Chevrolet 1988 Light Duty Truck Repair Manual

Chevrolet 1988 light duty truck unit repair manual

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Page 3 TABLE OF CONTENTS 1988 SEC. SECTION NAME GENERAL INFORMATION AIR CONDITIONING Air Conditioning Compressor 1B2 DA Air Conditioning Compressor UNIT REPAIR 1B3 R-4 Air Conditioning Compressor 1B4 DA-V5 Air Conditioning Compressor 1B5 HR Air Conditioning Compressor MANUAL STEERING 3B2 Manual Steering Gear 3B3 Power Steering AXLES Rear Axle...
Page 5: Table Of Contents
OA-1 SECTION OA GENERAL INFORMATION CONTENTS SUBJECT PAGE Service Parts Identification L a b e l ............................OA- 1 Vehicle Identification P la te ................................OA- 1 Certification L a b e l..................................OA- 1 Engine Identification N u m b e r..............................OA- 2 Model R e fe re n c e ...................................OA- 2 Metric F a s te n e rs ...................................OA- 2 Fastener Strength Id en tificatio n ..............................
Page 6: Engine Identification Number
/ ' ’] & I 4 o m i V e ^ j i ^ i c/) r to rJ / ^ / - Z j C L t? OA-2 GENERAL INFORMATION K p j 3 ij L 6 3 7 5 Or 3 t>...
Page 7: Fastener Strength Identification
GENERAL INFORMATION OA-3 NOTICE: M o st m e tric fa s te n e rs have a b lu e example, the custom ary 1 /4-20 and 1 /4-28 screws are c o lo r c o a tin g . H ow ever, th is s h o u ld n o t be u sed replaced by the metric M 6.0x1 screw which has nearly the same diam eter and has 25.4 threads per inch.
Page 8: Six Lobed Socket Head Fasteners
OA-4 GENERAL INFORMATION PREVAILING TORQUE FASTENERS A prevailing torque nut is designed to develop an interference between the nut and bolt threads. This is most often accom plished by distortion of the top of an all-metal nut by using a nylon patch on the threads in the m iddle of the hex flat.
Page 9 GENERAL INFORMATION OA-5 R V MODELS C ha ssis - Cab, R egular Cab Pickup, R egular Cab C ha ssis - Cab, B onus/C rew Cab P ickup, Bonus/C rew Cab S uburban U tility V e h icle J im m y (Blazer) F-02281 Figure 8—...
Page 10 OA-6 GENERAL INFORMATION G VAN MODELS VAN DURA (CHEVY VAN) RALLY (S P O R TV A N ) CUTAWAY VAN MAGNAVAN (HI-CUBE VAN) P MODELS VALUE VAN (STEP VAN) MOTOR HOME CHASSIS (ALUMINUM) FORWARD CONTROL CHASSIS VALUE VAN (STEP VAN) (STEEL) B-09178 Figure 9—...
Page 11 GENERAL INFORMATION OA-7 CK Pickup Sportside CK Chassis Cab CK Pickup, Extended Cab CK Chassis, Extended Cab F-04481 Figure 10— CK Models Figure 11— ST Models...
Page 12 OA-8 GENERAL INFORMATION Passenger Van Cargo Van 1. C ustom ary B o lt— 1 /4-20 2. M etric B o lt— M6.0x1 A. 1 /4-inch B. 6 mm C. 20 Threads Per Inch D. 1 Thread Per M illim e te r (25.4 Threads Per Inch) B-09261 F-00705...
Page 13 GENERAL INFORMATION OA-9 A. M e tric Sizes 1. Top Lock Type 6. N ylon S trip Or Patch B. Inch Sizes 2. C enter Lock 7. N ylon W asher Insert 3. Dry A dhesive C oating 8. N ylon Patch 4.
Page 14: Conversion T A B
CONVERSION TABLE to get eq uivalen t to get equivalent num ber of: Multiply num ber of: Multiply A CC ELERA TIO N LENGTH m illim eters (mm) Foot/sec2 0.304 8 m eter/sec2 (m /s2 ) Inch 25.4 0.025 4 m ete r/sec2 0.304 8 meters (m)
Page 15: Decimal And Metric Equivalents
GENERAL INFORMATION OA-11 DECIMAL AND METRIC EQUIVALENTS M e tric m m M e tric mm F ra c tio n s D ecim al In. F ractio n s D ec im a l In. 33/64 13.09687 1/64 0.015625 0.39688 0.515625 0.79375...
Page 17: A-6 Air Conditioning Compressor
1B1-1 SECTION 1 AIR CONDITIONING CONTENTS SUBJECT PAGE A-6 Air Conditioning C o m p re s s o r...............................1B1-1 DA-6 Air Conditioning C o m p re s s o r............................1B2-1 R-4 Air Conditioning C o m rp e s s o r...............................1B3-1 DA-V5 Air Conditioning C om pressor............................
Page 18 1B1-2 A-6 AIR CONDITIONING COMPRESSOR N ut C lu tch Ring Pulley Bearing Ring Bearing Pulley C lu tch Coil Ring C oil Shell Sleeve Seal Flat Seal Ring Seat Seal S haft Seal S haft Seal (O-ring) Front Head Seal (Front) D ischarge Valve Plate (Front)
Page 19: Minor Repair To The Compressor
A-6 AIR CONDITIONING COMPRESSOR 1B1-3 MINOR REPAIR TO THE COMPRESSOR Operations to the clutch plate and hub, pulley and bear J 9401-A Hub Drive Plate Remover ing, and coil and housing are covered as “ M inor” be J 25030 Clutch Hub Holding Tool cause they may be performed w ithout purging the system.
Page 20: Pulley And Bearing Assembly Replacement
1B1-4 A-6 AIR CONDITIONING COMPRESSOR Inspect Allow the shaft key (36) to extend 4.5 mm (3/ie-inch) out of the bottom of the hub keyway • Position of the shaft (39) (even with or (figure 4). slightly above the clutch hub). The shaft key (36) is curved to give an 3.
Page 21 A-6 AIR CONDITIONING COMPRESSOR 1B1-5 Figure 8— Removing the Pulley and Bearing Retainer Ring Install J 9395 over the end of the com pressor • Place J 24092 over J 9395 for the multi-groove shaft (38) (figure 7). pulley. Im p o rta n t •...
Page 22: Clutch Coil And Housing Assembly R Eplacem Ent
1B1-6 A-6 AIR CONDITIONING COMPRESSOR Im p o rtan t J 9481-A Pulley Bearing and Pulley Installer 1. B e aring (5) to the p u lle y (6) w ith J 8092 and After applying Loctite Depend, Loctite Trim J 9481-A (figure 10).
Page 23: Major Repair To The C O M P Re S S O R
A-6 AIR CONDITIONING COMPRESSOR 1B1-7 • Place the clutch coil “ face dow n” and apply • Align the coil locator projections on the coil the adhesive in a circular bead around the housing with the holes in the front head (16). three coil locator protrusions.
Page 24 1B1-8 A-6 AIR CONDITIONING COMPRESSOR J 9553 13. Seal 15. Seal (O-ring) F-01581 Figure 14— Rem oving/Installing the Shaft Seal Seat and Seal J 24340 Retainer Ring Pliers J 33011 Seal Remover 1. Seal (O-ring) (15) with J 33011 (figure 15). C.
Page 25: Pressure Relief Valve Replacement
A-6 AIR CONDITIONING COMPRESSOR 1B1-9 Dip the seal (13) into clean 525 viscosity • To check the position of the axial plate on the refrigerant oil. shaft, remove the clutch driven plate and Install J 23128 and the seal (13) over the measure the distance between the front head com pressor shaft (39).
Page 26: Compressor Disassembly
1B1-10 A-6 AIR CONDITIONING COMPRESSOR COMPRESSOR DISASSEMBLY 49. Plate 51. Gear 52. Seal 54. Rear Head 58. Scree F-01585 Figure 18— Removing the Rear Head Figure 17— Com pressor to J 9396 R em o ve or D isco n n ect (F ig u res 1 , 1 7 th ro u gh •...
Page 27 A-6 AIR CONDITIONING COMPRESSOR 1B1-11 Invert the com pressor and place the shaft end 11. Front head assem bly (16) from the shell (9). up on the bench with the internal assembly • Rest the com pressor shell (9) on its side and support block resting on the bench.
Page 28: Gaging Operation
1B1-12 A-6 AIR CONDITIONING COMPRESSOR F ront C ylin de r H alf Piston Figure 25 — Identifying the Notch at the Front of the Piston GAGING OPERATION Install or C on n ect (F ig u re s 27 th ro u gh 31) J-21352 Tools Required: J 9396 C om pressor H olding Fixture...
Page 29 A-6 AIR CONDITIONING COMPRESSOR 1B1-13 41. Bearing F-01595 Figure 28— Installing the Rear Thrust Races and Bearing 1. Needle bearing (21) to the front cylinder (29) with J 9432 (figure 27). • Lubricate the ball sockets with 525 viscosity • Support the cylinder half (29) on J 21352-A. refrigerant oil.
Page 30: Gaging Procedure
1B1-14 A-6 AIR CONDITIONING COMPRESSOR Figure 30 — Installing the Piston during the Gaging Operation GAGING PROCEDURE Im po rtant Tools Required: • Do not install the shoe discs (34) on the J 8001 Dial Indicator Set rear of the piston (32). J 9397 Com pressing Fixture Rotate the shaft and axial plate (39) until the high J 9402 Piston Assem bly Tray...
