs that would pre PINION AND RING GEAR vent the outer diameter of the pinion seal from sealing.
Page 127 8 1/2-INCH RING GEAR 4B2-5 F4693 Figure 9 —Removing the Pinion Rear Bearing Figure 6— Removing the Drive Pinion Nut • Bearing cups for wear, cracks, brinelling and scor ing. • Bearings and cups are only replaced as sets. • If the rear axle was operated for an extended period of time with very loose bearings, the ring gear and drive pinion will also require replace...
Page 128 4B2-6 8 1/2-INCH RING GEAR F4697 F4699 Figure 10— Installing the Front Pinion Bearing Cup Figure 12—Gage Plate Tools Figure 11— Installing the Rear Pinion Bearing Cup 10. Rotate the gage plate until the proper gaging area 2. Lubricate the front and rear pinion bearings with is parallel with the disks.
Page 129 8 1/2-INCH RING GEAR 4B2-7 (0.033-inch) as shown in (Figure 14). Record the • The bearing cups should have been installed in dial reading of 0.84 mm (0.033-inch) not 1.70 mm “ Pinion Depth Adjustment” in this section. (0.067-inch). 1. The pinion inner bearing (5) using J 8609-01. 17.
Page 130 4B2-8 8 1/2-INCH RING GEAR ed, the pinion will have to be removed, and a new collapsible spacer installed. • Once the preload has been obtained, rotate the pinion several times to assure that the bearings have seated. Recheck the preload, and adjust if necessary.
Page 131 8 1/2-INCH RING GEAR 4B2-9 SIDE BEARING PRE-LOAD ADJUSTMENT • Press the ring gear onto the case far enough to start the bolts using J 8107-4 to protect the dif • The differential side bearing preload is adjusted by ferential from the press ram (Figure 19). changing the thickness of both the left and right shims equally.
Page 132 4B2-10 8 1/2-INCH RING GEAR Figure 22— M easuring Side Bearing Shim Figure 23—Measuring the Gage Plate Thickness Requirem ents • The point just before additional drag begins is the correct feeler gage thickness. This is the zero setting without preload. 8.
Page 133 8 1/2-INCH RING GEAR 4B2-11 6. Check and record the backlash at three or four points around the ring gear. • The pinion must be held stationary when checking backlash. • The backlash should be the same at each point within 0.05 mm (0.002-inch).
Page 134 4B2-12 8 1/2-INCH RING GEAR 1. Wipe all oil out of the carrier, and carefully clean each tooth of the ring gear (figure 29). 2. Use gear marking compound 1052351 or equiva lent and apply this mixture sparingly to all ring gear teeth, using a medium-stiff brush.
Page 135 8 1/2-INCH RING GEAR 4B2-13 The backlash will decrease if the left shim thickness If the thickness of the right shim is increased (along is increased (along with a decrease in right shim thick with decreasing the left shim thickness), backlash will ness) increase.
Page 136 4B2-14 8 1/2-INCH RING GEAR SPECIA L TOOLS J 8611-01 J 8608 J8612-B J 22888 J 8092 J 22399 J 8001 J 22761 J 8609-01 1 2 . 22779 J 5590 J 8614-01 J 8107-4 1 . Front Pinion Bearing Cup Installer 11.
Page 137 9 1/2-INCH RING GEAR 4B3-1 SECTION 4B3 9 1/2-INCH RING GEAR 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 138 4B3-2 9 1/2-INCH RING GEAR 2. The case for metal chips and shavings. Determine 2. Pinion shaft lock bolt (29)(Figure 2). where these chips and shavings come from, such 3. Pinion shaft (28). as a broken gear or bearing cage. 4.
Page 139 9 1/2-INCH RING GEAR 4B3-3 • 12. Differential bearing caps (19). • Mark the caps and the housing as left and right. 16. Ring gear bolts (26). NOTICE: Be careful when prying the differen tial case out of the axle housing so not to •...
Page 140 4B3-4 9 1/2-INCH RING GEAR Figure 8— Removing the Drive Pinion Figure 6—Removing the Drive Pinion Nut 19. Pinion flange using J 8614-01 (Figure 7). 20. Pinion (15) from the axle housing. • Thread the pinion nut halfway onto the pinion. •...
Page 141 9 1/2-INCH RING GEAR 4B3-5 • The housing for foreign material such as metal ASSEMBLY OF THE REAR AXLE chips, dirt, or rust. Refer to “Cleaning” in this section. |-»4^ in stall or Connect (Figures 10 and 11) DIFFERENTIAL Tools Required: Inspect J 7817 Front Pinion Bearing Cup Installer J 22306 Rear Pinion Bearing Cup Installer...
Page 142 4B3-6 9 1/2-INCH RING GEAR 1. Clean all the gage parts. 2. Lubricate the front and rear pinion bearings with axle lubricant. 3. Place the bearings (10) and (13) into the pinion bearing cups. 4. Install J 21777-8, J 21777-42, J 21777-85 and J 21777-43 to the pinion bore (figure 12).
Page 143 9 1/2-INCH RING GEAR 4B3-7 A. Dial indicator and arbor positioned on the gage block. B. Measurement after the arbor is moved off of the gage block. ^ F4682 Figure 14— Checking Pinion Depth (figure 16). 1. The pinion inner bearing (13) to the pinion. 6.
Page 144 463-8 9 1/2-INCH RING GEAR DIFFERENTIAL CASE ASSEMBLY |+ * | Install o r Connect (Figure 1) Tools Required: J 8107-3 Differential Side Bearing Removal Plug J 8092 Driver Handle J 29710 Differential Side Bearing Installer • Lubricate all parts with rear axle lubricant. 1.
Page 145 9 1/2-INCH RING GEAR 4B3-9 • Press the ring gear onto the case far enough to start the bolts using J 8107-3 to protect the differential from the press ram (figure 20). 6. New ring gear bolts (26). • Tighten the ring gear bolts alternately in stages gradually pulling the ring gear onto the differen...
Page 146 4B3-10 9 1/2-INCH RING GEAR BACKLASH ADJUSTMENT Install a dial indicator to the case using a magnetic base. 2. Place the indicator stem at the heel end of a tooth. • Set the dial indicator so that the stem is in line with the gear rotation and perpendicular to the tooth angle.
Page 147 9 1/2-INCH RING GEAR 4B3-11 2. Use gear marking compound 1052351 or equiva GEAR TOOTH lent and apply this mixture sparingly to all ring PATTERN CHECK gear teeth, using a medium-stiff brush. When Checking the ring gear to pinion tooth pattern is to properly used, the area of pinion tooth contact will be done only after setting up the axle according to the be visible when hand load is applied.
Page 148 4B3-12 9 1/2-INCH RING GEAR ion head and the centerline of the ring gear. Decreas ion. (The adjusting shims are also used to set side ing the distance will move the pinion closer to the bearing preload). centerline of the ring gear. Increasing the distance will If the thickness of the right shim is increased (along move the pinion farther away from the centerline of the with decreasing the left shim thickness), backlash will...
Page 149 9 1/2-INCH RING GEAR 4B3-13 SPECIA L TOOLS J 8107-3 J 8092 J 22804-1 r t l __ J 8001-M J 24429 J 29710 • J 22888 J 22912-01 J 24433 J 5590 J 7817 J 22388 J 8614-01 1. Differential Side Bearing Plug 2.
Page 150 4B3-14 9 1/2-INCH RING GEAR...
Page 151 10 1/2-INCH RING GEAR 4B4-1 SECTION 4B4 10 1/2-INCH RING GEAR 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 152 4B4-2 10 1/2-INCH RING GEAR 17. Pinion assembly cage bolts (7) and washers (8) DISASSEMBLY OF THE (figure 4). REAR AXLE 18. Pinion assembly cage (10). • Tap on the pilot end of the pinion with a ham Remove or Disconnect (Figure 1) mer and a brass drift if necessary.
Page 153 10 1/2-INCH RING GEAR 4B4-3 15. Pinion Pilot Bearing 16. Axle Vent Tube 17. Axle Housing 18. Differential Side Bearing 19. Bearing Adjusting Nut 20. Bearing Cap 21. Adjusting Nut Lock 22. Bolt 23. Gasket 24. Cover 25. Bolt Brake Line Clip Washer Bolt Side Gear...
Page 154 4B4-4 10 1/2-INCH RING GEAR JL ______c F4736 ___________________________________ F4738 Figure 2—Removing the D ifferential Side Bearings Figure 4— Removing the Pinion Cage DIFFERENTIAL • The sealing surface of the pinion flange for nicks, burrs, or rough tool marks which would cause | P | inspect damage to the seals’...
Page 155 10 1/2-INCH RING GEAR 4B4-5 F4741 Figure 7—Pressing the Drive Pinion from the Cage Figure 9—Removing the P ilot Bearing • If the rear axle was operated for an extended ASSEMBLY OF THE REAR AXLE period of time with very loose bearings, the ring gear and drive pinion will also require replace...
Page 156 4B4-6 10 1/2-INCH RING GEAR F4744 _________________________________________ F4737 Figure 10—Installing the Inner Pinion Bearing Figure 12—Checking Pinion Preload • Remove J 8614-01. Using an inch-pound 2. Outer pinion bearing cup (6) using J 8608 and torque wrench, check the pinion preload by J 8092.
Page 157 10 1/2MNCH RING GEAR 4B4-7 PINION INSTALLATION |-»4-] in stall or Connect Tools Required: J 34943 Pinion Pilot Bearing Installer J 8092 Driver Handle 1. Pinion pilot bearing (15) using J 34943 and J 8092 (figure 13). • Bolt the guide plate to the axle housing. •...
Page 158 4B4-8 10 1/2-INCH RING GEAR 5. Adjusting nut lock (21) and lock bolt (22) to the left Tighten nut. • Do not tighten. • The ring gear bolts alternately in stages gradu • Tighten the right adjusting nut firmly to force the ally pulling the ring gear onto the differential case into solid contact with the left adjusting nut.
Page 159 10 1/2-INCH RING GEAR 4B4-9 BACKLASH ADJUSTMENT Install a dial indicator to the case using a magnetic base (figure 19). 2. Place the indicator stem at the heel end of a tooth. • Set the dial indicator so that the stem is in line with the gear rotation and perpendicular to the tooth angle.
Page 160 4B4-10 10 1/2-INCH RING GEAR LOW FLANK CONTACT DECREASE PINION SHIM TOE CONTACT INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM F2018 Figure 21—Gear Tooth Pattern...
Page 161 10 1/2-INCH RING GEAR 4B4-11 SPECIFICATIONS 10 1/2-1 NCH RING GEAR AXLE (CORPORATE) Ft. Lbs. Fastener Ring Gear Bolts..... Bearing Cap Bolts... Axle Cover Bolts.... Adjusting Nut Lock Bolts. Size Spacer and Shim Sizes 0.006- nch Pinion Bearing Shims..0.007- nch 0.008- nch 0.009- nch 0.010- nch...
Page 162 4B4-12 10 1/2-INCH RING GEAR...
Page 163 DANA REAR A XLES 4B5-1 SECTION 4B5 DANA REAR AXLES 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 164 4B5-2 DANA REAR AXLES 5. Differential case (22) from the carrier (1) using two CHECKING THE AXLE pry bars (figure 5). BEFORE DISASSEMBLY 6. The spreader J 24385-01 from the carrier (1). 7. Bearing cups (20). | P | inspect •...
Page 165 DANA REAR A XLES 4B5-3 22. Differential Case 1. Axle Housing 11. Washer 23. Ring Gear Bolt 2. Ring Gear and Pinion Set 12. Pinion Nut 24. Pinion Gear 14. Cover 3. Inner Pinion Bearing 25. Side Gear 16. Plug 4.
Page 166 4B5-4 DANA REAR AXLES Figure 3— Removing the Bearing Cap Figure 4—Spreading the Differential Case...
Page 167 DANA REAR A XLES 4B5-5 Figure 10— Removing the Pinion Gears 23. Bearing cups (3) and (7) from the axle housing INSPECTION using a hammer and a punch (figure 15). It is very important to carefully and thoroughly • Work the cups out of the housing evenly, mov inspect all drive unit parts before reassembly.
Page 168 4B5-6 DANA REAR A XLES F4768 Figure 15—Removing the Bearing Cups DIFFERENTIAL | y | Inspect • Pinion gear shaft for unusual wear. • Pinion gear and side gear teeth for wear, cracks, scoring, and spaliing. • Thrust washers for wear. •...
Page 169 DANA REAR A XLES 4B5-7 ASSEMBLY OF THE REAR AXLE DIFFERENTIAL CASE ASSEMBLY f+ 4 j Install o r Connect (Figure 1) • Lubricate all parts with rear axle lubricant. 1. New side gear thrust washers (27) to the side gears (25).
Page 170 4B5-8 DANA REAR A XLES 4. New pinion thrust washers (26). • The new ring gear bolts in sequence to 150 • Rotate the pinion gears toward the differential N m (110 ft. lbs.). Refer to “Specifications” for opening just enough to slide in the pinion bolt information.
Page 171 DANA REAR A XLES 4B5-9 F4704 F4703 Figure — Pinion Height B lock Figure 23—A rbor and Discs 3. Place D-116-2 onto D-115-3. 4. Install the arbor and discs into the axle housing (figure 23). 5. Install D-116-1 onto D-120 and against the arbor (figure 24).
Page 172 4B5-10 DANA REAR AXLES F4718 Figure 27—Measuring the Shims Figure 29— Installing the Pinion Front Cup PINION INSTALLATION |-»4-| Install or Connect Tools Required: J 7818 Front Pinion Bearing Cup Installer J 5590 Rear Pinion Bearing Cone Installer D-111 Cup Installer C-4171 Handle J 8092 Handle J 8614-01 Pinion Flange Remover...
Page 173 DANA REAR A XLES 4B5-11 6. Outer pinion bearing (7) (and slinger if used). • Do not assemble the preload shims or pinion oil seal at this time. 7. Pinion flange (10). 8. Washer (11) and pinion nut (12). Tighten •...
Page 174 4B5-12 DANA REAR AXLES 11. Outer bearing (7) and slinger (8). • Apply a light coat of axle lubricant to the pinion seal lip. 12. Outer pinion oil seal (9) using D-163 (National) sealer installer (figure 33). 13. Pinion flange (10). 14.
Page 175 DANA REAR A XLES 4B5-13 13. Assemble the dial indicator as shown in figure 38. Tighten Preset the gage at least 0.020-inch, and then rotate the indicator housing to zero the dial. The bearing cap bolts (19) to 115 N.m lbs.).
Page 176 4B5-14 DANA REAR A XLES 1 0 1/2-INCH RING GEAR 2. The case for metal chips and shavings. Determine DESCRIPTION where these chips and shavings come from, such The Dana 10 1/2-inch ring gear rear axle uses a as a broken gear or bearing case. conventional ring and pinion gear set to transmit the •...
Page 177 DANA REAR A XLES 4B5-15 30. Bolt 16. Plug 1. Axle Housing 31. Nut 17. Bolt 2. Ring and Pinion Gear Set 18. Bearing Cap 32. Hub Seal 3. Bearing 33. Bearing 19. Bolt 4. Shims 34. Bearing 20. Bearing 5.
Page 178 4B5-16 DANA REAR AXLES Figure 46—Removing the D ifferential F4756 Figure 45—Spreading the Differential Case...
Page 179 DANA REAR A XLES 4B5-17 10. Ring gear bolts (23). • Place shop towels over the vise jaws. Put the dif ferential case in the vise (figure 48). NOTICE: Do not pry the ring gear from the case, this will damage the ring gear and the differential case.
Page 180 485-18 DANA REAR A XLES Figure 54— Removing the Pinion Flange 22. Pinion outer bearing (7) and oil slinger (8). 23. Bearing cups (3) and (7) from the axle housing using a hammer and a punch (figure 56). • Work the cups out of the housing evenly, mov ing the punch back and forth between one side of the cup and the other.
Page 181 DANA REAR A XLES 4B5-19 • Bearing cups for wear, cracks, brinelling and scor INSPECTION ing. It is very important to carefully and thoroughly • Bearings and cups are only replaced as sets. inspect all drive unit parts before reassembly. •...
Page 182 4B5-20 DANA REAR A XLES 4. New pinion thrust washers (26). • Rotate the pinion gears toward the differential opening just enough to slide in the pinion thrust washers. 5. Pinion shaft (28). • Align the lock pin holes in the case and the shaft.
Page 183 DANA REAR A XLES 4B5-21 6. Force the differential assembly in the opposite direction as far as it will go. Repeat this step until the same reading is obtained. Record the number of thousandths that the dial indicator traveled, not the reading on the dial.
Page 184 4B5-22 DANA REAR AXLES Figure 66— Scooter Gage on the Height Block Figure 67—Scooter Gage on the A rbor 7. Slide the gage over the arbor (figure 67). 8. Record the reading at the point of greatest deflec tion (when the dial indicator needle is centered between movement to the left and to the right).
Page 185 DANA REAR A XLES 4B5-23 Figure 72—Checking the Pinion Preload Figure 70— Installing the Pinion Front Cup N-m (10 in. lbs.) to rotate the pinion (figure 72). 1. Place the required amount of shims (and baffle if Rotate the pinion several times to seat the used) in the inner bearing bore.
Page 186 4B5-24 DANA REAR A XLES amount the indicator needle is from the pinion marking. • Remove the pinion nut (12), washer (11), pinion flange (10), slinger (8) and bearing cone (7). 10. Preload shims (6). • Install the shims that were removed, or mea sure the old shims and replace them with new shims if necessary.
Page 187 DANA REAR A XLES 4B5-25 11. Place the proper shims on the differential side 6. Force the differential case away from the pinion bearing hub (opposite the ring gear) and drive the gear to obtain an indicator reading. Repeat this action until a consistent reading is obtained.
Page 188 4B5-26 DANA REAR AXLES step 7 from the total reading. The reading found in • Use a rawhide hammer to seat the differential assembly in the axle housing (figure 80). step 7 will be the shim size on the ring gear side. 18.
Page 189 DANA REAR A XLES 4B5-27 6. To adjust the backlash, the differential case must be removed from the housing, then the differential bearings removed, and the proper number of shims moved from one side to the other. FINAL ASSEMBLY |-»<-| install or Connect 1.
Page 190 4B5-28 DANA REAR A XLES SPECIFICATIONS 9 3/4-INCH RING GEAR AXLE Fastener Ft. Lbs. Ring Gear Bolts........................150 Bearing Cap Bolts........................115 Axle Cover Bolts........................47 Available Shim Sizes Size Differential Bearing Adjusting Shim.................. 0.003-inch 0.005-inch 0.010-inch 0.030-inch Outer Pinion Bearing Shim....................
Page 191 DANA REAR A XLES 4B5-29 SPECIAL TOOLS D-116-2 D-115-3 J 8092 D-116-1 J 5590 D 115 J 8614-01 J 23690 D 117 J 29721 D 120 J 24385-01 D 111 J 29721-70 C 4171 J 8107-03 J 7818 9. Differential Side Bearing Removal Plug 1.
Page 192 4B5-30 DANA REAR AXLES SPECIAL TOOLS D 116-2 J 8107-3 D 115-3 11 . J 8092 D 116-1 J 7817 D 115 J 5590 D 136 or D 117 J 8614-01 (Heavy Duty Axles) D 120 J 23690 C 4204 J 29721 C 4171 J 24385-01...
Page 193 12-INCH RING GEAR (ROCKW ELL) 4B6-1 SECTION 4B6 12-INCH RING GEAR (ROCKWELL) 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 194 4B6-2 12-INCH RING GEAR (ROCKW ELL) Figure 1—Rear Axle Components...
Page 195 12-INCH RING GEAR (ROCKW ELL) 4B6-3 1. Bolt 22. Axle Vent 43. Side Gears 44. Bolt 2. Washer 23. Bolt 3. Hub Cap 24. Washer 45. Washer 4. Gasket 46. Carrier 25. Bearing Cap 5. Axle Shaft 26. Nut 47. Bolt 6.
Page 196 4B6-4 12-INCH RING GEAR (ROCKW ELL) 8. Differential case bolts (44). 9. The top case half (36) (figure 8). 10. Side gears (43) and thrust washers (38) (figure 9). 11. Pinion gears (41) and thrust washers (42). 12. Differential pinion spider (40). 13.
Page 197 12-INCH RING GEAR (ROCKW ELL) 4B6-5 c J m M l! t '- * r ^ r — F4774 Figure 13— Removing the Pinion Cage Figure 10— Removing the D ifferential Side Bearing F4778 F4781 Figure 11—Removing the Pinion Nut Figure 14—...
Page 198 4B6-6 12-INCH RING GEAR (ROCKW ELL) AXLE HOUSING • Low mileage bearings may have very small scratches and pits on the rollers and the bearing l y | Inspect cups from the initial preload. Do not replace a bearing for this reason. •...
Page 199 12-INCH RING GEAR (ROCKW ELL) 4B6-7 • Wrap a soft wire around the cage and pull on the line with a pound scale. Measure the rotating torque, not the starting torque (figure 15). • The rotating torque should be 5 to 15 in. lbs. To determine the inch pounds: —...
Page 200 4B6-8 12-INCH RING GEAR (ROCKW ELL) Install or Connect • Measure the pinion bearing shims (50). If a new pinion and ring gear set is installed, the pinion bearing shim pack must be adjusted. • Examine the heads of the new and old drive pin ions.
Page 201 12-INCH RING GEAR (ROCKW ELL) 4B6-9 6. Ring gear (37) to the differential. CHECKING RING GEAR RUN OUT • Thread two studs into the ring gear on opposite sides. Measure € • Place the ring gear onto the case, and align the holes in the case with the studs.
Page 202 4B6-10 12-INCH RING GEAR (ROCKW ELL) 2. Backlash by moving the ring gear toward or away • The differential must be initially preloaded in order from the pinion. to determine the backlash of the gear set. After the • If setting up the original ring and pinion gear backlash has been set, the final bearing preload is set, use the backlash reading obtained earlier.
Page 203 12-INCH RING GEAR (ROCKW ELL) 4B6-11 SPECIAL TOOLS J 3154-04 J 7804-01 J 3453 J 22912-01 1. Seal Installer Set 2. Flange Holding Bar 3. Differential Side Bearing Installer J 23723-7 4. Yoke Remover 5. Rear Pinion Bearing Cone Remover...
Page 204 486-12 12-INCH RING GEAR (ROCKWELL)
Page 205 LOCKING DIFFERENTIAL 4B7-1 SECTION 4B7 LOCKING DIFFERENTIAL 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 206 4B7-2 LOCKING DIFFERENTIAL Pinion Thrust Washer Cam Plate Pinion Gear Thrust Block -lnch Ring Gear Side Gear Thrust Washer Pinion Shaft Clutch Plates -lnch Ring Gear Guide Clip -!nch Ring Gear Side Gear . Guide Clip . Differential Case Latching Bracket 21.
Page 207 LOCKING DIFFERENTIAL 4B7-3 ^ --------------— F4799 Figure 2—Removing the Governor Bushings • It is important to build up the differential properly, as the proper clearances between parts is neces sary for the proper operation of the units. • There are three adjustments to be made: (1) Left side gear backlash.
Page 208 4B7-4 LOCKING DIFFERENTIAL 6. Pinion shaft (18) and lock screw (3). Insert a large tapered tool such as a screwdriver firmly between each side gear and the pinion shaft. 7. A 1 to 2-inch telescoping gage between the side gear faces, not the gear teeth. •...
Page 209 LOCKING DIFFERENTIAL 4B7-5 ASSEMBLY OF THE DIFFERENTIAL 10 1/2-INCH RING GEAR f»<-j Install or Connect (Figure 1) DISASSEMBLY OF THE DIFFERENTIAL |<--»| Remove or Disconnect (Figure 9) 1. Left thrust washer (13). 2. Cam unit. Refer to “ Cam Unit Assembly” in this section.
Page 210 4B7-6 LOCKING DIFFERENTIAL 31. Differential Case Halves 37. Plates 32. Screw 38. Pinion Thrust Washer Plates 33. Cam Plate 39. Pinion Gear Side Gear Thrust Washer 34. Guide Clip 40. Side Cam Gear Side Gear 35. Thrust Sleeve 41. Reaction Block Guide Clip Governor 36.
Page 211 LOCKING DIFFERENTIAL 4B7-7 F4796 Figure 13—C lam ping the Cam Unit in Place F4795 Figure 14— Installing the Pinion take Figure 12—Cam Unit Components ers behind each side gear, and selective thickness 6. Mount a dial indicator on the case half face using thrust washers between the reaction blocks.
Page 212 4B7-8 LOCKING DIFFERENTIAL 7. Place the stem of the dial indicator on the pinion gear tooth. 8. Pull the pinion gear firmly into its seat, and rotate the gear back and forth while reading the dial indi cator. Record the reading. •...
Page 213 LOCKING DIFFERENTIAL 4B7-8 4. Left thrust washer (45). 8. Case halves (31) together. • Hold the side gear in the left side case half. • Assemble the plates as shown in figures 9 and 12 . 9. Case screws (32). 10.
Page 214 4B7-10 LOCKING DIFFERENTIAL SPECIFICATIONS Fastener Ft. Lbs. Differential Lockscrew 7 1/2, 7 5/8, and 8 1 /2-inch..........9 1/2-inch................THRUST BLOCK SIZES Color Code 7 1/2, 7 5/8-Inch 8 1/2-Inch 9 1/2-Inch Purple........1.260-inch 1.322-inch 1.598-inch White........1.264-inch 1.326-inch 1.602-inch Brown........
Page 215 LOCKING DIFFERENTIAL 4B7-11 SPECIAL TOOLS J 26252 J 22912-01 1. Rear Pinion Bearing Cone Remover 2. Locking Differential Governor Remover...
Page 216 4B7-12 LOCKING DIFFERENTIAL...
Page 217: Front Axle
8 1/2-INCH RING GEAR FRONT AXLE 4C1-1 SECTION 4C FRONT AXLE CONTENTS SUBJECT PAGE 8 1/2-Inch Ring Gear Front A x le ..........................4C1-1 9 3/4-Inch Ring Gear Front A x le ..........................4C2-1 7 1/4>inch Ring Gear Front A x le ..........................4C3-1 8 1/4 and 9 1/4-inch Ring Gear Front A x le ......................
Page 218 4C1-2 8 1/2-INCH RING GEAR FRONT AXLE DESCRIPTION selective shims between the bearings and the axle The GM 8 1/2-inch ring gear front axle uses a coven- housing. To move the ring gear, shims are deleted from tional ring and pinion gear set to transmit the driving one side and an equal amount are added to the other force of the engine to the wheels.
Page 219 8 1/2-INCH RING GEAR FRONT AXLE 4C1-3 22. Side Gear 1. Axle Housing 11. Gasket 23. Ring Gear Bolt 2. Air Vent 12. Cover 24. Differential Case 4. Collapsable Spacer 14. Bolt 28. Axle Shaft Seal 5. Inner Pinion Bearing 15.
Page 220 4C1*4 8 1/2-INCH RING GEAR FRONT AXLE Figure 6—Pinion Flange Removal Figure 7—Removing the Drive Pinion F4692 Figure A — Checking Pinion Bearing Preload Figure 8—Removing Drive Pinion Rear Bearing 18. Bearing cups (5) and (39) from the axle housing using a hammer and a punch.
Page 221 8 1/2-INCH RING GEAR FRONT AXLE 4C1-5 CLEANING AND INSPECTION PINION AND RING GEAR CLEANING • Do not steam clean drive parts having ground and Inspect polished surfaces such as gears, bearings, and shafts. These parts should be cleaned in a suit •...
Page 222 4C1-6 8 1/2-INCH RING GEAR FRONT AXLE ASSEMBLY OF AXLE PINION BEARING CUP INSTALLATION Install or Connect Tools Required: J 8608 Rear Pinion Bearing Cup Installer J 8611-01 Front Pinion Bearing Cup Installer J 8092 Driver Handle 1. Front pinion bearing cup using J 8611-01 and J 8092 (figure 9).
Page 223 8 1/2-INCH RING GEAR FRONT AXLE 4C1-7 A. Dial indicator and arbor positioned on the gage block. B. Measurement after the arbor is moved off of the gage block.1 F4682 Figure 13—Checking Pinion Depth • If the pinion is stamped with a plus number, •...
Page 224 4C1-8 8 1/2-INCH RING GEAR FRONT AXLE 19. Install the correct pinion shim to the pinion accord ing to this procedure. PINION INSTALLATION |-H “| Install or Connect Tools Required: J 8609-01 Rear Pinion Bearing Cone Installer J 22388 Pinion Oil Seal Installer J 8614-01 Pinion Flange Remover J 5590 Rear Pinion Bearing Cone Installer •...
Page 225 8 1/2-INCH RING GEAR FRONT AXLE 4C1-9 I ^ l Tighten • The ring gear bolts in sequence to 80 N-m (60 ft. lbs.). 8. Differential side bearings (8) using J 22761, J 8107-4 and J 8092 (figure 18). • Place J 8107-4 into the differential on the side opposite of the bearing installation to protect the differential case.
Page 226 401-10 8 1/2-INCH RING GEAR FRONT AXLE • Production shims are cast iron and are not to be reused. • Service spacers are available from 4.32 to 4.37 mm (0.170 to 0.172-inch) thick. • Service shims are available in kits from 0 040 to 0.070-inch.
Page 227 8 1/2-INCH RING GEAR FRONT AXLE 4C1-11 • Set the dial indicator so that the stem is in line with the gear rotation and at a right angle to the tooth angle (figure 23). NOTICE: See Notice on page 4C1-1 of this section.