Page 31 A-6 AIR CONDITIONING COMPRESSOR 1B1-15 SHOE DISC Min. Feeler Identification Part No. Gage Reading Ending In Stamp .0000 171 /2 .0175 .0180 .0185 .0190 .0195 191 /2 .0200 .0205 .0210 .0215 .0220 THRUST BEARING RACE Part No. Identification Dial Indicator Ending In Stamp Reading...
Page 32: Piston Ring Replacement
1B1-16 A-6 AIR CONDITIONING COMPRESSOR 10. Separate the cylinder halves while the unit is in the fixture. • If necessary, use a wood block and a mallet. 11. Remove the rear cylinder half; remove one piston at a tim e from the axial plate and front cylinder half. •...
Page 33 A-6 AIR CONDITIONING COMPRESSOR 1B1-17 32. P is to n F-01624 Figure 38 — Sizing the Piston Ring • P u sh J 2 4 6 0 8 -5 ( in s ta lle r ) d o w n o v e r J 24608-2 (guide).
Page 34: Compressor Assembly
1B1-18 A-6 AIR CONDITIONING COMPRESSOR N O TIC E: Do n o t p u s h th e p is to n a n d rin g 5. Piston (32) to J 24608-1 (figure 39). a s se m b ly in to J 24608-6 w ith o u t p o s itio n in g •...
Page 35 A-6 AIR CONDITIONING COMPRESSOR 1B1-19 Figure 42— Installing the Suction Crossover Tube Plate • Lubricate all the moving parts with clean 525 viscosity refrigerant oil. K. Oil Return S lot • Check for free rotation. 19. Valve 8. Suction cross-over cover (46) (figure 42). 20.
Page 36 1B1-20 A-6 AIR CONDITIONING COMPRESSOR Figure 47— Installing the Front Head Seal Figure 45— Installing the Front Discharge Valve Plate Im p o rtan t • Do not let the sealing area around the center bore of the head touch the shaft as the head is lowered.
Page 37 A-6 AIR CONDITIONING COMPRESSOR 1B1-21 F-01394 Figure 4 9 — Installing the Oil Pick-Up Tube F-01393 Figure 48— Installing the Com pressor Shell 19. Seal (31) and bushing (30) to the rear of the dis charge cross-over tube (26). 20. Rear suction reed (48) over the dowel pins (45). •...
Page 38: Leak Testing
1B1-22 A-6 AIR CONDITIONING COMPRESSOR • Lubricate the surface of the rear head (54) with 525 viscosity refrigerant oil. 26. Rear head (54) to the shell (9) (figure 51). • A lign the two lower threaded com pressor mounting holes with the com pressor sump. •...
Page 39: Specifications
A-6 AIR CONDITIONING COMPRESSOR 1B1-23 Attach the com pressor to J 9396 and clam p the fix • A pressure reading of less than 342 kPa (50 ture in a vise so that the com pressor can be m anu psi) would indicate one or more suction and/or ally turned with a wrench.
Page 40: Special Tools
1B1-24 A-6 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 9432 J 5139 J 9459 J 5403 © J 9480-B J 5453 J 9553-01 J 6083 J 9564-01 J 6271-01 J 9625 J 21352 J 9392-01 J 22974-A J 9393-A J 23128-A J 9396 J 9397 J 23500-01...
Page 41 A-6 AIR CONDITIONING COMPRESSOR 1B1-25 J 24092 J 26934 J 24095 J 29547 J 25030 J 25498 J 29884 J 29886 J 26549-B J 33011 19. C o m p re s s o r Test Set O il P ic k u p Tube R e m o ve r 20.
Page 42 1B1-26 A-6 AIR CONDITIONING COMPRESSOR...
Page 43 1B2-1 SECTION 1B2 DA-6 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE D escrip tion ......................................1B 2- 1 Minor Repair to the C o m p re s s o r...............................1B 2- 2 Clutch Plate and Hub Assembly R e p la c e m e n t........................ 1B 2- 2 Pulley and Bearing Assembly R e p la c e m e n t........................
Page 44: Air Conditioning Compressor
1B2-2 DA-6 AIR CONDITIONING COMPRESSOR MINOR REPAIR TO THE COMPRESSOR • Remove the forcing screw tip from J 33013-B Illustrations show the com pressor removed from the ve and reverse the body direction on the center hicle for easier viewing. screw.
Page 45 2. C lu tch P late and H ub A ssem bly 20. Axial Plate S haft A ssem bly 3. Pulley B earing R etainer 21. S haft Key 4. Pulley Bearing 22. C y lin d er Seal A.
Page 46 1B2-4 DA-6 AIR CONDITIONING COMPRESSOR Figure 6— Positioning the Shaft Key, Clutch Plate, and Hub Assembly • Remove the forcing screw from J 33020 and with the puller tangs still in place in the pulley slots, turn the assem bly upside down onto a flat surface (figure 11).
Page 47 DA-6 AIR CONDITIONING COMPRESSOR 1B2-5 A. Pulley P uller J-33020 Engages in Inner C ircle of Pulley R otor S lots F-04427 Figure 9 — Installing the Puller Pilot and Pulley Rotor Slot Location — The staked metal should not contact the outer race of the bearing to prevent the 2.
Page 48: Clutch Coil And Housing A S S E M B Ly
1B2-6 DA-6 AIR CONDITIONING COMPRESSOR J 33019 J 21352-A A. Staking Pin B. Rubber Band B-06544 Figure 13— Staking the Pulley Bearing in the Rotor Bore 4. Pulley bearing retainer (3) using J 6083 (figure 8). 5. Clutch plate and hub assem bly (2). CLUTCH COIL AND HOUSING ASSEMBLY REPLACEMENT R em ove or D isco n n ect (F ig u re s 3 and 16)
Page 49 DA-6 AIR CONDITIONING COMPRESSOR 1B2-7 J 8433-3 J 8433-1 J 33017 J 33026 5. Pulley (Rotor) B-06547 Figure 15— Installing the Pulley Bearing Assembly • T ig h te n J 8433-1 fo r c in g s c re w a g a in s t J 33025-A.
Page 50: Major Repair To The Compressor
1B2-8 DA-6 AIR CONDITIONING COMPRESSOR J 33026 C om pressor Holding Fixture 1. C om pressor assem bly on J 33026. 2. C lutch coil assembly (6) onto the front head (11) with the term inals positioned at the “ m arked” location. •...
Page 51 DA-6 AIR CONDITIONING COMPRESSOR 1B2-9 Figure 21— Removing or Installing the Shaft Lip Seal Retaining Ring • Rotate J 33011 to seat the O-ring seal and remove J 33011. J 5403 Snap Ring Pliers 2. Shaft lip seal using J 23128-A (figure 22). •...
Page 52: Pressure Relief Valve Replacement
1B2-10 DA-6 AIR CONDITIONING COMPRESSOR 32. H igh Pressure R elief Valve B-06626 Figure 25 — DA-6 Com pressor Rear Head Detail PRESSURE RELIEF VALVE REPLACEMENT R em o ve or D isco nn ect (F ig u res 3 and 25) •...
Page 53: Compressor Assembly -Internal Cylinder And Shaft
DA-6 AIR CONDITIONING COMPRESSOR 1B2-11 J 33016 A. O-Ring Seal Seat Recess B. T hum b Screw 21352-A 24. C ylin d e r Seal (Lubricated) 23. Rear C ylinder 11. Front Head B-06476 A. O pening to Rear S u ctio n Port (12 O ’C lock P o sition A sse m bly Reference) Figure 29 —...
Page 54 1B2-12 DA-6 AIR CONDITIONING COMPRESSOR Assemble cylinder and shaft assem bly over the guide pins onto the rear head (28) (figure 34). Using both hands, press the cylinder and shaft assembly down into the rear head (28). Im portant • Center cylinder seal (22) is not serviceable. 7.
Page 55 DA-6 AIR CONDITIONING COMPRESSOR 1B2-13 52-A A. 12 o’c lo c k R eference P o sition B. T ips of S u c tio n Reeds M ust Lo cate Above R ecess in C y lin d e r at C.
Page 56: Leak Testing
1B2-14 DA-6 AIR CONDITIONING COMPRESSOR T ig h ten • Six through bolts (7) alternately to 9 N m (84 in. lbs.). 13. Shaft seal parts (8). Im p o rtan t • Add new 525 viscosity refrigerant oil. • Refer to vehicle service manual for fill quantity. •...
Page 57: Specifications
DA-6 AIR CONDITIONING COMPRESSOR 1B2-15 Using a box-end wrench, or a socket and han Observe the reading on the high-pressure dle, rotate the com pressor shaft (20) or clutch gage at the com pletion of the tenth revolution plate on the shaft (20) several turns to lubri of the com pressor shaft (20).
Page 58: Special T O O
1B2-16 DA-6 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 33019 J 5403 J 9398 J 33020 J 6083 J 9481-A J 34614 8092 J 33022 J 9553-01 J 33023-A J 8433-1 J 9625-A J 33024 J 8433-3 J 23128-A 1. Snap Ring Pliers J 33025 2.