Page 228 4C1-12 8 1/2-INCH RING GEAR FRONT AXLE F2018 Figure 25—Gear Tooth Contact Pattern To decrease backlash decrease the right shim and 2. New cover gaskets and the cover (12). increase the left shim an equal amount. • Fill with lubricant to specs. It is important that the contact pattern be centrally located up and down on the face of the ring gear teeth.
Page 229 8 1/2-INCH RING GEAR FRONT AXLE 4C1-13 SPECIFICATIONS 8 1/2-INCH RING GEAR FRONT AXLE TORQUE SPECIFICATIONS Ft. Lbs. F a s t e n e r Ring Gear Bolts..Bearing Cap Bolts. Axle Cover Bolts... AVAILABLE SHIM AND SPACER SIZES Nominal Differential Side Bearing Spacer..................
Page 230 401-14 8 1/2-INCH RING GEAR FRONT AXLE SPECIA L TOOLS J 8611-01 J 8608 2‘ J 8612-B (<^g23;===ao J 22888 J 8092 J 22399 J 8001 J 22761 J 8609-01 J 22779 t — J 8614 01 J 5590 1. Front Pinion Bearing Cup Installer 11.
Page 231 9 3/4-INCH RING GEAR FRONT AXLE 4C2-1 SECTION 4C2 9 3/4-INCH RING GEAR FRONT AXLE 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 232 4C2-2 9 3/4-INCH RING GEAR FRONT AXLE DISASSEMBLY OF AXLE 6. The spreader J 24385-01 from the carrier (1). INSPECTION 7. Bearing cups (20). Perform the following checks before disassembling • Mark the cups as left and right, and place them the axle.
Page 233 9 3/4-INCH RING GEAR FRONT AXLE 4C2-3 11. Washer 22. Differential Case 1. Axle Housing 23. Ring Gear Bolt 12. Pinion Nut 2. Ring Gear and Pinion Set 24. Pinion Gear 14. Cover 3. Inner Pinion Bearing 25. Side Gear 15.
Page 234 4C2-4 9 3/4-INCH RING GEAR FRONT AXLE Figure 5— Removing the D ifferential Figure 3— Removing the Bearing Cap Figure 7—Removing the Ring Gear Figure 4—Spreading the Differential Case...
Page 235 9 3/4-INCH RING GEAR FRONT AXLE 4 0 2 5 F4693 F4762 Figure 9— Removing the Pinion Shaft F4763 Figure 13—Pinion Flange Removal Figure 10—Removing the Pinion Gears...
Page 236 4C2-6 9 3/4-INCH RING GEAR FRONT AXLE 18. Pinion (2) from the carrier using a rawhide ham mer to tap the pinion (figure 14). 19. Carrier cover (14) and the pinion (2). 20. Pinion preload shims (6). • Keep the shims together on the bench. 21.
Page 237 9 3/4-INCH RING GEAR FRONT AXLE 4C2-7 • The fit of the differential side gears in the differen • The large end of the bearing rollers for wear. This tial case. is where tapered roller bearing wear is most evi •...
Page 238 4C2-8 9 3/4-INCH RING GEAR FRONT AXLE 5. New pinion thrust washers (26). • Always use the correct service bolts. Do not attempt to use a substitute bolt. • Rotate the pinion gears toward the differential opening just enough to slide in the pinion •...
Page 239 9 3/4-INCH RING GEAR FRONT AXLE 4C2-9 3. Force the differential assembly as far as possible in the direction towards the indicator. 4. Preload the dial indicator one half of its travel. Place the tip of the indicator on a flat surface of the differential, just next to a ring gear bolt.
Page 240 4C2-10 9 3/4-INCH RING GEAR FRONT AXLE Figure 27—Scooter Gage on the Arbor Figure 28—Measuring the Shim s • This reading indicates the amount of shims needed for a nominal pinion setting. The pinion marking may change the pinion depth by adding or deleting shims from the nominal pin...
Page 241 9 3/4-INCH RING GEAR FRONT AXLE 4C2-11 2. Drive the inner bearing cup into the axle assembly 9. The pinion depth checking tools D 116-1, D 116-2, using D 111 and C 4171. The cup must be seated D 115-3, and D 115 to the top of the pinion. on the shims (figure 29).
Page 242 4C2-12 9 3/4-INCH RING GEAR FRONT AXLE ASSEMBLING THE DIFFERENTIAL TO THE AXLE HOUSING Tools Required: J 23690 Differential Side Bearing Installer J 8092 Driver Handle J 24385-01 Differential Carrier Spreader 1. Assemble the differential case (22) with master bearings installed to the axle housing. The pinion must be installed.
Page 243 9 3/4-INCH RING GEAR FRONT AXLE 4C2-13 Figure 38—Installing the D ifferential Bearings Figure 40—Installing the D ifferential Case 18. Remove the spreader. 19. Install the bearing caps (18) in their original posi tions. 20. Install the bearing cap bolts (19). Tighten •...
Page 244 4C2-14 9 3/4-INCH RING GEAR FRONT AXLE • Apply a bead of RTV sealer (GM part no. 6. To adjust the backlash, the differential case must be removed from the housing, then the differential 1052366 or equivalent) to the cover, inboard of bearings removed, and the proper number of the bolt holes.
Page 245 9 3/4-INCH RING GEAR FRONT AXLE 4C 245 SPECIAL TOOLS D-116-2 D-115-3 J 8092 D-116-1 J 5590 D 115 0^555* J 8614 01 J 23690 D 117 J 29721 D 120 J 24385-01 D 111 J 29721-70 C 4171 J 8107-03 J 7818 9.
Page 246 4C2-16 9 3/4-INCH RING GEAR FRONT AXLE...
Page 247 7 1/4-INCH RING GEAR 4C3-1 SECTION 4C3 7 1/4-INCH RING GEAR 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 248 4C3-2 7 1/4-INCH RING GEAR F5785 Figure 1—Axle Components...
Page 249 7 1/4-INCH RING GEAR 4C3-3 1. Shaft 16. Spring Insert 46. Nut 2. Deflector 17. S hift Shaft and Fork Sleeve 47. Plug 3. Seal 18. Bolt Side Bearing 48. Bushing 4. Bearing 19. Lock Tab Bolt 49. Vent Hose 5.
Page 250 4C3-4 7 1/4-INCH RING GEAR 10. Differential pilot bearing (21) from the output shaft, using J 34011 (figure 4). 11. Washer (24). 12. Shaft (59), and deflector (2). • Using J 2619-01, pull the output shaft out of the case (figure 5). 13.
Page 251 7 1/4-INCH RING GEAR 4C3-5 30. Bearing 32. Sleeve Figure 11—Remove the Pinion Flange F1782 Figure 9—Remove the Sleeve Bearing • Insert J 33837-6 into the pinion bore. • Thread the forcing screw (J 33837-3) into J 33837-6. • Turn the forcing screw to pull the parts from the case.
Page 252 4C3-6 7 1/4-INCH RING GEAR 29. Bolt (36) and shaft (52) from the differential case 33. Ring gear (37). (35). • Do not pry between the ring gear and the case. 30. Differential pinion gears (56) and thrust washers Drive the gear off with a brass drift and ham (55).
Page 253 7 1/4-SNCH RING GEAR 4C3-7 • Fit of the side gear on the axle shafts. • If the front axle was operated for an extended period of time with very loose bearings, the ring • Differential case for cracks and scoring. gear and drive pinion will also require replace...
Page 254 4C3-8 7 1/4-INCH RING GEAR 4. Tighten the dial indicator in this position. PINION BEARING CUP 5. Set the button of J 33838 on the differential bear INSTALLATION ing bore (figure 19). 6. Rotate the tool slowly back and forth until the dial Install or Connect (Figures 1, 2, 17 and 18) indicator reads the lowest point of the bore.
Page 255 7 1/4-INCH RING GEAR 4C3-9 B. Button Moved Out of Bearing Bore F5791 Figure 19—Measuring Pinion Depth...
Page 256 403-10 7 1/4-INCH Rif JG GEAR The correct preload is 1.7-2.8 N-m (15-25 in. lbs.). 1. Rotate the pinion with the torque wrench and observe the reading. 2. If the preload torque is below specifications, con tinue torquing the pinion nut in small increments. Check the preload after each tightening.
Page 257 7 1/4-INCH RING GEAR 4C3-11 • If the carrier halves do not make complete con tact, back out the right hand adjusting sleeve (32). Use J 33792 (figure 24). NOTICE: See Notice on page 4C3-1 of this section. 6. Four bolts (28) (figure 25). J 33788 Tighten •...
Page 258 403-12 7 1/4-INCH RING GEAR for burrs, a distorted case flange, uneven bolt 3. DIVIDE THE DIAL INDICATOR READING BY 2 to ing conditions, or foreign matter between the obtain the actual backlash when using this meth case and the ring gear. od.
Page 259 7 1/4-INCH RING GEAR 4C3-13 rotates one full revolution then reverse the rota It is important that the contact pattern be centrally located up and down on the face of the ring gear teeth. tion so that the ring gear rotates one revolution in the opposite direction.
Page 260 403-14 7 1/4-INCH RING GEAR 1. Right carrier case (29). Z Bolts (28). [^ 0 Tighten • Bolts to 47 N-m (35 ft. lbs.). • Make sure the sleeves (32) are in the proper posi tion, as marked previously. 3. Bolts (18) and locks (19). JjsjX] Tighten •...
Page 261 7 1/4-INCH RING GEAR 4C3-15 18. Carrier connector (9) with retainer (8). Tap into place. • Remove all oil and grease from the tube and carri er gasket surfaces. Use carburetor cleaner or equivalent. • Apply sealer (GM part not 1052357 {Loctite 514} or equivalent) to the carrier.
Page 262 403-16 7 1/4-INCH RING GEAR Tri-Pot Housing Assembly Shaft Retaining Ring Tri-Pot Joint Spider Needle Retainer Ring Needle Retainer Tri-Pot Joint Ball Needle Roller Spacer Ring Seal Retaining Clamp (Service Only) Retaining Clamp Protector 16. Race Retaining Ring Tri-Pot Joint Seal 17.
Page 263 7 1/4-INCH RING GEAR 4C3-17 3. Crimp seal-retaining clamp (12) with J 35910 to | V | Im portant 136 N-m (100 ft. lbs.). Refer to figure 41. 4. Place approximately half of the grease provided • Make sure that seal (14), housing (20) and inside the seal (14) and pack C/V with remaining swage ring (15) all remain in alignment (fig...
Page 264 4C3-18 7 1/4-INCH RING GEAR PUSH C/V JOINT ASSEMBLY ONTO AXLE SHAFT UNTIL RETAINING RING IS SEATED IN GROOVE ON AXLE SHAFT 13. Axle Shaft 20. C/V Joint Outer Race F7486 40— Figure Installing C/V Jo in t to Axle | Assemble 1.
Page 265 7 1/4-INCH RING GEAR 4C3-19 MAKE SURE SWAGE RING AND SWAGE RING CLAMP ARE IN PROPER ALIGNMENT 15. Swage Ring A. Swage Ring CLamp B. Axle Assembly C. Housing D. Seal E. Vise F7488 42— Figure Installing Swage Ring 8. Remove spacer ring (8) and seal (11) from axle shaft (13).
Page 266 403-20 7 1/4-INCH RING GEAR PIVOT CAGE AND INNER RACE AT 90° TO CENTER LINE OF OUTER RACE WITH CAGE WINDOWS ALIGNED WITH LANDS OF OUTER RACE. LIFT OUT CAGE AND INNER RACE. SLIDE SPACER RING AND SPIDER ASSEMBLY BACK ON SHAFT.
Page 267 7 1/4-INCH RING GEAR 4C3-21 Figure 48—Installing IK -pot to Housing...
Page 268 4C3-22 7 1/4-INCH RING GEAR SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Ft. Lbs. Tube Attaching Bolts..................Left Hand Output Shaft Cover Bolts............Carrier Case Bolts..................Adjusting Sleeve Lock Bolts................ — Differential Ring Gear Bolts................ AVAILABLE SHIM SIZES Pinion Shim Kits........................
Page 269 7 1/4-INCH RING GEAR 4C3-23 SPE C IA L TOOLS J 8614-01 J 21551 J 33844 J 29763 J 33782 J 33893 J 33785 J 29369-2 J 33788 J 29307 J 33790 J 33791 J 33792 J 8001 J 22912-01 J 25025-1 J 23423-A 20 .
Page 270 4C3-24 7 1/4-INCH RING GEAR...
Page 271 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-1 SECTION 4C4 8 1/4 AND 9 1/4-INCH RING GEAR 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 part number fastener is not available, a fastener o f equal size and strength (or stronger) may be used.
Page 272 4C4-2 8 1/4 AND 9 1/4-INCH RING GEAR The axle is produced with 8 1/4-inch and 9 1/4-inch The drive axles are completely flexible assemblies ring gears. The 8 1/4-inch ring gear is used on K1,2 consisting of inner and outer constant velocity (CV) models;...
Page 273 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-3 39. Differential pinion gears (56) and side gears (54). thrust washers (53). Mark the gears and differential case as left and right. • Roll the pinion gears out of the case with the •...
Page 274 4C4-4 8 1/4 AND 9 1/4-INCH RING GEAR Figure 1—Front Axle Components (K1, 2 Models)
Page 275 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-5 Figure 2—Front Axle Components (K3 Models)
Page 276 4C4-6 8 1/4 AND 9 1/4-INCH RING GEAR 1. Right Output Shaft 2. Deflector 3. Seal 4. Output Shaft Bearing 5. Axle Tube 6. Bolt 7. Thrust Washer 8. Retaining Ring 9. Connector 10. Differential Actuator 11. * Washer 12. ‘ Retaining Ring 13.
Page 277 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-7 F5858 Figure 9—Turning the A djuster Plug (K3 M odels) • Spring (16) for breakage. • Actuator (10) and engagement switch (13) for dam age and frayed wiring. SOLENOID CHECK • Apply 12 volt battery voltage to the solenoid termi nals.
Page 278 4C4-8 8 1/4 AND 9 1/4-INCH RING GEAR Seal...
Page 279 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-9 INSTALLATION J36616 F5285 Figure 17— Removing the Pin (K1, 2 Models) Figure 18—Replacing the C arrier Bushings ASSEMBLY OF AXLE • Rotate the forcing screw until the installer is | Im portant snug against the bearing cup.
Page 280 4C4-10 8 1/4 AND 9 1/4-INCH RING GEAR PINION DEPTH ADJUSTMENT Tools Required: J 36601 Pinion Depth Setting Gage J 29763 Dial Indicator 1. Refer to figures 1 through 3 and 21. 2. Pinion depth is adjusted by selecting a shim (38) of the proper thickness.