Page 59 1B3-1 SECTION 1B3 R-4 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE D escrip tion ......................................1 B 3 - 1 Minor Repair to the C o m p re s s o r...............................1 B 3 - 2 Clutch Drive Hub R eplacem ent......................\ ......1 B 3- Clutch Rotor and/or Bearing Replacem ent —...
Page 60: Air Conditioning Compressor
1B3-2 R-4 AIR CONDITIONING COMPRESSOR MINOR REPAIR TO THE COMPRESSOR ' t * i « * / 1. S haft Nut 13. Seal 2. C lutch H ub Key 14. B olt 3. C lu tch Drive H ub 15. Front Head 4.
Page 61 R-4 AIR CONDITIONING COMPRESSOR 1B3-3 C lutch Drive Rotor B-08998 Figure 3— Removing the Shaft Nut Figure 5 — Installing the Shaft Key • Hold the clutch plate and hub assem bly (3) Install or C o n n e c t (F ig u res 1, 3, 5 and 6) with J 25030.
Page 62: Clutch Rotor And/Or Bearing Replacement - V-Groove Type
1B3-4 R-4 AIR CONDITIONING COMPRESSOR Figure 7— Removing the Rotor and Bearing Assembly Retainer Ring • Use J 25030 to hold the clutch plate and hub assembly. T ig h ten Shaft nut (1) to 17 N m (13 ft. lbs.). Hand spin the pulley (11) to check for free rotation.
Page 63: Clutch Rotor And/Or Bearing Replacement - Poly-Groove Type
R-4 AIR CONDITIONING COMPRESSOR 1B3-5 Apply Loctite 601 or equivalent to the threads. Hand spin the pulley to check for free rotation. T ig h ten • Screws to 11 N m (100 in. lbs.). Im p o rta n t •...
Page 64 1B3-6 R-4 AIR CONDITIONING COMPRESSOR J 26271-A F-01459 Figure 13— Installing the Rotor and Bearing Figure 14— Installing the Rotor and Bearing Assembly — Poly-Groove Type Assembly — V-Groove Type Clutch (7), pulley rim ( ), clutch rotor (5) and bearing •...
Page 65: Clutch Coil And/Or Pulley Rim Replacement - Poly-Groove Type
R-4 AIR CONDITIONING COMPRESSOR 1B3-7 CLUTCH COIL AND/OR PULLEY RIM REPLACEMENT — POLY-GROOVE TYPE R em ove or D is c o n n e c t (F ig u re s 1 and 16) Tools Required: J 8433 Heavy Duty Pulley Puller J 24092 Clutch Coil Puller Legs J 25031 R o to r...
Page 66: Major Repair To The Compressor
1B3-8 R-4 AIR CONDITIONING COMPRESSOR MAJOR REPAIR TO THE COMPRESSOR J 23128-A Figure 17— Removing the Shaft Seal with J 23128-A • Rotate J 21508-A to seat the seal (o-ring). SHAFT SEAL REPLACEMENT 2. Shift seal (12). • Shaft seal to J 23128-A. The shaft seal is designed to seep oil for lubrication.
Page 67: High-Side-High Pressure Cut Off Switch Replacement
R-4 AIR CONDITIONING COMPRESSOR 1B3-9 Install or C o n n ect (F ig u re 1) . Seal (23). • Dip the seal in clean 525 viscosity refrigerant oil before inserting it into the valve cavity. 2. Valve (24). &...
Page 68: Thrust And Belleville Washers Replacement
1B3-10 R-4 AIR CONDITIONING COMPRESSOR THRUST AND BELLEVILLE WASHERS REPLACEMENT R em o ve or D is c o n n e c t (F ig u res 1 and 22) 5. Rotor (5) and bearing ( ) assembly. 1. Rotor (5) and bearing ( ) assembly.
Page 69: Discharge Value Plate And/Or Retainer R Eplacem Ent
R-4 AIR CONDITIONING COMPRESSOR 1B3-11 A lte rna tely T ighten the Screws 1 /4 Turn Tool Step C on ta cts the C om pre ssor Shell Seal J 25008-A F-01467 Figure 24 — Removing the Shell of the shell to cylinder seals. Do not turn the DISCHARGE VALVE PLATE screws any further than necessary to release AND/OR RETAINER...
Page 70: Cylinder And Shaft Assembly Replacement
1B3-12 R-4 AIR CONDITIONING COMPRESSOR 5. Clutch drive hub (3). 31. Valve Plate 33. Piston and Reed CYLINDER AND SHAFT A sse m bly ASSEMBLY REPLACEMENT R em o ve or D isco nn ect (F ig u re 1) 1.
Page 71: Specifications
R-4 AIR CONDITIONING COMPRESSOR 1B3-13 Im p o rta n t — A reading of less than 310.275 kPa (45 psi) would indicate one or more suction and/or dis — Oil will drain out of the com pressor suc charge valves are leaking, an internal leak tion port adapter if the com pressor is and/or discharge valves leaking, an internal placed with the suction port downward.
Page 72: Special Tools
1B3-14 R-4 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 4245 J 9399 J 24896 J 5420 J 9480-B J 25008-A J 6083 J 25030 J 9481-A J 8092 J 9553-01 J 25031 J 9625-A J 8433 J 25287 J 23128-A J 26271-A J 9393-A J 9398-A J 33011...
Page 73: Description
1B4-1 SECTION 1B4 DA-V5 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE D escrip tion ..............................} ........ 1B 4- 1 Theory of O p e r a tio n ..................................1B 4- Minor Repair to the C o m p re s s o r...............................1 B 4- 4 Clutch Plate and Hub Assembly R e p la c e m e n t........................
Page 74 1B4-2 DA-V5 AIR CONDITIONING COMPRESSOR bearing. The rotation acts as an oil separator, which 1. C lu tc h C o il T e rm in a ls rem oves some of the oil from the crankcase-suction 2. H ig h P re ssu re R e lie f Valve bleed, rerouting it to the crankcase where it can lubricate 3.
Page 75 DA-V5 AIR CONDITIONING COMPRESSOR 1B4-3 H ig h P re ssu re R e lie f Valve H ig h S id e Low P re ss u re Valve H ig h S id e C u t-O ff S w itc h C o n tro l Valve S h a ft N u t C lu tc h P late and H u b...
Page 76: Minor Repair To The Compressor
1B4-4 DA-V5 AIR CONDITIONING COMPRESSOR MINOR REPAIR TO THE COMPRESSOR Figure — Removing the Clutch Plate and Hub Assembly In sp ect All parts and replace as necessary. Install or C o n n ect (F ig u re s 1, 7 and Tools Required: J 33013-B Hub and Drive Plate Remover and Installer...
Page 77: Pulley And Bearing Assembly Replacement
DA-V5 AIR CONDITIONING COMPRESSOR 1B4-5 J 34992 Figure 9 — Removing the Pulley Rotor and Bearing Assembly Retaining Ring A. K e yw a y (S haft) Inspect 22. C lu tc h P late and H u b A s s e m b ly Position of the shaft (38) (even with or slightly above 23.
Page 78 1B4-6 DA-V5 AIR CONDITIONING COMPRESSOR J 33023-A J 34992 A. P u lle y P u lle r J-33020 E n g a g e s in In n e r C irc le o f P u lle y R o to r S lo ts F-04563 Figure 10—...
Page 79 DA-V5 AIR CONDITIONING COMPRESSOR 1B4-7 Figure 14— Staking the Pulley Bearing in the Pulley Bore NOTICE: Do n o t s u p p o rt the ro to r b y re s tin g the p u lle y rim on a fla t s u rfa c e d u rin g b e a rin g in s ta lla tio n o r the ro to r face w ill be bent.
Page 80: Pressure Relief Valve Replacement
1B4-8 DA-V5 AIR CONDITIONING COMPRESSOR • Install J 8433-1 with J 33025 (figure 17). PRESSURE RELIEF VALVE • T ig h te n J 8 4 3 3 -3 fo rc in g s c re w a g a in s t REPLACEMENT J 33025.
Page 81: High-Side Pressure And High-Side Low-Pressure Cutoff Switches Replacement
DA-V5 AIR CONDITIONING COMPRESSOR 1B4-9 Retainers (44) from switches (3) and (4). Switches (3) and (4). O-ring seals (44) from the switch cavities with J 9553-01. Clean • Switch cavity and O-ring seal groove. -► 4- Install or C o n n e ct (F ig u res 3 and 4) Tools Required: J 5403 Snap Ring Pliers J 33011 O-ring Seal Installer...
Page 82 1B4-10 DA-V5 AIR CONDITIONING COMPRESSOR A. Steel Shell B. Lip Seal B-06551 Figure — Compressor Shaft Seal Details J 23128-A Seal Remover and Installer J 34614 Shaft Seal Protector 1. Clutch plate and hub assembly (22). • Install J 34614 over the threaded end of the shaft (38).
Page 83 DA-V5 AIR CONDITIONING COMPRESSOR 1B4-11 Figure 26— Tapping the Front or Rear Head Free of the Cylinder • Dip the shaft lip seal in clean 525 viscosity refrigerant oil and install the shaft lip seal on Install or C o n n ec t (F ig u res 4, 27 and 28) J 23128-A.
Page 84 1B4-12 DA-V5 AIR CONDITIONING COMPRESSOR J 33016 J 35372 A. O p e n in g to R ear S u c tio n Port (12 O ’C lo c k P o s itio n A s s e m b ly R e fe re n ce ) B.
Page 85 DA-V5 AIR CONDITIONING COMPRESSOR 1B4-13 Install the shaft nut (21) on the com pressor shaft Observe the reading on the high-pressure gage at (38) if the pulley assem bly and clutch plate and hub the com pletion of the tenth revolution of the com assembly are not installed.
Page 86 1B4-14 DA-V5 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 5403 J 33022 J 23128-A J 33023-A J 6083 J 29886 8092 J 33011 J 33024 J 8433-1 J 33013-A J 33025 J 8433-3 J 33016 J 9398-A J 33017 J 34492 J 9481-A J 33019 9553-01...
Page 87 HR-6 AIR CONDITIONING COMPRESSOR 1B5-1 SECTION 1B5 HR-6 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE D escrip tion ......................................1B 5- 1 Minor Repair to the C o m p re s s o r...............................1B 5- 3 Clutch Plate and Hub Assembly R e p la c e m e n t........................ 1 B 5- 3 Pulley and Bearing Assembly R e p la c e m e n t........................
Page 88 1B5-2 HR-6 AIR CONDITIONING COMPRESSOR kerosene or equivalent solvent and dry with dry air. Use only lint free cloths to wipe parts. Drain and measure the refrigerant oil. Add new 525 vis cosity refrigerant oil to the compressor. Refer to “ S pecifi cations.”...
Page 89: Minor Repair To The Compressor
HR-6 AIR CONDITIONINGCOMPRESSOR 1B5-3 MINOR REPAIR TO THE COMPRESSOR Figure — Removing the Clutch Plate and Hub Assembly Illustrations show the com pressor removed from the ve hicle for easier viewing. • Hold the body of J 33013-B with a wrench and tighten the center screw into the remover body Remove only the parts that need servicing.
Page 90: Pulley And Bearing Assembly Replacement
1B5-4 HR-6 AIR CONDITIONING COMPRESSOR 2. C lutch Plate and H ub A sse m bly 5. Pulley (Rotor) 21. Key 35. Keyway (Shaft) F-04459 Figure — Installing the Clutch Plate and Hub Figure 7— Positioning the Shaft Key, Clutch Plate, Assembly and Hub Assembly T ig h te n...
Page 91 HR-6 AIR CONDITIONING COMPRESSOR 1B5-5 Figure 9— Removing the Pulley Rotor and Bearing Retaining Ring J 8433-1 Puller Bar 4. Pulley bearing (4) from the pulley (5) using J 9398-A J 33026 C om pressor Holding Fixture and J 29886 (figure 12). J 6083 Snap Ring PI iers •...
Page 92 1B5-6 HR-6 AIR CONDITIONING COMPRESSOR — The staked metal should not contact the outer race of the bearing to prevent the possibility of bending the outer race. — Stake 3 places 120 degrees apart (figure 15). 3. Pulley (5) on the front head. •...
Page 93: Clutch Coil And Housing Assembly Replacement
HR-6 AIR CONDITIONING COMPRESSOR 1B5-7 • Position J 8433-1 on J 33023-A and assemble the through bolts and washers through the puller bar slots and thread them into J 33026 (figure 16). J 8433-3 — The thread of the through bolts should engage the full thickness of J 33026.
Page 94: Major Repair To The Compressor
1B5-8 HR-6 AIR CONDITIONING COMPRESSOR Figure 19— Staking the Clutch Coil Assembly to the Coil Head — Stake size should be one half the area of th e p u n c h a nd 0 .2 8 -0 .3 5 (0.010-0.015-inch) deep (figure 20).
Page 95 HR-6 AIR CONDITIONING COMPRESSOR 1B5-9 A. Seal Seat R etainer Ring J 5403 J 33026 F-04524 Figure 22— Removing or Installing the Shaft Lip Seal Retaining Ring +4- Install or C o n n e c t (F ig u res 4 and 25) •...
Page 96: Pressure Relief Valve Replacement
1B5-10 HR-6 AIR CONDITIONING COMPRESSOR 32. H igh Pressure R elief Valve B-06626 Figure 26— HR-6 Com pressor Rear Head Detail COMPRESSOR DISASSEMBLY • Bottom the shaft lip seal into the com pressor neck area using J 23128-A. —INTERNAL CYLINDER AND •...
Page 97: Compressor Assembly -Internal Cylinder And Shaft
HR-6 AIR CONDITIONING COMPRESSOR 1B5-11 J 33016 A. P lastic Headed H am m er 21352-A B. W ood B lock 11. Front Head 28. Rear Head A. O pening to Rear S u ctio n Port B-06177 (12 O ’C lock P o sition A sse m b ly Reference) B.
Page 98 1B5-12 HR-6 AIR CONDITIONING COMPRESSOR • Lubricate a new cylinder seal (24) with clean 3. Valve plate (26). 525 viscosity refrigerant oil and position the • Over the guide pins into position (figure 33). seal on the rear cylinder (23) (figure 30). Roll the cylinder seal into the groove.
Page 99 HR-6 AIR CONDITIONING COMPRESSOR 1B5-13 A. 12 o’c lo c k R e fe re n ce P o s itio n A. 12 o’clo c k R eference P osition B. S u c tio n C ro s s o v e r O p e n in g s B.
Page 100: Leak Testing
1B5-14 HR-6 AIR CONDITIONING COMPRESSOR Im p o rtan t • Front head (11) is now a ssem bled in the “ s ta n d a rd ” p o s itio n and m ay d iffe r 120 degrees either direction.
Page 101: Specifications
HR-6 AIR CONDITIONING COMPRESSOR 1B5-15 type hoses are used, loosen the hose connec • Rotate the com pressor shaft (20) or drive plate tions at gage manifold to release the vapor hub six to eight com plete revolutions at a pressure from the compressor.
Page 102: Special Tools
1B5-16 HR-6 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 5403 J 23128-A © J 33022 J 21352-A J 6083 J 33023-A 29886 J 8433-1 J 33024 J 33011 J 8433-3 J 33025 J 33013-B J 8389 J 33016 J 9481-A J 33017 J 9553-01 J 33019 J 9625-A...
Page 103 3B2-1 SECTION 3B2 MANUAL STEERING GEAR NOTICE: These fa ste n e rs are im p o rta n t a tta c h in g p a rts in th a t th e y c o u ld a ffe c t the p e rfo rm a n c e o f vita l c o m p o n e n ts a n d system s, a n d /o r c o u ld re s u lt in m a jo r re p a ir expense.
Page 104 1 - N U T , W ORM BRG. A D JU S T E R LOCK 14 - BUSHING OR N E E D LE BRG. P IT M A N S H A F T 2 - A D JU S T E R , W ORM T H R U S T BRG. 15 - G E A R , P ITM AN S H A F T 3 - R A C E , T H R U S T B E A R IN G 16 - AD JU S TER , P R E LO A D...
Page 105 MANUAL STEERING GEAR 3B2-3 1. REMOVE AND INSTALL WORM SHAFT SEAL GEAR ASSEMBLED R E M O VE IN S TA LL 1. W rap 0.1 m m to 0.2 mm 1. Install parts as shown. (.005" to .008") shim stock around shaft and insert betw een shaft and seal.
Page 106 3B2-4 MANUAL STEERING GEAR INSTALL REMOVE DISASSEMBLE ASSEMBLE Loosen lock nut Use punch Install parts as shown Pry lo w e r b e a rin g re ta in e r P re s s c u p in to a d ju s te r against edge of slot o u t w ith s c re w d riv e r.
Page 107 MANUAL STEERING GEAR 3B2-5 ADJUST WORM BEARING PRELOAD ADJUST “ OVER CENTER” PRELOAD T ig hten w orm be aring ad ju ster u n til it bo tto m s then loosen o n e -q u a rte r turn T u rn ad ju ste r in un til B a c k...
Page 108 3B2-6 MANUAL STEERING GEAR W o rm B e a rin g A d ju s te r L o c k n u t W o rm B e a rin g A d ju s te r L o w e r W o rm B e a rin g C up Lo w e r W o rm B e a rin g Lo w e r B e a rin g R e ta in e r Ball N u t...
Page 109 MANUAL STEERING GEAR 3B2-7 1. REMOVE AND INSTALL WORM SHAFT SEAL GEAR ASSEMBLED R E M O V E IN S TA LL 1. W rap 0.1 mm to 0.2 mm 1. Install parts as shown. 2. REMOVE AND INSTALL PITMAN SHAFT AND SIDE COVER R EM O VE IN S TA LL...
Page 110 3B2-8 MANUAL STEERING GEAR 3. REMOVE AND INSTALL WORMSHAFT 4. DISASSEMBLE AND ASSEMBLE WORM AND BALL NUT BEARING ADJUSTER REMOVE INSTALL DISASSEMBLE ASSEMBLE Pry lower bearing retainer 1. Press cup into adjust 1. Loosen lock nut. Use punch Install parts as shown. out with screwdriver.
Page 111 MANUAL STEERING GEAR 3B2-9 . R E M O V E A N D IN S T A L L P ITM A N S H A F T 7. A D J U S T W O R M B E A R IN G P R E L O A D S E A L S A N D B E A R IN G 1.