Page 281 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-11 J 36601-4 (K15-25) J 36601-3 (K35) Button Located In Bore Bearing Swung Out of Bore Washer Pilot Flats Bearing (Inner Pinion) J 21777-35 (K15-25) J 29763 Bearing (Outer Pinion) J 21777-8 (K35) F5869 Figure 21—...
Page 282 4C4-12 8 1/4 AND 9 1/4-INCH RING GEAR J 8092 J 22761 (K15-25) J 29710 (K35) F5871 25— Figure -Installing the D ifferential Side Bearing 5. Ring gear (37) onto the differential case (35). NOTICE: See "NOTICE” on page 4C4-1 of this section.
Page 283 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-13 4. Side bearing cups (33). Use J 36603 with J 8092 (figure 29). 5. Differential assembly to the carrier case half. • Place the differential assembly into the carrier case half which contains the pinion gear. •...
Page 284 4C4-14 8 1/4 AND 9 1/4-INCH RING GEAR 5. Turn the right sleeve OUT two notches. • Changing the sleeves one notch will change 6. Turn the left sleeve (K1, 2 models) or adjuster plug backlash about 0.08 mm (0. 003-inch). (K3 models) IN one notch.
Page 285 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-15 the ring gear and the drive pinion for low noise level and long life can be assured. GEAR TOOTH TERMS The side of the ring gear tooth which curves outward, or is convex, is referred to as the “drive” side. The concave side is the “coast”...
Page 286 4C4-16 8 1/4 AND 9 1/4-INCH RING GEAR The position of the drive pinion is adjusted by increasing or decreasing the shim thickness between the pinion head and the inner race of the rear bearing. The shim is used in the differential to compensate for manufacturing tolerances.
Page 287 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-17 Preferred Method: Tool Required: J 34672 Depth Gage (or equivalent) • Refer to figures 36 and 37 1. Push on the inner end of the shaft (1), and move the shaft outboard as far as it will go. The shaft must be in this position when measuring dimen...
Page 288 4C4-18 8 1/4 AND 9 1/4-INCH RING GEAR C. Measure with Axle Shaft Forced Outboard 1. Shaft 5. Tube 9. Carrier Connector 23. Output Shaft 29. Carrier Case F5877 Figure 36—Measuring to Calculate Shim Size...
Page 289 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-19 MEASURING DIMENSION “A (K15-25 SHOWN) F5878 Figure 37—M easuring to Calculate Shim Size F5878 Figure 38— Measuring Axle Shaft End Play 7. Actuator (10). Apply sealer (GM part no. 1052942 {Loctite 518} or equivalent) to the threads. 8.
Page 290 4C4-20 8 1/4 AND 9 1/4-INCN RING GEAR DRIVE AXLE ASSEMBLY • Crimp the self retaining clamp (11) with J 35910 to OUTER DEFLECTOR RING 136 N-m (100 ft. lbs.) (figure 45). REPLACEMENT • Place approximately half of the grease provided inside the seal (13) and repack the C/V with the Remove o r Disconnect (Figures 40, 41 and 42) remaining grease.
Page 291 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-21 1. Tri-pot Housing Assembly 2. Shaft Retaining Ring 3. Tri-pot Joint Spider 4. Needle Retainer Ring 5. Needle Retainer 6. Tri-pot Joint Ball 7. Needle Roller 8. Spacer Ring 9. Swage, Ring 10.
Page 292 404-22 8 1/4 AND 9 1/4-INCH RING GEAR ONTO AXLE SHAFT UNTIL RETAINING RING IS SEATED IN GROOVE ON AXLE SHAFT 12. Axle Shaft 18. C/V Joint Outer Race ________________________________F6725 Figure 44— Installing C/V Joint SQUARE UP DEFLECTOR RING AND TIGHTEN NUT UNTIL RING BOTTOMS AGAINST SHOULDER OF OUTER RACE 18.
Page 293 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-23 MAKE SURE SWAGE RING AND SWAGE SWAGE CLAMP SIZE CHART RING CLAMP ARE IN PROPER ALIGNMENT APPLICATION TOOL NO. DESCRIPTION J 36652-1 Split Plate Swage Clamp K 10/20 K 30 (Outboard) J 36652-2 Split Plate Swage Clamp Split Plate Swage Clamp K 30 (Inboard)
Page 294 404-24 8 1/4 AND 9 1/4-INCH RING GEAR SPIDER ASSEMBLY ROTATE INNER RACE UP AND OUT OF CAGE SLIDE SPACER RING AND SPIDER ASSEMBLY BACK ON SHAFT. REMOVE RETAINING RING AND SLIDE SPIDER ASSEMBLY OFF OF SHAFT. INNER RACE CAGE LAND WINDOW 2.
Page 295 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-25 lower half of tool and check for proper alignment and dimension (figures 46 and 53). — Insert the bolts and tighten by hand until snug. Im portant • Make sure that the seal (10), housing (1) and swage ring (9) all remain in alignment (figure 46).
Page 296 4C4-26 8 1/4 AND 9 1/4-INCH RING GEAR SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Ft. Lbs. In. Lbs. — Ring Gear Bolts................... — Carrier Case Bolts..................— Axle Tube Bolts.................... Actuator......................— — Front Axle Switch..................— Drain and Fill Plugs..........
Page 297 8 1/4 AND 9 1/4-INCH RING GEAR 4C4-27 SPECIAL TOOLS J 29307 J 36616 4 * * J 36612 J 22761 J 36613 J 29710 J 22888 J 8092 J 36609 J 8107-2 J 36597 J 29369-1 J 29369-2 J3612-B J 36606 V >...
Page 298 404-28 8 1/4 AND 9 1/4-INCH RING GEAR SPECIAL TOOLS <%f & J 34037 J 35512 J 36614 J 34672 J 36366 J 36600 J 22833 J 36615 J 36598 J 34047-3 J-36599 J 36601 J8059 J 29763 J 35910 J 36603 19.
Page 299 ALL W HEEL DRIVE FRONT AXLE 4C5-1 SECTION 4C5 ALL WHEEL DRIVE FRONT AXLE 7 1/4-INCH RING GEAR 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 300 4C5-2 A LL W HEEL DRIVE FRONT AXLE DISASSEMBLY OF AXLE 9. Separate the carrier case (29). INSPECTION • Insert a screwdriver into the slots provided and Perform the following checks before disassembling pry to separate the case (figure 5). the axle.
Page 301 ALL W HEEL DRIVE FRONT AXLE 4C5-3 • Sealing surface of the pinion flange for nicks, INSPECTION burrs, or rough tool marks which would cause It is very important to carefully and thoroughly damage to the seal’s inside diameter and result in inspect all drive unit parts before assembly.
Page 302 405-4 A LL W HEEL DRIVE FRONT AXLE F7475 Figure 1—All Wheel Drive Front Axle...
Page 303 ALL W HEEL DRIVE FRONT AXLE 4C5-5 45. Washer 1. Shaft 31. Insert 2. Deflector 32. Sleeve 46. Nut 33. Side Bearing 47. Plug 3. Seal 48. Buching 4. Bearing 34. Bolt 49. Vent Hose 5. Tube 35. Differential Case 50.
Page 304 4C5-6 A LL W HEEL DRIVE FRONT AXLE 18. Bolt 29. Carrier Case 19. Lock Tab 32. Sleeve F1780 Figure 9— Removing the Pinion Nut Figure 6—Removing the Lock Tabs Figure 10—Removing the Pinion Flange Figure 11— Removing the Pinion Bearing F1782 Figure 8—Removing the Sleeve Bearing...
Page 305 ALL W HEEL DRIVE FRONT AXLE 4C5-7 Figure 14—Replacing the Case Bushings PINION BEARING CUP INSTALLATION |+ + | Install or Connect (Figures 1, 2, 15 and 17) J 33790 Tool Required: J 33837 Pinion Bearing Remover and Installer 1. Bearing cup (41) into the case using J 33837-1, J 33837-3, and J 33837-4 (figure 16).
Page 306 4C5-8 A LL W HEEL DRIVE FRONT AXLE • The shim must be of the proper size, as select ed previously. J 33837-1 2. Bearing (39) onto the pinion gear (37) using J 33785 (figure 19). J 33837-3 3. New spacer (40) onto the pinion gear (37). 4.
Page 307 A LL W HEEL DRIVE FRONT AXLE 4C5-9 B. Button Moved Out of Bearing Bore F5791 Figure 18—Measuring Pinion Depth...
Page 308 4C5-10 ALL W HEEL DRIVE FRONT AXLE 6. Four bolts (28) (figure 24). Tighten • Bolts (28) to 50 N.m (37 ft. lbs.). ADJUSTING BACKLASH Tools Required: J 33792 Side Bearing Adjuster Wrench J 34047 Dial Indicator Adapter J 25025-1 Dial Indicator Stand J 8001-1 Dial Indicator Clamp 1.
Page 309 ALL W HEEL DRIVE FRONT AXLE 405-11 J 33788 F-01791 F1829 Figure 24—Carrier Case Bolts Installed Figure 22—installing the Sleeve Bearing 29. Carrier Case 32. Sleeve A. Mark Location on the Case F1830 Figure 23—Adjusting the Sleeve Figure 25— Marking Sleeve Location verify the correct running position of the ring gear and 3.
Page 310 4C5-12 ALL W HEEL DRIVE FRONT AXLE ADJUSTMENTS AFFECTING TOOTH CONTACT Two adjustments can be made which will affect the tooth contact pattern. These are backlash and the posi tion of the drive pinion (pinion depth) in the carrier. The effects of bearing preloads are not easily seen on hand loaded teeth pattern tests.
Page 311 ALL W HEEL DRIVE FRONT AXLE 4C5-13 FINAL ASSEMBLY |+ + | Remove or Disconnect (Figures 1, 2 and 24) 1. Four case bolts (figure 24). 2 Right carrier case half. Clean • Sealing surfaces on the carrier case halves. Remove all oil and grease.
Page 312 4C5-14 ALL W HEEL DRIVE FRONT AXLE Tri-Pot Housing Assembly Shaft Retaining Ring Tri-Pot Joint Spider Needle Retainer Ring Needle Retainer Tri-Pot Joint Ball Needle Roller Spacer Ring Seal Retaining Clamp (Service Only) Retaining Clamp Protector 16. Race Retaining Ring Tri-Pot Joint Seal 17.
Page 313 ALL W HEEL DRIVE FRONT AXLE 4C5-15 OUTER JOINT SEAL |-n -j Install or Connect Remove or Disconnect (Figures 30 and 33 1. Small the seal-retaining clamp (12) on neck of new seal (14). Do not crimp. through 36) 2. Slide the seal (14) onto axle shaft (13) and position neck of seal in seal groove on axle shaft.
Page 314 4C5-16 A LL W HEEL DRIVE FRONT AXLE PUSH C/V JOINT ASSEMBLY ONTO AXLE SHAFT UNTIL RETAINING RING IS SEATED IN GROOVE ON AXLE SHAFT 13. Axle Shaft 20. C/V Joint Outer Race F7486 Figure 34—Installing C/V Joint to Axle 8.
Page 315 A LL W HEEL DRIVE FRONT AXLE 405-17 MAKE SURE SWAGE RING AND SWAGE RING CLAMP ARE IN PROPER ALIGNMENT F7488 Figure 36— Installing Swage Ring INNER TRI-POT SEAL |+-»| Remove or Disconnect (Figures 30, 35, and 40 through 43) Tools Required: J 8059 Snap Ring Pliers J 35910 Seal Clamp Tool...
Page 316 405-18 ALL W HEEL DRIVE FRONT AXLE PIVOT CAGE AND INNER RACE AT 90“ TO CENTER LINE OF OUTER RACE WITH CAGE WINDOWS ALIGNED WITH LANDS OF OUTER RACE. LIFT OUT CAGE AND INNER RACE. SLIDE SPACER RING AND SPIDER ASSEMBLY BACK ON SHAFT.
Page 317 W HEEL DRIVE FRONT AXLE 4C5-1S Figure 42—Installing Di-pot to Housing 7. Slide tri-pot spider (3) towards end of shaft (13) and reseat spacer ring (8) in groove on shaft. 8. Place approximately half of grease provided in seal (11) and use remainder to pack tri-pot housing (1). 9.
Page 318 4C5-20 ALL W HEEL DRIVE FRONT AXLE SPECIFICATIONS TORQUE SPECIFICATIONS Ft. Lbs. In. Lbs. Fastener — Tube Attaching Bolts..................— Left Hand Output Shaft Cover Bolts............Carrier Case Bolts..................— Adjusting Sleeve Lock Bolts................ — — Differential Ring Gear Bolts..........
Page 319 ALL W HEEL DRIVE FRONT AXLE 4C5-21 SPE C IA L TOOLS J 8614-01 J 21551 J 29763 J 33844 J 33782 J 33893 J 33785 J 29369-2 J 33788 J 29307 J 33790 J 33791 J 33792 J 8001 J 22912-01 J 25025-1 J 23423-A...
Page 320 4C5-22 ALL WHEEL DRIVE FRONT AXLE...
Page 321 BRAKES 5-1 SECTION 5 BRAKES 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 322 5-2 BRAKES 16. Cover 17. Bracket 18. Nut 6. O-Ring 19. Boot 7. Spring 20. Pedal Rod 8. Housing 21. Pin 9. Bolt 22. Piston Assembly 10. Seal 23. Seal 1. Retainer 11. Accumulator Valve 24. Retainer 2. Accumulato 12. Return Line Fitting 25.
Page 323 BRAKES S 3 8. Housing B. 3.0 mm (0.125*inch) 11. Accumulator Valve C. 57 mm (2.25-inches) 22. Piston Assembly A. Wire Hook F0768 F9318 Figure 7—Installing the Piston Assembly Figure 4— Removing the Accumulator Valve J 24551 or 8. Housing j 25083 25.
Page 324 BRAKES 11. Output pushrod assembly (figure 8). 15. Accumulator assembly. • O-ring (3) onto the accumulator (2). • Retainer (24), piston return spring (25), baffle • O-ring (3) and accumulator (2) by using (27) and output pushrod(28) by using J 24551-A J 26889 and a C-clamp (figure 2).
Page 325 BRAKES 5-5 1. Cover 2. Diaphragm 3. Reservoir 4. Grommet 5. Quick Take-Up Valve 6. Spring 7. Spring Retainer 8. Primary Seal 9. Secondary Piston 10. Secondary Seal 11. Snap Ring 12. Primary Piston Assembly 13. Body F0769 Figure 9—Composite Master Cylinder Components CAUTION: In the follow ing step if a ir pressure 7.
Page 326 5-6 BRAKES 1. Cover 2. Diaphragm 3. Reservoir 4. Grommet 5. Quick Take-Up Valve 6. Spring 7. Spring Retainer 8. Primary Seal 9. Secondary Piston 10. Secondary Seal 11. Snap Ring 12. Primary Piston Figure 11—Removing The Reservoir Assembly 13. Body <...