Page 112 3B2-10 MANUAL STEERING GEAR SPECIFICATIONS ADJUSTMENT ADJUSTM ENT TORQUE TO TURN WORM SHAFT Worm B e a rin g .............................. 0.6-1.0 N m 5-8 In. Lbs. Over Center P re lo a d ........................... 0.5-1.2 N m 4-10 In. Lb.s In excess of Worm Bearing Preload Total Steering Gear P re lo a d ........................
Page 113 MANUAL STEERING GEAR 3B2-11 SPECIAL TOOLS J 29369-1 W o rm B e a rin g A d ju s te r C up P u lle r (Use w ith J-2619-01) J 6278 P itm a n S h a ft B e a rin g R e m o ve r P itm a n S h a ft B e a rin g J 35469...
Page 114 3B2-12 MANUAL STEERING GEAR...
Page 115 POWER STEERING 3B3-1 SECTION 3B3 POWER STEERING The following notice applies to one or more steps in the assem bly procedure of com ponents in this portion of the manual as indicated at appropriate locations by the term inology “ NOTICE: Refer to Notice on page 3B3-1 of this S ection.” NOTICE: A ll s te e rin g fa ste n e rs are im p o rta n t a tta c h in g p a rt in th a t it c o u ld a ffe c t the p e rfo rm a n c e o f vita l c o m p o ...
Page 116 3B3-2 POWER STEERING 203. Nut 204. Spring W asher 205. R etaining Ring 207. W asher 208. Seal 209. Bearing 210. Screw 211. Clam p 212. Ball G uide 213. Balls 214. Rack Piston 215. Plug 216. Seal 217. Ring 218.
Page 117: Saginaw Integral Power Steering Gear Rv, G, P, St, M
POWER STEERING 3B3-3 SAGINAW INTEGRAL POWER STEERING GEAR RV, G, P, ST, M Figure 2— Unseating the Retaining Ring A. S c re w d riv e r B. P u n ch NOTICE: R epair the s te e rin g g e a r in a clean, 220.
Page 118 3B3-4 POWER STEERING 6. Pitman shaft (221). Turn the stub shaft (251) to the left until the pitm an shaft teeth (221) and rack piston (214) disengage. 7. Retaining ring (205) with J 4245. 8. Washers (207) and seals (208) using a screwdriver. 9.
Page 119: Cleaning And Inspection
POWER STEERING 3B3-5 • Pull the shaft assem bly until the shaft cap clears the valve body by about 6 mm (1 /4-inch). • Valve spool (252) and seals (230) and (231) (figure 11). 15. Screws (210), clam p (211) and ball guide (212). •...
Page 120: Assembly
3B3-6 POWER STEERING - 2 ,° J 7624 Bearing Preload Spanner W rench A. In s ta ll B a lls In T h is H o le W h ile S lo w ly 1. Connectors (229), using J 6217 (figure 12). R o ta tin g W o rm C o u n te rc lo c k w is e 2.
Page 121 POWER STEERING 3B3-7 240. A d ju s te r Plug 251. S tub S haft B-06531 Figure 16— Bottoming the Adjuster Plug Figure 18— Remarking the Housing 8. Seal (239) on the adjuster plug (240). the left until the plug and bearing (237) are firm ly bottomed - about 27 N-m (20 ft.
Page 122 3B3-8 POWER STEERING • Rotate the adjuster to the left until the hole in the adjuster is in line with the second mark (figure 19). NOTICE: R e fe r to “ N o tic e ” on page 3 B - 1 o f th is m anual.
Page 123: Saginaw Integral Power Steering Gear- Ck (Gmt 4 0 0 )
POWER STEERING 3B3-9 SAGINAW INTEGRAL POWER STEERING GEAR— CK (GMT 400) NOTICE: R e p a ir the s te e rin g g e a r in a clean, Service inform ation is shown in figures 24, 25, 26, 27 and 28.
Page 124 Kay No. Part Nama Kay No. Pari Nama Kay No. Part Nama 1 — H O U S IN G , S T E E R IN G G E A R P LU G , AD JU S TE R —...
Page 125 POWER STEERING 3B3-11 1. REMOVE AND INSTALL PITMAN SHAFT 3. REMOVE AND INSTALL HOUSING END SEALS PLUG REMOVE INSTALL REMOVE INSTALL 1 Clean exposed end . Install parts as shown, 1. Remove parts Install parts as shown of pitm an shaft and as shown Open end of retaining end of housing after...
Page 126 3B3-12 POWER STEERING 5. REMOVE AND INSTALL ADJUSTER PLUG 7. REMOVE AND INSTALL BEARING, WORM, ASSEMBLY AND VALVE ASSEMBLY REMOVE INSTALL REMOVE INSTALL 1. Loosen lock nut. 1. Install parts 1. Grasp stub shaft and 1. Install parts as Use punch against as shown.
Page 127 POWER STEERING 3B3-13 DISASSEMBLE AND ASSEMBLE RACK 10. REMOVE AND INSTALL PITMAN SHAFT PISTON SEALS AND BEARING e m o v e in s t a l l DISASSEMBLE ASSEMBLE 1. Clean end of housing 1 Coat seal lip and washer face D isassem ble parts 1 Assem ble parts thoroughly to prevent dirt...
Page 128 3B3-14 POWER STEERING 13. PITMAN SHAFT “ OVER-CENTER’ 11. REMOVE AND INSTALL CHECK SECTOR ADJUSTMENT VALVE REMOVE INSTALL 1. R em ove p a rts as show n. 1. Install parts as show n W ith sm all scre w d river, pry c h e c k valve fro m ho using C are sh o u ld be taken no t to dam age threads w hen p ryin g...
Page 129: D Isassem B
POWER STEERING 3B3-15 SAGINAW POWER STEERING PUMP—MODEL TC CLEANING AND INSPECTION NOTICE: R e p a ir the p u m p o n ly in a clean, d u st- jjjl free lo c a tio n , u s in g clean to o ls a nd e q u ip m e n t. D irt o r g rit w ill dam age the m a c h in e d su rfa ces Clean an d re s u lt in leakage o r dam age to the p u m p .
Page 130 3B3-16 POWER STEERING A. Used On Some M odels 1. H ousing 2. Sleeve 3. Dowel Pin 4. O-Ring Seal 5. Pressure Plate S pring 6. O-Ring Seal 7. Pressure Plate 8. Dowel Pin 9. Vane 10. R otor 11. Pump Ring 12.
Page 131 POWER STEERING 3B3-17 Figure 32 — Removing the Fitting, Control Valve, Spring and Seal E. N ote the p o sitio n o f the large lug. 17. Drive S haft 19. R etaining Ring F-01879 Figure 33— Remove and Install Retaining Ring •...
Page 132 3B3-18 POWER STEERING 13. T hru st Plate Vane H ou sing 14. T hru st Plate R etaining Ring R otor Sleeve 15. Return Tube Pum p Ring Dowel Pin O-Ring Seal O-Ring Seal Pressure Plate Spring O-Ring Seal Pressure Plate, Dowel Pin F-02152...
Page 133: D Isassem B
POWER STEERING 3B3-19 N — — N. H ou sing A lig n m e n t In d e n ta tio n s J r v P . Id e n tific a tio n Marks on Pum p Ring 12.
Page 134 3B3-20 POWER STEERING Drive Shaft Seal O-Ring Seal H ousing O-Ring Seal T hru st Plate F ille r Cap Flow C ontrol Valve Flow C ontrol Spring O-Ring Seal Pump R otor Shaft R etainer Ring V ane \ chp Pump Ring Pressure Plate Pressure Plate...
Page 135: Com Ponent R E P A
POWER STEERING 3B3-21 Key No. Part Name Key No. Part Name 11 - RING, PUMP 1 - TU B E, RETURN 12 - VA NE (10) 2 - H O U S IN G A SM , HYD PUMP 13 - R O TO R, PUM P 3 - SEAL, D RIVE SH AFT 14 - RING, S H A F T R E TA IN IN G 4 - S PR IN G , FLO W C O N TR O L...
Page 136: Hydraulic Pump A S S E M B
3B3-22 POWER STEERING RETURN TUBE spring (17), pum p ring (11), pum p vanes (12), and drive shaft sub assembly consisting of: Im p o rtan t — Pump rotor (13). Plug the return tube (1) to prevent chips from —...
Page 137 POWER STEERING 3B3-23 5. Drive shaft sub assem bly into the housing (2). THIS SIDE FACE UP 6. Vanes (12) into the pump rotor (13). 7. Pump ring (11) with holes positioned correctly onto DOWEL PIN DOWEL PIN the dowel pins (9) in the housing (2). HOLE HOLE (LARGE)
Page 138: S P E C Ific A Tio N
3B3-24 POWER STEERING SPECIFICATIONS FASTENER TORQUE Integral Pow er Steering Gear Pitman Shaft Over Center P re lo a d ......................0.6-1.2 N m (6-10 in. lbs.) Pitman Shaft Preload Adjuster Screw Jam N u t....................27 N m (20 in. lbs.) Side Cover B olts................................60 N m (40 ft.
Page 139 POWER STEERING 3B3-25 SPECIAL TOOLS J 4245 J 6278 J 6217 J 29107 J 6219 J 7576, J 8947 J 22407 J 7728 J 7079-2 1. S n a p R ing P lie rs 8. P itm a n S h a ft B e a rin g P u lle r 2.
Page 140 3B3-26...
Page 141: Rear Axle
4B1-1 SECTION 4B REAR AXLE CONTENTS PAGE SUBJECT 71/2 and 7 /s-inch Ring Gear A x le s ...............................4B 1-1 -inch Ring Gear A x le ................................. 4B 2-1 -inch Ring Gear A x le ................................. 4B 3-1 -inch Ring Gear A x le ................................4B 4-1 10 1 -inch Ring Gear Axle (D ana)..........................
Page 142: /S-Inch Ring Gear Axles
4B1-2 7V AND 7 /s-INCH RING GEAR AXLES • Mark the races and the shim s as left and right, CHECKING THE AXLE and place them with the bearing caps. BEFORE DISASSEMBLY 11. D iffe re n tia l sid e b e a rin g s u sin g J 8107-2 and J 22888 (figure 3).
Page 143 7 1 /2 AND 7 /s-INCH RING GEAR AXLES 4B1-3 27^ 2 6 21 22 25 o/i 1. B rake D rum 19. S h im 2. A x le S h a ft 20. P in io n and R ing G e a r S et 3.
Page 144: Inspection
4B1-4 AND 7 /s-INCH RING GEAR AXLES 7 1/2 Figure 5— Pinion Collapsable Spacer AXLE HOUSING In sp ect The c a rrie r bore for nicks or burrs th a t w ould • prevent the outer diam eter of the pinion seal from sealing.
Page 145: Assembly Of The Rear Axle
71/2 AND 7 /8-INCH RING GEAR AXLES 4B1-5 PINION AND RING GEAR Inspect Pinion and ring gear teeth for cracking, chipping, scoring, or excessive wear. Pinion splines for wear. Pinion flange splines for wear. The fit of the pinion on the pinion flange. The sealing surface of the pinion flange for nicks, burrs, or rough tool marks w hich w ould cause dam age to the seals’...
Page 146 4B1-6 7 AND 7s/8-INCH RING GEAR AXLES DIFFERENTIAL CASE ASSEMBLY T ig h ten Install or C on n ect (F ig u re 1) • Stud nut to 2.2 N m (20 in. lbs.). 6. R o ta te th e g a g e p la te and b e a rin g s se ve ra l Tools Required: com plete revolutions to seat the bearings.
Page 147 AND 7 /8-INCH RING GEAR AXLES 4B1-7 A. Dial in d ic a to r and arbor p o sitio n e d on the gage block. B. M easurem ent a fte r the arbor is moved o ff o f the gage block. F-04682 Figure 10—...
Page 148 4B1-8 7 1 /2 AND 7 -INCH RING GEAR AXLES 4 .3 2 M M (0.170-IN C H ) SERVICE SPACER Total Thickness of Total Thickness of S ervice Shims To Be Both Prod. Shims Used As A Starting Point Rem oved 1.52 mm (0.060-inch) 10.57 mm (0.420-inch)
Page 149 71/2 AND 7 /8-INCH RING GEAR AXLES 4B1-9 Figure 17— Differential Bearing Preload Shim Installation Preload should be at or below 2.7 to 3.6 N m (24 to 32 in. lbs.) on new bearings, or 1.0 to 1.4 8. If the backlash is not within specifications, move the N m (8 to 12 in.
Page 150: Gear Tooth Pattern C H E C
4B1-10 AND 7 /a-INCH RING GEAR AXLES 7 1/2 distance will move the pinion closer to the centerline of the ring gear. Increasing the distance will move the pinion farther away from the centerline of the ring gear. Backlash is adjusted by m eans of the side bearing adjusting shim s w hich move the entire case and ring gear assem bly closer to, or farther from, the drive pinion.
Page 151: Specifications
71/2 AND 7 /s-INCH RING GEAR AXLES 4B1-11 LOW FLANK CONTACT DECREASE PINION SHIM TOE CONTACT INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM F-02018 Figure 19— Gear Tooth Pattern SPECIFICATIONS 7 1/2 AND 7 /s-INCH RING GEAR AXLE FASTENER FT.
Page 152 4B1-12 7 AND 7 /s-INCH RING GEAR AXLES SPECIAL TOOLS J-7817 J-23911 J-25299 J-7818 J-8107-2 J-25320 J-8092 J-8614-01 J-5590 1. Front Pinion Bearing Cup In s ta lle r 2. Rear Pinion Bearing Cup In s ta lle r 3. D iffe re ntia l Side Bearing Rem over Plug 4.
Page 153: Description
4B2-1 SECTION 4B2 8 1/2-INCH r in g g e a r CONTENTS SUBJECT PAGE D escrip tion ......................................4 B 2 - 1 Checking the Axle Before Disassem bly..........................4 B 2 - 1 Disassembly of the Rear A x le ..............................4 B 2 - 1 C le a n in g ................................
Page 154 4B2-2 1/2-INCH RING GEAR 1. A xle Housing 21. Pinion G ear 22. Side G ear 2. A ir V ent 23. Ring G ear Bolt 3. Plug 24. D ifferential C ase 4. C ollap sab le S pacer 5.
Page 155 -INCH RING GEAR 4B2-3 • Refer to “ Checking the Axle Before D isassem bly” in In sp ect this section. • Drive pinion bearing preload (figure 4). 4. Pinion shaft lock screw (15). • For looseness of pinion assem bly by moving it 5.
Page 156 4B2-4 -INCH RING GEAR Figure 5— Drive Pinion Nut Removal 20. Bearing cups (5) and (39) from the axle housing CLEANING using a hammer and a punch. • Work the cups out of the housing evenly, Do not steam clean drive parts having ground and moving the punch back and forth between one polished surfaces such as gears, bearings, and shafts.
Page 157 -INCH RING GEAR 4B2-5 • The fit of the side gears on the axle shafts. • Differential case for cracks and scoring. • Replace all worn parts. PINION AND RING GEAR In sp ect • Pinion and ring gear teeth for cracking, chipping, scoring, or excessive wear.
Page 158 4B2-6 1 /2-INCH RING GEAR 14. At the point of greatest deflection, set the dial indicator to zero. Repeat the rocking action of the gage shaft to verify the zero setting. 15. Rotate the gage shaft until the dial indicator rod does not touch the gage block.
Page 159 -INCH RING GEAR 4B2-7 A. Dial in d ica to r and arbor p o sitio n e d on the gage block. B. M easurem ent after the arbor is moved o ff o f the gage b lo ck F-04682 Figure 13—...
Page 160 4B2-8 1/2-INCH RING GEAR T ig h ten DIFFERENTIAL CASE ASSEMBLY • The ring gear bolts in sequence to 80 N m (60 Install or C o n n ect (F ig u re 1) ft. lbs.). Tools Required: 7. Differential side bearings (8) using J 22761, J 8107-4 J 8107-4 Differential Side Bearing Remover and J 8092 (figure 19).
Page 161 1/2-INCH RING GEAR 4B2-9 Figure 21— Measuring Side Bearing Shim Requirem ents • Service shims are available from 0.040 to 0.100-inch. • Be sure that the side bearing surfaces are clean and • Leave the tool in place. free of burrs. 6.
Page 162 4B2-10 1/2-INCH RING GEAR 8. If the backlash is not within specifications, move the 11. For an initial backlash setting, move the ring gear away from the pinion by subtracting 0.010-inch from ring gear in or out from the pinion by increasing the the ring gear side shim pack and adding 0.010-inch th ic k n e s s o f o ne s h im , and d e c re a s in g th e to the shim pack on the opposite side.
Page 163 -INCH RING GEAR 4B2-11 ADJUSTMENTS AFFECTING TOOTH CONTACT Two adjustm ents can be made which will affect tooth contact pattern: backlash, and the position of the drive pinion in the carrier. The effects of bearing preloads are not readily apparent on hand loaded tooth contact pattern tests;...
Page 164 4B2-12 1/2-INCH RING GEAR SPECIFICATIONS -INCH RING GEAR AXLE FASTENER FT. LBS. Ring Gear B olts............................Bearing Cap B o lts............................Axle Cover B o lts ............................SPACER AND SHIM SIZES SIZE Differential Side Bearing S p a c e r.............................. 0.170-inch D ifferential Side Bearing Shim K its ..........................0.064-0.070- 0.072-0.078- 0.080-0.086-...
Page 165 1 /2-INCH RING GEAR 4B2-13 SPECIAL TOOLS J-8611-01 J-8608 Li*iJ I t J-8612-B J-22888 J-8092 J-22399 J-22761 J-8609-01 J-22779 J-5590 J-8614-01 J-8107-4 1. F ront Pinion Bearing Cup In sta lle r 11. D iffe re ntia l Side Bearing In sta lle r 2.
Page 166 4B 2-14 -INCH RING GEAR...
Page 167 4B3-1 SECTION 4B3 9 1/2-INCH r in g g e a r CONTENTS SUBJECT PAGE D escrip tion ......................................4 B 3 - 1 Checking the Axle Before D isassem bly..........................4 B 3 - 1 Disassembly of the Rear A x le ..............................4 B 3 - 1 C le a n in g ......................................4 B 3 - 4 In sp e ctio n ......................................
Page 168 4B3-2 91/2-INCH RING GEAR 26. Ring Gear Bolt 1. Brake Drum 27. D iffe re n tia l Case 14. Shim 2. W heel Stud 28. Pinion Shaft 15. Ring and Pinion Gear Set 3. A xle Shaft 29. Pinion Shaft Lock Screw 16.