Page 327 BRAKES 5-7 21. Bail 22. Cover 23. Diaphragm 24. Body 25. Spring 26. Spring Retainer 27. Primary Seal 28. Secondary Piston 29. Secondary Seals 30. Primary Piston Assembly 31. Snap Ring F0774 Figure 14— Cast Iron Master Cylinder Components...
Page 328 5-8 BRAKES 26. Spring Retainer 27. Primary Seal 28. Secondary Piston 29. Secondary Seals F4398 Figure 16—Secondary Piston Assembly 30. Primary Piston Assembly 31. Snap Ring F4397 Figure 15—Cast Iron Master Cylinder Components BENDIX MASTER CYLINDER |+ + | Remove or Disconnect (Figure 19) 1.
Page 329 BRAKES 5-9 41. Cover 42. Diaphragm -4 2 43. Filter 44. Reservoir 45. Compensating Valve Seal 46. Valve Poppet 47. Spring .— 44 48. Secondary Spring 49. Secondary Piston _ _ __ 55 50. Piston Return Spring 51. Primary Piston 52.
Page 330 5-10 BRAKES VACUUM BOOSTERS Delco Moraine NDH vacuum boosters have a build 9. Power piston and pushrod assembly (16). date on a small paper label glued onto the front hous • Grasp the outside edge of the diaphragm sup ing. The first digit indicates the Delco Moraine NDH port (15) and diaphragm (14).
Page 331 BRAKES 5-11 • Lubricate the inside and outside of the bearing with silicone grease. 7. Power piston group into the rear housing (7). 8. Return spring (9). 9. Front housing to the rear housing. • Align the marks made during disassembly. •...
Page 332 5-12 BRAKES • Scribe a mark on the front and rear housings to 10. Secondary diaphragm (20) and secondary support aid in reassembly. plate (21) from the housing divider (19). • Unlock the front and rear housings using J 23456 11.
Page 333 BRAKES 5-13 8. Primary Piston Bearing 9. Rear H ou sing 10. Front H ou sing 11. Return Spring Power Piston Group 12. Piston Rod (Gaged) 13. Reaction Retainer 14. Power Head Silencer 15. Diaphragm Retainer 16. Primary Diaphragm F5823 17.
Page 334 5-14 BRAKES A. Diaphragm Lip 18. Secondary Piston Bearing 20. Secondary Diaphragm 19. Housing Divider 21. Secondary Support Plate 20. Secondary Diaphragm 41. Power Piston Assembly 41. Power Piston Assembly F5894 F5895 Figure 28—Assembling the Secondary Figure 29—Assembling the Housing Divider Diaphragm and Support •...
Page 335 BRAKES 5-15 SPECIFICATIONS Ft. Lbs. Hydro-Boost Housing to Cover Bolts................... Hydro-Boost Nut........................Reservoir Bolts........................T2519 SPECIAL TOOLS J 37839 J 23456 J 24551-A J 26889 J 25083 J 6217 1. Power Brake Push Rod Height Gage 2. Piston Seal Protector 3.
Page 336 saxvua 9i--s...
Page 337 GENERAL ENGINE MECHANICAL 6A-1 SECTION 6 ENGINE CONTENTS SUBJECT PAGE General Engine Mechanical............................6A-1 2.5L L4 E ngine................................6A1-1 2.8LV 6 E n g in e ................................6A2-1 4.3L V6 E ng in e ................................6A3-1 V8 E n g in e s..................................6A5-1 6.2L Diesel E n g in e ..............................6A7-1 TBI Unit Model 220..............................6C1-1 TBI Unit Model 700..............................6C2-1...
Page 338 6A-2 GENERAL ENGINE MECHANICAL CONTENTS (cont’d) SUBJECT PAGE A sse m b ly................................... 6A-18 Measuring Main Bearing Clearance........................6A-18 Measuring Connecting Rod Bearing Clearance....................6A-20 Special T o ols................................6A-21 GENERAL INFORMATION • Anaerobic gasket eliminator hardens in the STATEMENT ON absence of air. This sealer is used where two rigid CLEANLINESS AND CARE parts (such as castings) are assembled together.
Page 339 GENERAL ENGINE MECHANICAL 6A-3 REPLACING ENGINE GASKETS CAUTION: Composite type gaskets are used in some areas of the engine assembly. These gaskets have a thin metal core. Use caution when removing or handling com posite gas kets to help avoid personal injury. CYLINDER BORES, PISTONS, RINGS, AND CONNECTING RODS MEASURING CYLINDER BORE...
Page 340 6A-4 GENERAL ENGINE MECHANICAL an outside micrometer, with the gage at the same ommended for trueing the bore. If wear or zero setting when removed from the cylinder (fig out-of-round exceeds these limits, the bore should ure 3). be trued up with a boring bar of the fly cutter type, 3.
Page 341 GENERAL ENGINE MECHANICAL 6A 5 NOTICE: Handle the pistons with care and do BORING not attempt to force them through the cylin 1. Before the honing or reboring operation is started, der until the cylinder has been honed to the correct size as the piston can be distorted measure all new pistons with the micrometer con...
Page 342 6A*6 GENERAL ENGINE MECHANICAL 1. Upper Compression Ring 2. Lower Compression Ring 6. Oil Control Ring g 7. Snap Ring 8. Piston Pin B9400 Figure 7—Piston and Components—6.2L Engine 3. Snap rings. Use snap ring pliers. • Place remover J 24086-8 (J 24086-88A for 2.8L 4.
Page 343 GENERAL ENGINE MECHANICAL 6 * 7 — Remove the carbon from the ring grooves. Use a ring groove cleaning tool. — Oil control ring groove holes. I P I Inspect — Piston pin bore in the piston and connecting rod. Check for scuffing, burrs, etc.
Page 344 6A-8 GENERAL ENGINE MECHANICAL PISTON SELECTION ASSEMBLY (ALL EXCEPT 2.5L Assembling the Piston and Connecting Rod (All except 6.2L Engines) AND 2.8L ENGINES) 1. Check the used piston to cylinder bore clearance. |n%-| Assemble (Figure 13) Measure (Figures 11 and 12) Tool Required: J 24086-B Piston Pin Remover and Installer Set •...
Page 345 GENERAL ENGINE MECHANICAL 6Ar9 • Adjust the piston pin installer (J 24086-9) to the correct length, using the letter-number scale on the installer adjuster (figure 13). This is neces sary to insure that the piston pin is pressed into the piston to the correct depth. Refer to the instructions supplied with the tool for the prop...
Page 346 6A-10 GENERAL ENGINE MECHANICAL Installing the Piston Rings (All Except 6.2L) Measure (Figures 4 and 16) • Ring end gap as follows: 1. Select rings comparable in size to the piston being used. 2. Slip the compressing ring in the cylinder bore: then press the ring down into the cylinder bore about 7 mm (1 /4-inch) above ring travel.
Page 347 GENERAL ENGINE MECHANICAL 6A-11 Measure (Figures 7 and 16) • Ring end gap as follows: 1. Select rings comparable in size to the piston being used. 2. Slip the compression ring in the cylinder bore; then press the ring down into the cylinder bore about 7 mm (1/4-inch) above ring travel.
Page 348 6A-12 GENERAL ENGINE MECHANICAL Clean A. Checking oil hole alignment with brass rod. Make rod as shown using " rod about Camshaft bearing bores in the block. 762 mm (30") long. Assemble (Figures 19, 20, and 21) Tool Required: J 6098-01 Camshaft Bearing Remover and Installer •...
Page 349 GENERAL ENGINE MECHANICAL 6A-13 — Lifter foot (flat type lifters). The lifter foot must be smooth and slightly convex. If worn, pitted, or damaged the mating camshaft lobe should also be checked. — Roller (roller type lifters) for: 223 224 " —...
Page 350 6A-14 GENERAL ENGINE MECHANICAL 1. Check ball (225) to the small hole in the bottom of the plunger (226). 2. Check ball spring (225) to the check ball retainer (223). 3. Check ball retainer (223) with check ball spring (224) to the plunger (226). Make sure the spring rests on the ball.
Page 351 GENERAL ENGINE MECHANICAL 6A-15 4. Plunger spring (222) to the check ball retainer (223). 5. Lifter body (221) to the plunger (226). • Slide the lifter body over the plunger, being careful to line up the oil feed holes in the lifter body and plunger.
Page 352 6A-16 GENERAL ENGINE MECHANICAL Check the valve stems for scoring or excessive • Excessive valve stem to guide bore clearance wear. Stems must not be bent. will cause excessive oil consumption and may — Rocker arm studs (if used) for wear, damage or cause valve breakage.
Page 353 GENERAL ENGINE MECHANICAL 6A-17 Figure 34— Measuring Valve Spring Length Figure 33—Measuring Valve Spring Tension REAMING VALVE GUIDES REPAIR The valve guides used in engines covered by this manual are simply holes bores into the cylinder head. VALVE GRINDING The valve guides are therefore not replaceable. Valves that are pitted must be refaced to the proper If the valve stem to bore clearance as measured pre...
Page 354 6A-18 GENERAL ENGINE MECHANICAL — 6.2L: — Intake and exhaust: 0.08 mm (0.003-inch), 0.38 mm (0.015-inch). Select a reamer which will provide a straight, clean bore through the guide’s entire length (figure 36). Reamer availability is as follows. Sizes given are nominal.
Page 355 GENERAL ENGINE MECHANICAL 6A-19 5L engines) difference. 4. Normally main bearing journals wear evenly and are not out-of-round. However, if a bearing is being fitted to an out-of-round journal, be sure to fit to the maximum diameter of the journal. If the bear ing is fitted to the minimum diameter and the jour...
Page 356 6A-20 GENERAL ENGINE MECHANICAL MEASURING CONNECTING ROD BEARING CLEARANCE Connecting rod bearings are of the precision insert • Gaging plastic at its widest point, using the scale type and do not use shims for adjustment. DO NOT at the gaging plastic envelope (figure 40). FILE RODS OR ROD CAPS.
Page 357 GENERAL ENGINE MECHANICAL 6A-21 SPECIAL TOOLS J 8087 J 8089 J 24086-B J 8101 J 29134-B J 8001 J 6098 01 J 9666 J 5830-02 J 5790-B J 7049 1. Cylinder Bore Gage 2. Piston Pin Replacer Set 3. Piston Pin Clip Installer 4.
Page 358 6A-22 GENERAL ENGINE MECHANICAL...
Page 359 2.5L L4 ENGINE 6A1-1 SECTION 6A1 2.5L (151 CID) ENGINE 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 for the application. If the correct part number is not available, a fastener of equal size and strength (or stronger) may be used.
Page 360 6A1-2 2.5L L4 ENGINE CONTENTS (cont’d) SUBJECT PAGE Main Bearing Installation (W ithout Removing the Crankshaft)..............6A1-21 Camshaft Installation............................6A1-22 Front Cover In s ta lla tio n ............................6A1-22 Crankshaft Pulley Hub Insta lla tio n ........................6A1-23 Piston and Connecting Rod Installation......................6A1-23 Oil Pump Installation............................6A1-24 Oil Pan In s ta lla tio n ...............................6A1-25 Oil Pump Driveshaft Installation........................6A1-25...
Page 361 2.5L L4 ENGINE 6A1-3 A. Oil Pump Drive Gear Oiling B. Oil Pressure Sending Unit B7950 Figure 1—Engine Lubrication Diagram...
Page 362 6A1-4 2.5L L4 ENGINE 15. Hose Clamp 16. Hose 17. Cylinder Head Gasket 1. Outer Engine Heat Stove 18. Intake Valve 35. Valve Spring 19. Exhaust Valve 2. Bolt 36. Intake Valve Stem Seal 20. Plug 3. Stud 37. Washer 4.
Page 363 2.5L L4 ENGINE 6A1-5 102. Front Cover 76. Oil Pan 50. Push Rod Cover 103. Screw 77. Oil Pump 51. Piston and Pin 104. Camshaft Gear 78. Nut 52. Piston Rings 105. Camshaft Thrust Bearing 79. Pin 53. Connecting Rod 106.
Page 364 6A1-6 2.5L L4 ENGINE F9391 Figure A — Block and Components...
Page 365 2.5L LA ENGINE 6A1-7 37. Washer 38. Bolt 42. Stud 43. Intake Manifold 44. Gasket F9403 Figure 5— Intake Manifold Components Figure 6—Exhaust Manifold Components COOLANT PUMP REMOVAL THERMOSTAT HOUSING REMOVAL Remove or Disconnect (Figure 7) |» + | Remove or Disconnect (Figure 4) 1.
Page 366 6A1-8 2.5L L4 ENGINE VALVE TRAIN COMPONENT REMOVAL Tools Required: J 3049A Valve Lifter Remover (Plier Type) Remove or Disconnect (Figures 2, 8, 9, and 10 ) 1. Rocker arm cover bolts. 2. Rocker arm cover. 31. Bolt 32. Rocker Arm Ball 33.
Page 367 2.5L L4 ENGINE 6A1-9 3. Bolts (31), balls (32), rocker arms (33), pushrods (47), and pushrod guides (45). • Every effort should be made to insure that these mating parts are installed in their original locations during assembly. A simple valve train component organizer rack can be made from a piece of wood, as shown in figure 9.
Page 368 6A1-10 2L5L L4 ENGINE OIL PUMP REMOVAL CRANKSHAFT PULLEY HUB REMOVAL [+-»| Remove or Disconnect (Figure 4) |» + | Remove or Disconnect (Figure 4 and 12) 1. Bolts (84) and nut (78) at oil screen bracket. 2. Oil pump (77). 1.
Page 369 2.5L L4 ENGINE 6A1-11 2. Timing gear cover (102). • If the timing gear cover adheres to the cylinder head, carefully pry it loose. DO NOT DISTORT THE SEALING FLANGE. PISTON AND CONNECTING ROD REMOVAL |<»+| Remove or Disconnect (Figures 4, 14 and 15) 1.
Page 370 6A1-12 2.5L L4 ENGINE Remove or Disconnect (Figures 4, 16 and 17) • Check the main bearing caps (124 and 126) loca tion markings. The main bearing caps are num bered 1 through 5 from the front to the rear of the engine.
Page 371 2.5L L4 ENGINE 6A1-13 CLEANING, INSPECTION, AND REPAIR A solvent tank, large enough to hold the larger PISTON SELECTION engine parts, will be needed along with various bristle In order to select the proper piston for each bore, it is brushes and a gasket scraper.
Page 372 6A1-14 2.5L L4 ENGINE A. Indicator B. Checking Fixture 108. Camshaft F1998 Figure 23—Measuring Camshaft Journal Runout Figure 22—Measuring Cylinder Bore Diameter which is 45.84 mm (1.805 inch) from the piston crown. By measuring at this point, the largest piston diameter will be obtained. •...
Page 373 2.5L L4 ENGINE 6A1-15 4. Camshaft gear (104). 0.0015-inch replace the spacer ring (106). If the clearance is more than 0.0050-inch, replace the • Make sure that the timing mark is to the out thrust plate (105). side. • Press the camshaft gear onto the camshaft jjjSj] Disassemble (Figure 26) until it bottoms on the spacer (106).
Page 374 6A1-16 2.5L L4 ENGINE 2. Rear bearing (109) and expansion plug. • Drive the bearing in from the rear of the engine. • Make sure that the oil holes in the bearing are aligned with the oil holes in the block. •...
Page 375 2.5L L4 ENGINE 6A1-17 — Pressure relief valve (85) for fit. The regulator OIL PUMP valve should slide freely in its bore without sticking or binding. Disassemble (Figure 30) Assemble (Figures 30 and 31) 1. Cover screws (81). Z Cover (82). Tool Required: 3.
Page 376 6A1-18 2.5L L4 ENGINE VALVE TRAIN COMPONENTS PUSHRODS, PUSHROD GUIDES, ROCKER ARMS AND BALLS PCH Clean • Parts in solvent. Blow dry with compressed air. • Make sure the oil passages in the pushrods are clear. I P l Inspect (Figures 2 and 8) —...
Page 377 2.5L L4 ENGINE 6A1-19 For information on cylinder head measuring and Assemble (Figure 2) reconditioning, refer to GENERAL ENGINE MECHANI CAL (SEC. 6A) in this manual. 1. Thermostat (12). 2. Gasket (11). | Assemble (Figures 32, 33 and 34) 3. Coolant outlet (10). 4.
Page 378 6A1-20 2.5L L4 ENGINE ( j j | | Measure (Figures 35 and 36) — Main bearing and connecting rod journal diame ters. Compare with “Specifications” at the end of this section. Because the 2.5L engine crankshaft is of the rolled fillet type, the crankshaft cannot be reground.
Page 379 2.5L L4 ENGINE 6A1-21 6. Bolts (125). Make sure the special bolt, which retains the oil pump pickup tube and screen is installed in the proper position (#4 main bearing cap, camshaft side hole.) IH O Tighten • Main bearing cap bolts to 95 N-m (70 ft. lbs.). 7.
Page 380 6A1-22 2.5L L4 ENGINE 105 108 • Insert the plain end of the insert (without the Timing Marks bearing tang) of the insert between the crank Crankshaft Gear shaft and the notched side of the block. Thrust Plate Bolts • Rotate the crankshaft to ‘‘roll” the insert into Camshaft Gear the block.
Page 381 2.5L L4 ENGINE 6A1-23 CRANKSHAFT PULLEY HUB INSTALLATION Install or Connect (Figures 4 and 45) 1. Crankshaft pulley and hub. Slide the hub on the crankshaft until it bottoms against the crankshaft gear. 2. Bolt (98) and washer (99). Tighten •...
Page 382 6A1-24 2.5L L4 ENGINE with a rolled fillet on the crankshaft journal to increase crankshaft strength. Do not grind a crankshaft with a rolled fillet. Undersize bearings other than 0.001-inch ENGINE UEFT ENGINE FKONT ENGINE RIGHT undersize are not available. Measure •...
Page 383 2.5L L4 ENGINE 6A1-25 OIL PAN INSTALLATION CYLINDER HEAD INSTALLATION f»4-| Install or Connect (Figures 4 and 49) |-n-| Install or Connect (Figures 2 and 51) • Make sure the block and cylinder head sealing • Apply RTV sealant to the oil pan flange and block. surfaces are clean.
Page 384 6A1-26 2.5L L4 ENGINE • Draw a line across the head of each bolt with a marking crayon to mark the position of each bolt. 3. All head bolts, 90 degrees (1/4 turn). Tighten the bolts in the specified sequence. VALVE TRAIN COMPONENT INSTALLATION Install or Connect (Figures 2, 4, 52, and 53)
Page 385 2.5L L4 ENGINE 6A1-27 9. Rocker arm cover (48) and gasket (49). 10. Rocker arm cover bolts. Tighten • Bolts to 8.5 N-m (75 in. lbs.). COOLANT PUMP INSTALLATION |+*-| Install or Connect (Figure 54 and 55) 1. Gasket. 110. Bolt 111.
Page 386 6A1-28 2.5L L4 ENGINE 2. Coolant pump. 2. Thermostat housing bolts. 3. Bolts. 3. Thermostat bypass hose. 4. Coolant pump pulley. INTAKE MANIFOLD INSTALLATION 5. Fan and fan clutch. THERMOSTAT HOUSING |-K-| Install or Connect (Figure 56) INSTALLATION 1. Gasket. Install or Connect (Figure 55) •...
Page 387 2.5L L4 ENGINE 6A1-29 ENGINE ACCESSORY Ti ght en INSTALLATION • Intake manifold bolts to 34 N-m (25 ft. lbs.). Install the engine accessories (distributor, TBI unit oil 4. Vacuum lines and electrical connectors, as need filter, generator, etc.) as directed in the proper Truck Service Manual.
Page 388 6A1-30 2.5L L4 ENGINE SPECIFICATIONS Ail Specifications are in INCHES unless otherw ise noted. GENERAL DATA: Type Displacement 2.5L (151 CID) Bore 4.00 Stroke 3.00 Compression Ratio 8.3:1 Firing Order 1-3-4-2 Oil Pressure 36-41 psi @ 2000 RPM CYLINDER BORE: Diameter 4.000 Out Of Round...
Page 389 2.5L L4 ENGINE 6A1-31 SPECIFICATIONS (CONT.) All Specifications are in INCHES unless otherw ise n o ted CRANKSHAFT: Diameter 2.300 Taper 0.0005 Main Journal 0.0005 Out of Round 0.0005-0.0022 Main Bearing Clearance 0.0035-0.0085 Crankshaft End Play Diameter 2.000 Crankpin Taper 0.0005 0.0005 Out of Round...
Page 390 6A1-32 2.5L L4 ENGINE SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Item Ft. Lbs. In. Lb Main Bearing Cap Bolts................— Connecting Rod Nuts................... — — Oil Pan Bolts (All)..................10.0 — Oil Pump to Block Bolts................— Oil Pickup Tube Nut..................—...
Page 391 2.5L LA ENGINE 6A1-33 SPECIAL TOOLS J 21882 J 8037 J 34995 J 34924-A J 8080 J 22330 J 8062 J 3049 1. Piston Ring Compressor 2. Front Crankshaft Seal Installer 3. Main Bearing Replacer 4. Valve Spring Compressor 5. Cam Bearing Replacer 6.
Page 392 6A1-34 2.5L I A ENGINE...
Page 393 Z 8 L V6 ENGINE 6A2-1 SECTION 6A2 V6 ENGINE 2.8L (173 CID) 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 394 6A2-2 2-8L V6 ENGINE CONTENTS (cont’d) SUBJECT PAGE Prior to Assembly ..............................6A2-17 Crankshaft and Main Bearing Installation ......................6A2-17 Rear Crankshaft Oil Seal Installation ......................6A2-18 Camshaft, Tim ing Chain and Sprocket Installation ..................6A2-19 Front Cover and Coolant Pump Installation ....................6A2-19 Torsional Damper Installation ...........................
Page 395 2JBL V6 ENGINE 6A^3 Figure 1—Engine Lubrication Diagram Figure 2—Engine Lubrication Diagram...
Page 396 6A2-4 2JQL V6 ENGINE A. Lubrication Begins B. 189° Duration Of Lubrication C. End Of Lubrication D . Lubrication Ends 154° BTDC E. Cylinders 2, 4 And 6 F. 190° Duration Of Lubrication G. Lubrication Ends 134° BTDC H. For Cylinders 1, 3 And 5 J.
Page 397 2JBL V6 ENGINE 6A2-5 Figure 4— Engine Lubricetion Diagram Methods used to clean the engine will depend on the ACCESSORY REMOVAL aids which are available. Steam cleaning, pressure This manual assumes that the engine accessories washing or solvent cleaning are some acceptable meth have been removed.
Page 398 6A2-6 2-8L V6 ENGINE AIR INJECTION TUBE REMOVAL 75. Nut Remove or Disconnect (Figure 5) 76. Air Injection Pipe 1. Nut (75). 2. Air injection tube from the manifold. EGR VALVE REMOVAL Remove or Disconnect (Figure 6) 1. Bolts (80). 2.
Page 399 2 3 L V6 ENGINE 6A2-7 7. Rocker Arms 2. Reinforcements \ 8. Balls 3. Rocker Arm C o v e rV -^ ^ ^ 9. Push Rods 4. Gasket 10. Lifters 5. Studs B9315 _________________________________________ B9553 Figure 8—Rocker Arm Cover Removal Figure 9—Valve Train Components •...
Page 400 6A2-8 2.8L V6 ENGINE A. Front 40. Bolt 41. Oil Pump 42. Shaft F6523 Figure 11— Removing the Hydraulic Lifters (Typical) Figure 12—Oil Pump Removal 2. Oil pan. TORSIONAL DAMPER REMOVAL 3. Gasket. NOTICE: The inertial weight section of the tor OIL PUMP REMOVAL sional damper is assembled to the hub with a rubber sleeve.
Page 401 2JBL V6 ENGINE 6A2-9 CAMSHAFT REMOVAL \*"*\ Remove or Disconnect (Figure 13) • Camshaft by pulling lightly and turning. Important • All camshaft bearing journals are the same diameter and care must be exercised in remov ing the camshaft to avoid bearing damage. A.
Page 402 6A2-10 ZL8L V6 ENGINE PISTON AND CONNECTING CRANKSHAFT REMOVAL ROD REMOVAL |»*»| Remove or Disconnect (Figure 16) Ridge Reaming Cylinder • The main bearings and rear oil seal can be Remove or Disconnect replaced without removing the crankshaft as out lined later in this section.
Page 403 2 A LV 6 ENGINE 6A2-11 7. Transmission case mating surface. • Place a feeler gage, (0.060 mm for used pis tons, 0.050 mm for new pistons, at least 150 | j | Important mm long and not over 12mm wide) into the bore at a 90 degree angle from the piston pin •...
Page 404 6A2-12 2JQL V6 ENGINE INTAKE AND EXHAUST MANIFOLDS ii ■ Clean ■ m • Old pieces of gasket from gasket surfaces. • Excessive carbon build-up in the exhaust pas sages of the intake manifold. • Scale and deposits from the coolant passages of the intake manifold.
Page 405 2L8L V6 ENGINE 6A2-13 CRANKSHAFT SPROCKET REPLACEMENT OIL RAN AND ROCKER ARM COVERS |» + | Remove or Disconnect (Figure 20) f f i l Clean Tool Required: J 5825-A Crankshaft Sprocket Puller • Parts in solvent. Remove all sludge and varnish. 1.
Page 406 6A2-14 2LBLV6 ENGINE The pump gears, cover and body are not serviced Inspect separately. If the parts are damaged or worn, replace the entire oil pump assembly. • Rocker arms and balls at their mating surfaces. Pick-up screen and pipe (187) for damage to the These surfaces should be smooth and free from screen, pipe or relief grommet.
Page 407 Z 3 L V6 ENGINE 6A2-15 20. Intake Valve 21. Exhaust Valve 22. Valve Keepers 23. Valve Cap 24. Oil Shedder 25. Seal 26. O-Rina B9551 Figure 23— Valves and Components ROCKER ARM STUD AND PUSHROD GUIDE REPLACEMENT The rocker arm studs are threaded into the cylinder heads.
Page 408 6A2-16 ZB L V6 ENGINE • Apply a small amount of grease to the area of the upper valve stem groove. Assemble the two valve keepers using the grease to hold the keys in place. Make sure the keepers seat properly ■i^ r p n in the groove.
Page 409 2J8L V6 ENGINE 6A2-17 • Crankpins, main bearing journals and thrust sur • Main bearing and connecting rod journals for taper faces for scoring, nicks or damage caused by lack and out-of-round (figure 28). If the journals are of lubrication. tapered or out-of-round more than 0.005mm, •...
Page 410 6A2-18 2-8L V6 ENGINE | ^ | Measure (Figure 30) • Crankshaft end play. 1. Tap the end the crankshaft first rearward then forward with a lead hammer. This will line up the rear main bearing and crankshaft thrust surfaces. 2.
Page 411 2JBL V6 ENGINE 6A2-19 CAMSHAFT, TIM ING CHAIN AND SPROCKET INSTALLATION Install or Connect (Figures 32 and 33) NOTICE: All camshaft bearing journals are the same diameter. Care must be exercised in installing the camshaft to avoid bearing dam age. •...
Page 412 6A2-20 2JQL V6 ENGINE FILE RODS OR ROD CAPS. If clearances are exces PISTON AND CONNECTING sive install a new bearing. Service bearings are avail ROD INSTALLATION able in standard size and 0.013mm and 0.026mm undersize for use with new and used standard size CONNECTING ROD BEARING SELECTION crankshafts.
Page 413 2J8L V6 ENGINE 6A2-21 OIL PUMP INSTALLATION Install or Connect (Figure 37) 1. Pump and shaft with retainer to the rear main bearing cap. • Align the top end of the hexagon extension shaft with the hexagon socket on the lower end of the distributor drive gear.
Page 414 6A2-22 5L8L V6 ENGINE CYLINDER HEAD INSTALLATION Clean • Carbon deposits from combustion chambers. • All traces of old head gasket from the cylinder head and block. • Cylinder head bolt threads and threads in the block. Sealing surfaces of the block and cylinder head for nicks, heavy scratches or other damage.
Page 415 2JQL V6 ENGINE 6A2-23 should be turned over one more time to reach the INTAKE MANIFOLD INSTALLATION number one position. 2. With the engine in the number one firing position |-»*-| Install or Connect (Figure 42) as determined above, the following valves may be adjusted: 1.
Page 416 6A2-24 2J8L V6 ENGINE ROCKER ARM COVER EGR VALVE INSTALLATION INSTALLATION |++-| Install or Connect (Figure 6) j Clean 1. Gasket (82). 2. EGR valve (81). 3. Bolts (80). All traces of old gasket from the rocker arm cover and cylinder head. Tighten Inspect •...
Page 417 2L8L V6 ENGINE 6A2-25 4. Fill the cooling system with the proper coolant con ENGINE SET-UP AND TESTING forming to GM-6038-M. 1. After overhaul, the engine should be tested before 5. With the ignition “OFF” or disconnected, crank installation in the vehicle. If a suitable test stand is the engine several times.
Page 418 6A2-26 2JBL V6 ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) AH specifications are in MILLIMETERS iw less others noted. CRANKSHAFT: Diameter — 3 Dots 67.241-67.249 Diameter — 2 Dots 67.249-67.257 Main Diameter — 1 Dot 67.257-67.265 Journal Taper 0.005 (Maximum) Out of Round 0.005 (Maximum) Main Bearing Clearance 0.032-0.069...