Page 169 /2-INCH RING GEAR 4B3-3 NOTICE: Do n o t p ry th e rin g g e a r fro m th e case. T h is w il l d a m a g e th e r in g g e a r a n d th e d iffe re n tia l case.
Page 170 4B3-4 91/2-INCH RING GEAR INSPECTION It is very im portant to carefully and thoroughly inspect all drive unit parts before reassembly. Thorough inspection of the drive parts for wear or stress and subsequent replacem ent of worn parts will elim inate costly drive com ponent repair after reassembly. AXLE HOUSING Inspect •...
Page 171 /2-INCH RING GEAR 4B3-5 Figure 9 — Front Pinion Bearing Cup Installation • If the rear axle was operated for an extended period J 8092 Driver Handle of time with very loose bearings, the ring gear and 1. Front pinion bearing cup (10) using J 7817 and drive pinion will also require replacement.
Page 172 4B3-6 91/2-INCH RING GEAR 15. Rotate the gage shaft until the dial indicator rod does not touch the gage block. 16. Record the actual num ber on the dial indicator and not the number which represents how far the needle travels.
Page 173 91/2-INCH RING GEAR 4B3-7 F-04726 Figure 14— Installing the Pinion Inner Bearing Figure 15— Installing the Pinion Oil Seal PINION INSTALLATION Install or C o n n ect Tools Required: J 22388 Pinion Oil Seal Installer J 22804-1 Pinion Oil Seal Spacer J 5590 Rear Pinion Bearing Cone Installer •...
Page 174 4B3-8 91/2-INCH RING GEAR tig h te n in g . Each tig h te n in g increases the bearing preload by several pounds. If the A. Left Hand Studs bearing preload is exceeded, the pinion will 20. Ring G ear have to be removed, and a new collapsible 24.
Page 175 /2-INCH RING GEAR 4B3-9 J-24429 F-04733 F-04712 Figure 21— Adjusting the Nut Figure 22— Checking Ring Gear Backlash 8. Differential case (27) to the axle housing. Refer to BACKLASH ADJUSTM ENT “ Side Bearing Preload A djustm ent” in this section. 1.
Page 176 4B3-10 1/2-INCH RING GEAR distance will move the pinion closer to the centerline of the ring gear. Increasing the distance will move the pinion farther away from the centerline of the ring gear. Backlash is adjusted by m eans of the side bearing adjusting shims which move the entire case and ring gear assem bly closer to, or farther from, the drive pinion.
Page 177 91/2-INCH RING GEAR 4B 3-11 LOW FLANK CONTACT DECREASE PINION SHIM TOE CONTACT INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM F-02018 Figure 24— Gear Tooth Pattern...
Page 178 91/2-INCH RING GEAR 3 - 1 2 SPECIFICATIONS 91/2-INCH r in g g e a r a x l e FT. LBS. FASTENER Ring Gear B olts............................Bearing Cap B o lts ............................. Axle Cover B o lts ............................Adjusting Nut Lock B o lt ...............
Page 179 91 /2-INCH RING GEAR 4B3-13 SPECIAL TOOLS J-8107-3 J-8092 J-22804-1 J-8001-M J-24429 J-29710 J-22912-01 J-22888 J-5590 J-24433 J-7817 J-22388 O n e J-8614-01 1. D iffe re n tia l S id e B e a rin g P lug 2.
Page 180 4B3-14 91 /2-INCH RING GEAR...
Page 181 4B4-1 SECTION 4B4 101/2-INCH RING GEAR CONTENTS SUBJECT PAGE D e s c rip tio n ....................................4 B 4 - 1 Checking the Axle Before Disassem bly..........................4 B 4 - 1 Disassembly of the Rear A x le ........................ j ......4 B 4 - 2 C le a n in g ................................
Page 182: Disassembly Of The Rear Axle
4B4-2 1/2-INCH RING GEAR 19. Pinion flange nut (1) and washer (2) using J 8614-01 DISASSEMBLY OF THE to hold the flange (figure 5). REAR AXLE 20. Pinion flange using J 8614-01 (figure 6). 21. Pinion (14) from the pinion cage (10). •...
Page 183 /2-INCH RING GEAR 4B4-3 Pinion Pilot Bearing Axle Vent Tube Axle Housing Differential Side Bearing Bearing A djusting Nut Bearing Cap A djusting Nut Lock Bolt Gasket Cover Bolt Brake Line Clip Washer Bolt Side Gear Side Gear Thrust W asher Pinion Gear Thrust Washer Pinion Gear Set Pinion Cross Shaft...
Page 184 4B4-4 -INCH RING GEAR 1 0 1 Figure 7— Pressing the Drive Pinion from the Cage...
Page 185: Assembly Of The Rear Axle
/2-INCH RING GEAR 4B4-5 PINION AND RING GEAR BEARINGS Inspect Inspect • Pinion and ring gear teeth for cracking, chipping, Bearings visually and by feel. scoring, or excessive wear. The bearings should feel smooth when oiled and rotated while applying as much hand pressure as •...
Page 186 4B4-6 -INCH RING GEAR 1 0 1 PINION INSTALLATION 2. O uter pinion bearing cup (6) using J 8608 and J 8092. Install or C on n ect 3. Inner pinion bearing cup (13) using J 24432 and Tools Required: J 8092.
Page 187 /2-INCH RING GEAR 4B4-7 Figure 16— Ring Gear to Case Installation 2. Differential side gears (29) and thrust washers (30) to the d iffe re n tia l case halves in th e ir orig in a l CODE NUMBER ON ORIGINAL PINION locations.
Page 188 4B4-8 10 /2-INCH RING GEAR & T ig h ten • Do not tighten. Tighten the right adjusting nut firm ly to force the • The ring gear bolts in sequence to 163 N m case into solid contact with the left adjusting nut. (120 ft.
Page 189: Gear Tooth Pattern Check
/2-INCH RING GEAR 4B4-9 5. If the reading is too high, remove the adjusting nut 4. Expand the brake shoes until a torque of 40 to 50 ft. locks, and loosen the right nut one slot, and tighten lbs. is required to turn the pinion. the left nut one slot (figure 18).
Page 190 4B4-10 -INCH RING GEAR 1 0 1 LOW FLANK CONTACT DECREASE PINION SHIM TOE CONTACT INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM F-02018 Figure 21— Gear Tooth Pattern...
Page 191: Specifications
/2-INCH RING GEAR 4B 4-11 SPECIFICATIONS -INCH RING GEAR AXLE (CORPORATE) FASTENER FT. LBS. Ring Gear B o lts............................Bearing Cap B o lts ............................Axle Cover B o lts ............................. Adjusting Nut Lock B o lt s .......................... SPACER AND SHIM SIZES SIZE Pinion Bearing S him s............................
Page 192 4B4-12 -INCH RING GEAR 1 0 1 SPECIAL TOOLS J-8614-01 J-8092 J-22888 J-24433 J-8608 J-24429 1. P in io n F la n g e R e m o ve r 2. S id e B e a rin g R e m o ve r 3.
Page 193 4B5-1 SECTION 4B5 DANA REAR AXLES CONTENTS SUBJECT PAGE 93/4-lnch Ring G e a r ............................L ......4 B 5 - 1 D e s c rip tio n ..............................L......4 B 5 - 1 Checking the Axle Before D isassem bly....................[ ......4 B 5 - 1 Diassembly of the Rear A x le ........................
Page 194 4B5-2 DANA REAR AXLES Lock pin (29) from the differential using a hamm er Determine the cause of the axle problem before and a punch (figure 8). disassem bly if possible. Pinion shaft (28) using a hamm er and a brass drift DISASSEMBLY OF THE (figure 9).
Page 195 DANA REAR AXLES 4B5-3 1. A xle H ousing 11. W asher 22. D iffe re n tia l Case 2. Ring Gear and Pinion Set 12. Pinion N ut 23. Ring Gear Bolt 3. Inner Pinion Bearing 24. Pinion Gear 14.
Page 196 4B5-4 DANA REAR AXLES .... w i G fteHSf \ §plll>\\ \ a z l ^ l i U / lf\ F-04757 Figure 7 — Removing the Ring Gear Figure 4— Spreading the Differential Case...
Page 197 DANA REAR AXLES 4B5-5 Figure 10— Removing the Pinion Gears Figure 13— Pinion Flange Removal...
Page 198 4B5-6 DANA REAR AXLES AXLE HOUSING Inspect • The carrier bore for nicks or burrs that would prevent the outer diameter of the pinion seal from sealing. Remove any burrs that are found. • The bearing cup bores for nicks or burrs. Remove any burrs that are found.
Page 199 DANA REAR AXLES 4B5-7 Figure 18— Installing the Lock Pin SHIMS • Press the ring gear onto the case, and align the holes in the case with the studs. Inspect 8. New ring gear bolts (23) (figure 19). • Shims for cracks and chips. Damaged shims should •...
Page 200 4B5-8 DANA REAR AXLES Figure 20— Differential with the Master Bearings Figure 22— Master Pinion Block PINION DEPTH ADJUSTMENT 2. Mount a dial indicator having a m inim um travel of Tools Required: 0.200-inch with a magnetic base on the ring gear bolt side of the housing (figure 21).