Page 419 2L8L V6 ENGINE 6A2-27 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Item Na m Ft. Lbs. Rocker Arm Cover Bolts......................8 Intake Manifold Bolts........................21 Exhaust Manifold Bolts........................34 Cylinder Head Bolts........................95 Torsional Damper Bolt.........................95 Timing Chain Damper........................21 Front Cover Bolts 10mm Bolt (4)...........................50 8mm Bolts (6)...........................30 Oil Pan Bolts (Rear Two).....................
Page 420 6A2-28 5L8L V6 ENGINE SPECIAL TOOLS J 3049 J 9290-1 J 5590 J 23523-E J 5825-A J 24420-B J 8062 J 29113 J 8037 J 34686 J 8080 J 35468 J 21882 1. Hydraulic Lifter Remover (Plier Type) 2. Crankshaft Sprocket Installer 3.
Page 421 4.3L V6 ENGINE 6A3-1 SECTION 6A3 4.3L V6 ENGINE (262 CID) 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 422 6A3-2 4.3L V6 ENGINE CONTENTS (cont’d) SUBJECT PAGE Assembly ................................... 6A3-17 Prior to A ssem bly..............................6A3-17 Crankshaft and Bearings Installation....................... 6A3-17 Rear Crankshaft Oil Seal Retainer Installation....................6A3-18 Rear Crankshaft Oil Seal Installation....................... 6A3-18 Camshaft, Tim ing Chain and Sprockets Insta lla tio n ..................6A3-19 Front Cover In s ta lla tio n ............................6A3-19 Torsional Damper Installation..........................
Page 423 4.3L V6 ENGINE 6A3-3 It is beyond the scope of this section to cover in Special tools are listed and illustrated throughout this detail the many different accessory installations. Refer section, with a complete listing at the end of the sec tion.
Page 424 6A3-4 4.3L V6 ENGINE Front View Rear View Showing Path Of Oil To Timing Chain. Showing Main Gallery, Oil Filter And Crankshaft Oil Feed. V0575 Figure 2—Engine Lubrication Diagram...
Page 425 4.3L V6 ENGINE 6A3-5 DRAINING THE ENGINE Remove or Disconnect 1. Oil pan drain plug and washer • Allow the oil to drain into a proper container. 2. Oil filter. 3. Coolant drain plug and or ESC Knock sensor from the block.
Page 426 6A3-6 4.3L V6 ENGINE 40. Bolt 41. Retainer 42. Nuts 43. Balls 44. Rocker Arms 45. Pushrods 46. Restrictor 47. Lifter B7611 Figure 4 — Valve Train Components Remove or Disconnect (Figure Tool Required: J 23523-E Torsional Damper Puller and Installer. 1.
Page 427 4.3L V6 ENGINE 6A3-7 3. Crankshaft sprocket, if necessary. Use J 5825 (fig ure 9). 4. Screws (88) and thrust plate (87). 5. Camshaft. • Install three 5/16-18 inch bolts 100-125 mm (4-5 inches) long into the camshaft’s threaded holes. Use these bolts to handle the camshaft (figure 8).
Page 428 6A3-8 4.3L V6 ENGINE 2. Check the connecting rod and cap for identifica tion marks. • Mark the parts if required. • Marking them from the front to the rear, with the engine in an upright position: — The left bank is numbered 1-3-5. Figure 9—Removing the Crankshaft Sprocket —...
Page 429 4.3L V6 ENGINE 6A3-9 A. Rear o f B lock 80. Screw 81. Nut 82. Retainer 83. Stud 84. Gasket F2922 Figure 13—Rear Crankshaft Oil Seal Retainer Piston REAR CRANKSHAFT OIL SEAL RETAINER REMOVAL Remove or Disconnect 1. Screws (80) and nuts (81). 2.
Page 430 6A3-10 4 .3 LV 6 ENGINE 1. Main bearing cap bolts. 2. Main bearing caps. 3. Lower main bearing inserts from the main bearing caps. 4. Upper main bearing inserts. • Insert J 8080 into the crankshaft oil hole (figure 14).
Page 431 4.3 LV 6 ENGINE 6A3-11 • If the gap is found to be less than 0.25 mm INTAKE AND EXHAUST (0.010-inch) at any sealing location and a MANIFOLDS cause for leakage is suspected, then the minor irregularities may be carefully machined from Clean the block.
Page 432 6A3-12 4 .3LV 6 ENGINE TIMING CHAIN AND SPROCKETS ® Inspect • Sprockets for chipped teeth and wear. • Timing chain for damage. • Excessively worn sprockets will rapidly wear a new chain. • An excessively worn chain will rapidly wear a new set of sprockets.
Page 433 4.3L V6 ENGINE 6A3-13 5. Idler gear (4) and drive gear (3). 6. Retaining pin (8). 7. Pressure regulator spring (7) 8. Pressure regulator valve (6). IJ)* Clean 1. Shaft Extension All parts in clean solvent and dry them with com 2.
Page 434 6A3-14 4.3L V6 ENGINE | < \ | Tighten 20. Valve Keeper 26. Spring 21. Cap 27. Intake Valve — Screws (9) to 5.0 N-m (84 in. lbs.). 22. Shield 28. Rotator • With the shaft extension (1) installed on the pump, 23.
Page 435 4.3L V6 ENGINE 6A3-15 1. Valve keepers (20). • Compress the springs with J 8062 (figure 22). • Remove the keepers. • Remove J 8062. 2. Intake valve components (figure 21). • Cap (21) • Shield (22) • Seal (24) •...
Page 436 6A3-16 4.3L V6 ENGINE ASSEMBLY • If the seal will not hold a vacuum, it may have been damaged or improperly installed. 21, 22 and 26) Install or Connect (Figures • Repeat the preceding steps on the remaining valves. Tools Required: Measure J 8062 Valve Spring Compressor J 23738-A Vacuum Pump...
Page 437 4.3L V6 ENGINE 6A3-17 satisfactory. If the lower insert shows evidence of wear or damage, both the upper and lower inserts must be replaced. • Main bearing inserts for scoring or other damage. • Crankshaft for cracks. — Use the magnaflux method, if available. •...
Page 438 6A3-18 4.3L V6 ENGINE A. Feeler Gage V0577 Figure 28— Measuring Crankshaft End Play Figure 29—Rear Crankshaft Oil Seal Retainer Installation Measure REAR CRANKSHAFT OIL SEAL Crankshaft end play, as follows: RETAINER INSTALLATION — Tap the end of the crankshaft first rearward Clean then forward with a lead hammer.
Page 439 4.3L V6 ENGINE 6A3-19 87. Thrust Plate 88. Screw B7615 Figure 31—Camshaft and Components a Lubricate the inner and outer diameter of the seal with engine oil. b. Install the seal on J 35621. c. Position J 35621 against the crankshaft. Thread the attaching screws into the tapped holes in the crankshaft.
Page 440 6A3-20 4.3L V6 ENGINE A. Installation Stud B. Nut C. Washer and Bearing L0707 Figure 33—Timing Mark Alignment Figure 34— Installing the Torsional Damper Tighten • Front cover to block bolts to 14 N m (120 in. ENGINE LEFT ENGINE FRONT ENGINE RIGHT lbs.).
Page 441 4.3L V6 ENGINE 6A3-21 • Install the bearing inserts in the connecting rod and connecting rod cap. • Lubricate the bearings with engine oil. 2. Piston and connecting rod into the proper bore. • With the connecting rod cap removed, install J 5239 onto the connecting rod studs (figure 37).
Page 442 6A3-22 4.3L V6 ENGINE VALVE TRAIN COMPONENT INSTALLATION Important Replace all hydraulic lifters, change the engine oil and filter and add GM Engine Oil Supplement (GM part number 1052367 or equivalent) to the engine oil whenever a new camshaft is installed. Install or Connect (Figure 41) 1.
Page 443 4.3L V6 ENGINE 6A3-23 A-Forward 70. Gasket B-Sealant 71. Reinforcement F4488 Figure 39—Oil Pan Installation...
Page 444 6A3-24 4.3L V6 ENGINE INTAKE MANIFOLD INSTALLATION Install or Connect (Figures 42 and 43) I© 0 0 > 1. Gaskets to the cylinder head with the port blocking plates facing the rear of the engine. 0 000 0 0 2. RTV to the front and rear sealing surfaces on the block.
Page 445 4.3L V6 ENGINE 6A3-25 \^-V, >rii" U 1\ VIEW B C. Port Blocking Plate D . RTV Sealant F5521 Figure 42—Intake Manifold Installation ROCKER ARM COVER INSTALLATION "►4- Install or Connect (Figure 44) 1. Rocker arm cover (701). FRT | 0 d ) ( T ) ( 3 ) 2.
Page 446 6A3-26 4.3L V6 ENGINE EGR VALVE INSTALLATION Install or Connect 1. New gasket. 2. EGR valve. 3. Bolts or studs and nuts. Tighten • Refer to specifications for proper torques. FLYWHEEL INSTALLATION -H -j Install or Connect 1. Flywheel. 2. Flywheel bolts. Tighten •...
Page 447 4.3L V6 ENGINE 6A3-27 4. Crank the engine several times. Listen for any ENGINE SET-UP AND TESTING unusual noises or evidence that any parts are After overhaul, the engine should be tested before binding. installing it in the vehicle. 5. Using the proper Truck Service Manual or Emis 1.
Page 448 6A3-28 4.3L V6 ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherw ise noted. GENERAL DATA: Type 4.3L (262 CID) Displacement LB4/LU2 Bore 4.00 Stroke 3.48 Compression Ratio (LB4 & LU2 9.3:1) (LB4 HD 8.6:1) Firing Order 1-6-5-4-3-2 Oil Pressure (Minimum) 6 psi @ 1000 RPM;...
Page 449 4.3L V6 ENGINE 6A3-29 SPECIFICATIONS (CONT.) ENGINE SPECIFICATIONS (CONT.) All Specifications are in INCHES w le s s otherw ise noted. 4.3L (262 CID) DISPLACEMENT: CRANKSHAFT: 2.4484-2.4493 Diameter #2, #3 2.4481-2.4490 Main 2.4479-2.4488 Journal Taper 0.0002 (Maximum) 0.0002 (Maximum) Out Of Round 0.0008-0.0020 Production #2, #3...
Page 450 6A3-30 4.3L V6 ENGINE SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Item Ft. Lbs. In. Lbs..........— Rocker Arm Cover Bolts ..... — Intake Manifold Bolts..................Exhaust Manifold Bolts Center Two Bolts..................— All Others......................— Cylinder Head Bolts................. —...
Page 451 4.3L V6 ENGINE 6A3-31 SPECIA L TOOLS 23523* E 2 s * VI J 5802-01 J 5715 J 6036 J 8062 J 6880 J 35468 J 5825 A J 8037 J 5590 J 5239 J 35621 J 23738-A 1. Torsional Damper Remover and Installer Stud Remover 2.
Page 452 6A3-32 4.3L V6 ENGINE...
Page 453 V8 ENGINES 6A5-1 SECTION 6A5 V8 ENGINES 5.0L (305 CID) S.7L (350 CID) 7.4L (454 CID) 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 454 6A5-2 V8 ENGINES CONTENTS (cont’d) SUBJECT PAGE Torsional Dam per..............................6A5-24 Crankshaft and B e a rin g s ............................ 6A5-24 Rear Crankshaft Oil Seal Retainer (5.0L and 5.7L Engines)..............6A5-25 Assembly ................................... 6A5-25 Prior to A ssem bly..............................6A5-25 Crankshaft and Main Bearing Insta lla tio n .......................6A5-25 Rear Crankshaft Oil Seal Installation (7.4L Engines)...................6A5-27 Rear Crankshaft Oil Seal and Retainer Installation (5.0L and 5.7L E ngines)........
Page 455 V8 ENGINES BA5-3 Figure 1—Lubrication Diagram (5.0L and S.7L Engines)
Page 456 6A5-4 V8 ENGINES F9474 Figure 2—Lubrication Diagram (5.0L and 5.7L Engines)
Page 457 V8 ENGINES 6A5-5 A. To Oil Cooler B. From Oil Cooler C. From Oil Pump D. Camshaft Bearings E. Valve Lifters F. Oil Filter G. Oil Cooler Diverter H. Main Bearings I. Oil Cooler Bypass Valve J. Oil Filter Bypass Valve F9477 Figure 3—...
Page 458 6A5-6 V8 ENGINES Block drain plugs. Allow the coolant to drain. I ^ l Tighten |+ + | Install or Connect • Block drain plugs to 12 N-m (112 lbs.). 1. Oil pan drain plug. EXHAUST MANIFOLD REMOVAL j ^ l j Tighten Remove or Disconnect (Figures 4 and 5) •...
Page 459 V8 ENGINES 6A5-7 • On 5.0L and 5.7L engines, bend back the tab washers (3). 2. Bolts and studs (4). 3. Tab washers (3) and washers (2). 4. Heat shields (6). 5. Exhaust manifold (1). Take care not to damage the AIR injection tubes (if used).
Page 460 6A5-8 V8 ENGINES — Do not attempt to loosen the manifold by prying under the gasket surface w ith any tool. 3. Gasket (22). 4. Seals (23) (7.4L engines). ROCKER ARM COVER REMOVAL |+ + | Remove or Disconnect (Figures 9 and 10) 1.
Page 461 V8 ENGINES 6A5-8 — Note that on 7.4L engines, the exhaust valve pushrods are longer than the intake valve push- rods. — Every effort should be made to insure that these mating parts are installed in their original locations during assembly. A simple valve train component organizer rack can be made from a piece of wood, as shown in figure 13.
Page 462 6A5-10 V8 ENGINES J 9290-01 Figure 15-—Removing the Hydraulic Lifter D . 10 mm (3/e-inch) drill, 25 mm (1-inch) deep E. 22 mm (7/e-inch) drill, 25 mm (1-inch) deep F. Material: 50 mm x 200 mm (2 x 8-inch) lumber __________________ ___________________ B5267 Figure 13—Valve Train Component Organizer OIL PAN REMOVAL...
Page 463 V8 ENGINES 6AS-11 70. Oil Pump 76. Nut 77. Bolt 79. Oil Pan Baffle (H.D. 5.7L) F9365 Figure 18—Oil Pan Baffle 70. Oil Pump • Use care to prevent damage to the camshaft 71. Oil Pan and bearings. 72. Bolt 73.
Page 464 6A5-12 V8 ENGINES 101. Camshaft Sprocket 102. Timing Chain B8012 Figure 21—Timing Chain and Sprockets A. Sealing Compound 74. Gasket 75. Bolt 76. Oil Pan F9331 Figure 19—Oil Pan (7.4L Engines) ing rod cap at a time. Place the piston at the bottom of its stroke.
Page 465 V8 ENGINES 6A5-13 Figure 23—Removing the Cylinder Ridge Figure 25—Flywheel (5.0L and 5.7L Engines) _________________________________________ F4497 Figure 26— Rear Crankshaft Oil Seal Retainer (5.0L and 5.7L Engines) FLYWHEEL REMOVAL Remove or Disconnect (Figure 25) 1. Bolts (111). 2. Flywheel (110). Figure 24—...
Page 466 6A5-14 V8 ENGINES CRANKSHAFT REMOVAL Remove or Disconnect (Figure 27) • Check the main bearing caps for location mark ings. Mark the caps if necessary. The caps must be returned to their original locations during assembly. 1. Bolts (134). 2 Main bearing caps (132 and 133). 3.
Page 467 V8 ENGINES 6A5-15 — The area where the main bearing inserts con Cylinder Bore Reconditioning tact the main bearing bore should be smooth. Refer to GENERAL ENGINE MECHANICAL (SEC. — If a main bearing cap is damaged and requires 6A). replacement, replace it as outlined later.
Page 468 6A5-16 V8 ENGINES INTAKE AND EXHAUST MANIFOLD Clean — Old pieces of gasket from the gasket surfaces. — Excessive carbon build-up in the exhaust pas sages of the intake manifold. — Scale and deposits from the coolant passages of the intake manifold. —...
Page 469 V8 ENGINES 6A5-17 FRONT COVER Clean • Old gasket from the gasket surfaces. |L»l Inspect — Timing marker for damage. — Front cover for damage, dents, or cracks. Disassemble • Front crankshaft seal. Pry the seal out with a screwdriver. %-| Assemble •...
Page 470 6A5-18 V8 ENGINES COOLANT PUMP Clean • Old gasket from the gasket surface. 178. Oil Pump Driveshaft | Important 179. Connector • Do not immerse the pump in solvent. The sol Body vent may enter the pump’s permanently lubri Drive Gear and Shaft * - 1 8 7 cated bearings, dissolve the bearings’...
Page 471 V8 ENGINES 6AS-19 Figure 37—Installing the Oil Pump Pickup Tube and Screen (5.0L and 5.7L Engines) 7. Pickup screen and pipe (187) (if removed) (figure | f f | Inspect 37). • If the pickup screen and pipe assembly was —...
Page 472 6A5-20 V8 ENGINES 40. Bolt 41. Ball 42. Rocker Arm 46. Cylinder Head " - j ; 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 39—Cylinder Head and Components (7.4L Engines)
Page 473 V8 ENGINES 6A5-21 Figure 43— installing the Rocker Arm Stud (5.0L and 5.7L Engines) 3. O-ring seals (252) (if used) and seals (257). 4. Valves (258 and 259). Place them in a rack so they can be returned to their original position at assem bly.
Page 474 6A5-22 V8 ENGINES oversize studs; J 6036 for 0.013-inch oversize studs (figure 42). 3. Coat lower end (press-fit area) of stud with hypoid axle lubricant. Drive the stud into place with a hammer and J 6880. Stud is installed to proper depth when the tool bottoms on the cylinder head (figure 43).
Page 475 V8 ENGINES GAS-23 ASSEMBLY (7.4L ENGINES) Assemble (Figures 39 and 40) Tool Required: J 8062 Valve Spring Compressor 1. Valves (258 and 259). • Lubricate the valve stems with engine oil. • Insert the valve into the proper port. 2. Rotators (254). 3.
Page 476 6A5-24 V8 ENGINES |+ + j Install or Connect (Figures 1. Thermostat (303). 2 Gasket (302). 3. Water outlet (301). 4. Bolts or studs (300). Tighten • Bolts or studs to specifications. — 5.0L and 5.7L engines: 28 N-m (21 ft. lbs.). —...
Page 477 V8 ENGINES 6A5-25 REAR CRANKSHAFT OIL SEAL RETAINER (5.0L AND 5.7L ENGINES) Disassemble (Figure 51) • Rear crankshaft oil seal. Insert a screwdriver into the notches provided in the seal retainer and pry the seal out (figure 51). ; u u Clean ■...
Page 478 6A5-26 V8 ENGINES Measure (Figure 54) • Crankshaft end play, as follows: • Tap the end of the crankshaft first rearward then forward with a lead hammer. This will line up the rear main bearing and crankshaft thrust surfaces. | ^ | Tighten •...
Page 479 V8 ENGINES 6A5-27 • On 5.0L and 5.7L engines, if correct end — Rear crankshaft oil seal. play cannot be obtained, be certain that the • Make sure the crankshaft rear chamfer is free correct size rear main bearing has been of grit, loose rust, and burrs.
Page 480 6A5-28 V8 ENGINES 1. Gasket (120) to the block. It is not necessary to | ? | Important use sealant to hold the gasket in place. 2. Seal retainer (121). • Align the timing marks on the camshaft sprock 3. Screws and nuts. et and crankshaft sprocket (figure 58).
Page 481 V8 ENGINES 6A5-29 TORSIONAL DAMPER INSTALLATION ENGINE LEFT ENGINE FRONT ENGINE RIGHT CZ^ |+4-| Install or Connect (Figure 60) Tools Required: J 23523-E Torsional Damper Puller and Installer 1. Crankshaft key. NOTICE: The inertia weight section of the tor sional damper is assembled to the hub with a A.
Page 482 6A5-30 V8 ENGINES B0412 _________________________________________F9355 Figure 64— Measuring Piston Diameter Figure — Piston Installed (7.4L Engines) INSTALLATION Install or Connect (Figures 61 through 66) Tools Required: J 5239 Connecting Rod Guide Set J 8037 Ring Compressor • Lubricate the cylinder walls lightly with engine oil. •...
Page 483 V8 ENGINES 6AS31 numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore. If a connecting rod is ever transposed from one block or cylinder to anoth er, new connecting rod bearings should be fit ted and the connecting rod should be Clearance 70.
Page 484 6A5-32 V8 ENGINES f» 45. Bolt 46. Cylinder Head 47. Gasket F9327 Figure 71—Cylinder Head (7.4L Engines) 7.4L ENGINES Install or Connect (Figure 70) • Apply PST sealer (GM part no. 1052080 or equiva lent) in four places where the front and rear main bearing caps meet the engine block as shown in figure 70.
Page 485 V8 ENGINES 6A5-33 Bolt Ball Rocker Arm Pushrod Hydraulic Lifter Cylinder Head 260. Pushrod Guide F9325 Figure 72—Cylinder Head and Components (7.4L Engines) B9570 Figure 74— Cylinder Head Bolt Tightening Figure 73—Cylinder Head Bolt Tightening Sequence (5.0L and 5.7L Engines) Sequence (7.4L Engines) —...
Page 486 6A5-34 V8 ENGINES Engines) VALVE TRAIN COMPONENT |"H"| Install or Connect (Figure 72) INSTALLATION % • Lubricate the hydraulic lifter bodies and feet with Engine Oil Supplement (GM part no. 1051396 or Important equivalent). 1. Hydraulic lifters (44) to the block. Replace all hydraulic lifters if a new camshaft was 2.
Page 487 V8 ENGINES 6A5-35 VALVE ADJUSTMENT 5.0L and 5.7L ENGINES 1. Remove the rocker arm covers. 2. Crank the engine until the mark on the torsional damper lines up with the center or "0” mark on the timing tab (figure 75). The engine must be in the number one firing position.
Page 488 V8 ENGINES Figure 80— Intake Manifold Tightening Sequence (7.4L Engines) 5. Crank the engine one revolution until the pointer "0” mark and torsional damper mark are again in alignment. This is the number six firing position. With the engine in this position the following b ' i /•' i'f G —...
Page 489 V8 ENGINES 6A5-37 1. Exhaust Manifold 2. Washer 3. Lock 4. Bolt/Stud F9366 Figure 83— Exhaust Manifold (5.0L and 5.7L Engines) 1. Exhaust Manifold 4. Bolt/Stud 6. Spark Plug Heat Shield F9328 Figure 84— Exhaust Manifold (7.4L Engines) of the engine. The side stamped “This Side Down”...
Page 490 6A5-38 V8 ENGINES 12. Bolt 10. Coolant Pump 11. Gasket 13. Plug F9349 Figure 85—Coolant Pump (5.0L and 5.7L Engines) Figure 86-4Coolant Pump (7.4L Engines) front and rear of the block in four places as • Outside bolts: 28 N-m (20 ft. lbs.). shown in figure 79.
Page 491 V8 ENGINES 6A S39 6. Run the engine at about 1000 RPM until the engine is at operating temperature. 7. Listen for improperly adjusted valves or sticking lifters, and other unusual noises. 8. Check for oil and coolant leaks while the engine is running.
Page 492 SA5-40 V8 ENGINES SPECIFICATIONS ENGINE SPECIFICATIONS (5.0U 5.7L) (Cont.) A ll specifications are in INCHES unless otherwise noted. DISPLACEMENT: 5.0L (305 Cu. In.) 5.7L (350 Cu. In.) CRANKSHAFT: 2.4484-2.4493 Diameter #2, #3, #4 2.4481-2.4490 2.4479-2.4488 Main Production 0.0002 (Maximum) Journal Taper Service Limit 0.001 (Maximum)
Page 493 V8 ENGINES 6A&41 SPECIFICATIONS ENGINE SPECIFICATIONS (7.4L) All Specifications are in INCHES unless otherw ise noted. GENERAL DATA: Type 7.4L (454 Cu. In.) Displacement 4.25 Bore 4.00 Stroke 7.9:1 Compression Ratio 1-8-4-3-6-5-7-2 Firing Order 10 psi @ 500 RPM Minimum; 40-60 psi @ 2000 RPM Oil Pressure (Minimum) CYLINDER BORE: 4.2500-4.2507...
Page 494 6A5-42 V8 ENGINES SPECIFICATIONS ENGINE SPECIFICATIONS (7.4 L) (CONT.) All Specifications are in INCHES iw less otherw ise noted. DISPLACEMENT: 7.4L CRANKSHAFT: Diameter #1, #2, #3, #4, #5 2.7482-2.7489 Production 0.0002 (Maximum) Taper Main Service Limit 0.001 (Maximum) Journal Production 0.0002 (Maximum) Out Of Round...
Page 495 V8 ENGINES 6A S43 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS (5.0L AND 5.7L ENGINES) In. Lbs. Item Ft. Lbs. 10.2 Rocker Arm Cover Bolt................— Intake Manifold Bolts................— Exhaust Manifold Bolts Center Two Bolts................— All Others..................— Cylinder Head Bolts................—...
Page 496 6A5-44 V8 ENGINES SPE C IA L TOOLS \'o\ J 3049-A J 8062 J 5802-01 J 21882 J 5715 J 6036 r - — J 35468 J 6880 J 22102 J 8037 J 5239 J 35621 J 38841 J 23738-A J 1619 J 9290-01 10.
Page 497 6.2L D IESEL ENGINE 6A7-1 SECTION 6A 7 6.2L DIESEL ENGINE 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 498 6A7-2 6.2L D IESEL ENGINE CONTENTS (cont’d) SUBJECT PAGE Glow P lugs................................6A7-17 Thermostat and Coolant C rossover......................... 6A7-17 Injection Nozzle Tests............................6A7-18 Injection Lines................................6A7-19 Injection Pum p............................... 6A7-19 Crankshaft and B ea ring s.............................6A7-19 Flyw heel................................... 6A7-20 Torsional Dam per..............................6A7-20 Oil Filter Bypass Nfelve Replacement.......................
Page 499 6.2L D IESEL ENGINE 6A7-3 Oil flows from the oil filter to the oil galleries, provid ENGINE LUBRICATION ing pressurized lubrication to various components. A lubrication schematic is shown in figure 1. The hydraulic valve lifters receive oil from the oil The gear type oil pump is driven from either the galleries.
Page 500 6A7-4 6.2L D IESEL ENGINE ed. The use of these tools will also minimize possible damage to engine components. Some precision measuring tools are required for inspection of certain components. Torque wrenches will be necessary for correct assembly of various parts. ACCESSORY REMOVAL This manual assumes that the engine accessories have been removed.
Page 501 6.2L D IESEL ENGINE 6A7-5 A. Left Bank B. Right Bank B8130 Figure 4— Injection Lines VACUUM PUMP/OIL PUMP DRIVE REMOVAL Remove or Disconnect (Figure 2) 1. Hold down clamp and bolt. 2. Speed sensor wire. 3. Vacuum pump or oil pump drive. Pull out to remove.
Page 502 6A7-6 6.2L D IESEL ENGINE • Cap the lines and nozzles immediately. • Do not bend injection lines. 3. Injection lines at the pump. • Cap the lines and pump fittings immediately. • Tag the lines for installation. 4. Injection line brackets. INJECTION NOZZLE REMOVAL |* + | Remove or Disconnect (Figure 5) Tool Required:...
Page 503 6.2L D IESEL ENGINE 6A7-7 EXHAUST MANIFOLD REMOVAL 40. Studs Remove or Disconnect (Figures 6 and 7) 1. Exhaust manifold bolts. 2. Exhaust manifolds. DIPSTICK TUBE REMOVAL Remove or Disconnect (Figure 8) 1. Dipstick bracket bolt. 2. Dipstick tube. Pull out to remove. 3.
Page 504 6A7-8 6.2L D IESEL ENGINE so they can be returned to the original location at assembly. 3. Pushrods (18) important • The pushrods must be installed in the original direction at assembly. This is because the pushrods have a different degree of hardness at each end.
Page 505 6.2L D IESEL ENGINE 6A7-9 Figure 13— Injection Pump the block) the maximum amount with finger pres FRONT COVER REMOVAL sure on the outside of the chain. 6. The total indicator travel can be noted. With used Remove or Disconnect (Figure 11) parts, the deflection must not exceed 20.3 mm (0.80 inch).
Page 506 6A7-10 6.2L D IESEL ENGINE Figure 15—Oil Pan and Oil Pump • Pull the camshaft from the block carefully to avoid damage to the camshaft bearings. OIL PAN REMOVAL Remove or Disconnect (Figure 15) 1. Bolts (133). 2. Oil Pan (134). 3.
Page 507 6.2L D IESEL ENGINE 6A7-11 • Perform the cutting operation with a ridge reamer (figure 16). • Turn the crankshaft until the piston is at TDC. • Remove the cloth and cuttings. 2. Connecting rod cap. Check the connecting rod and cap for identification marks.
Page 508 6A7-12 6.2L D IESEL ENGINE Measure CAMSHAFT Fire deck warpage. Use a straightedge and feeler Important gage. If the block is warped more than 0.15 mm (0.006-inch) longitudinally or 0.08 mm (0.003-inch) • Whenever the camshaft needs to be replaced, a transversely, it should be replaced.
Page 509 6.2L D IESEL ENGINE 6A7-13 1. Rear camshaft plug. hole is located at about the 4 o’clock position; 2. Inner camshaft bearings. Use J 6098-01 and the other is located between the 12 o’clock and 1 o’clock position (block upright). The bearing J 6098-11 (figure 20).

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