Page 201 DANA REAR AXLES 4B5-9 8. R e co rd th e re a d in g at th e p o in t of g re a te s t d e fle c tio n (w hen th e d ia l in d ic a to r n e e d le is centered between movement to the left and to the right).
Page 202 4B5-10 DANA REAR AXLES F-04719 Figure 30— installing the Inner Bearing Drive the inner bearing cup into the axle assembly 9. P in io n d e p th c h e c k in g to o ls D-116-1, D-116-2, using D-111 and C-4171.
Page 203 DANA REAR AXLES 4B5-11 Figure 3 2 — Checking the Pinion Depth Setting A SSEM B LIN G THE D IFFE R EN TIA L TO TH E AXLE • Remove the pinion nut (12), washer (11), pinion HOUSING flange (10), slinger (8) and bearing cone (7). Tools Required: 10.
Page 204 4B5-12 DANA REAR AXLES 7. Remove the indicator and the differential case from 12. Assem ble J 24385-01 to the axle housing as shown the carrier. in figure 38. 13. Assem ble the dial indicator as shown in figure 38. 8.
Page 205 DANA REAR AXLES 4B5-13 £ T ig h te n 6. To adjust the backlash, the differential case must be removed from the housing, then the differential The bearing cap bolts (19) to 115 N m (85 ft. bearings removed, and the proper num ber of shims lbs.).
Page 206 4B5-14 DANA REAR AXLES 30. B olt 16. Plug 1. Axle H ousing 31. N ut 17. Bolt 2. Ring and Pinion Gear Set 32. H ub Seal 18. Bearing Cap 3. Bearing 33. Bearing 19. B o lt 4. Shim s 34.
Page 207 DANA REAR AXLES 4B5-15 Figure 44— Removing the Bearing Cap All Dana axles are identified by the part num ber on the 3. Bearing cap bolts (19) (figure 44). right axle tube next to the carrier. The model num ber is 4.
Page 208 4B5-16 DANA REAR AXLES Lock pin (29) from the differential using a hamm er 7. Bearing cups (20). and a punch (figure 49). • Mark the cups as left and right, and place Turn the differential over on D-166. them with the proper bearing caps. Pinion shaft (28) using a ham m er and a brass drift 8.
Page 209 DANA REAR AXLES 4B5-17 Figure 50— Removing the Pinion Shaft Figure 53— Drive Pinion Nut Removal 17. Pinion flange (10) using J 8614-01 (figure 54). 18. Pinion (2) from the carrier using a rawhide ham m er to tap the pinion (figure 55). 19.
Page 210 4B5-18 DANA REAR AXLES CLEANING Do not steam clean drive parts having ground and polished surfaces such as gears, bearings, and shafts. These parts should be cleaned in a suitable solvent. All parts should be disassem bled before cleaning. Parts should be thoroughly dried im m ediately after cleaning.
Page 211 DANA REAR AXLES 4B5-19 Figure 59— Installing the Lock Pin BEARINGS 3. Pinion gears (24) to the differential w ithout the thrust washers (26). Inspect • Place the pinion gears onto the side gears so Bearings visually and by feel. that the holes in the pinion gears are 180 The bearings should feel smooth when oiled and degrees apart.
Page 212 4B5-20 DANA REAR AXLES Figure 60— Installing the Ring Gear Bolts DETERMINING TO TAL DIFFERENTIAL SHIM 7. Remove the dial indicator from the axle. PACK SIZE — B OR U MODEL 8. Remove the differential case from the axle housing. 1.
Page 213 DANA REAR AXLES 4B5-21 D-115 Scooter Gage (Miller) 1. Clean the carrier bores and all the tools. The pinion bore must be free of nicks and dirt. 2. Install D-120 or D-137 to the pinion bore (figure 63). 3. Place D-116-2 onto D-115-3 (figure 64). 4.
Page 214 4B5-22 DANA REAR AXLES • This reading indicates the am ount of shims Drive the inner bearing cup into the axle assem bly using C-4204 and C-4171. The cup must be seated needed fo r a nom inal pinion setting. The on the shim s (figure 69).
Page 215 DANA REAR AXLES 4B5-23 F-04719 Figure 71— Installing the Inner Bearing Figure 73— Checking the Pinion Depth Setting specifications, change the shim pack by the pinion (figure 72). Rotate the pinion several am ount the indicator needle is from the pinion tim es to seat the bearings and assure a more marking.
Page 216 4B5-24 DANA REAR AXLES Figure 75— Tightening the Pinion Nut Figure 77— Measuring Differential Movem ent 6. Force the differential case away from the pinion • Remove shim s to increase the preload. gear to obtain an indicator reading. Repeat this •...
Page 217 DANA REAR AXLES 4B5-25 Figure 80— Installing the Differential Case 11. Place the proper shim s on the differential side bearing hub (opposite the ring gear) and drive the differential bearing onto the hub using J 23690 and J 8092. •...
Page 218 4B5-26 DANA REAR AXLES 20. Drive the outboard spacers (43) into the proper 1. A ssem ble the differential case (22) with master sides using C-4205 and C-4171. bearings installed to the axle housing. The pinion 21. Remove the spreader. must be installed.
Page 219 DANA REAR AXLES 4B5-27 SPECIFICATIONS 93/4-INCH r in g g e a r a x le FASTENER FT. LBS Ring Gear Bolts. . . Bearing Cap B o lts . Axle Cover Bolts . . SIZE Differential Bearing Adjusting Shim .0.003-inch 0.005-inch 0.010-inch...
Page 220 4B5-28 DANA REAR AXLES 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. D iffe re ntia l Side Bearing Removal Plug 1. M aster D iscs (M iller) 10.
Page 221 DANA REAR AXLES 4B5-29 SPECIAL TOOLS < S > 4205 J-29721-70 1. M aster D iscs (M iller) 10. D iffe re ntia l Side Bearing Rem over Plug 2. A rb o r (M iller) 11. Driver H andle 3.
Page 222 4B5-30 DANA REAR AXLES...
Page 223 4B6-1 SECTION 4B6 12-INCH RING GEAR (ROCKWELL) CONTENTS SUBJECT PAGE D e s c rip tio n ....................................4 B 6 - 1 Disassembly of the Rear A x le ..............................4 B 6 - 1 C le a n in g ......................................4 B 6 - 5 In sp ectio n ......................................
Page 224 4B6-2 -INCH RING GEAR (ROCKWELL) F-04734 Figure 1— Rear Axle Com ponents...
Page 225 12-INCH RING GEAR (ROCKWELL) 4B6-3 1. Bolt 22. Axle Vent 43. Side Gears 2. W asher 23. Bolt 44. Bolt 3. Hub Cap 24. W asher 45. W asher 4. Gasket 25. Bearing Cap 46. C arrier 5. Axle Shaft 26.
Page 226 4B6-4 12-INCH RING GEAR (ROCKWELL) F-04758 F-04770 Figure 6— Removing the Bearing Cap Figure 7— Removing the Differential Figure 10— Removing the Differential Side Bearing...
Page 227 12-INCH RING GEAR (ROCKWELL) 4B6-5 16. Pinion shaft nut (62) and washer (61) using J 3453 CLEANING to hold the pinion yoke (figure 11). Do not steam clean drive parts having ground and 17. Pinion yoke (60) using J 7804-01 (figure 12). polished surfaces such as gears, bearings, and shafts.
Page 228 12-INCH RING GEAR (ROCKWELL) 6 - 6 AXLE HOUSING In sp ect • The ca rrie r bore for nicks or burrs th a t w ould prevent the outer diam eter of the pinion seal from sealing. Remove any burrs that are found. •...
Page 229 12-INCH RING GEAR (ROCKWELL) 4B6-7 Figure 18— Removing the Pinion Nut — Divide the diam eter by 2 to find the radius in 12. Pinion washer (61) and a new nut (62) using J 3453 inches. to hold the pinion (figure 17). —...
Page 230 4B6-8 12-INCH RING GEAR (ROCKWELL) Figure 23 — Checking the Bearing Cup Fit Figure 20— Differential Components Tig h ten 3. Cage bolts (56). • Bolts (44) to 61 N m (45 ft. lbs). Tig h ten Check that the m ating surfaces of the differential •...
Page 231 12-INCH RING GEAR (ROCKWELL) 4B6-9 • Press the bearings on using a suitable tool. DIFFERENTIAL INSTALLATION Install or C on n ect 1. Bearing cups (33) to the carrier (36). 2. A djusting nuts (32). 3. Bearing caps (25). 4. Cap bolts (23). &...
Page 232 -INCH RING GEAR (ROCKWELL) 6 - 1 0 2. Drive axles. Refer to the proper service manual. FINAL ASSEMBLY 3. The axle housing to the v ehicle. Refer to the proper -►4- Install or C onnect service manual. 4. Lubricant to the rear axle. C arrier (46) to the axle housing.
Page 233 12-INCH RING GEAR (ROCKWELL) 4B6-11 SPECIAL TOOLS Special Tools...
Page 234 4B6-12 12-INCH RING GEAR (ROCKWELL)
Page 235 4B7-1 SECTION 4B7 LOCKING DIFFERENTIAL CONTENTS SUBJECT PAGE Locking D ifferen tials..................................4 B 7 - 7 1 /2, 7 -lnch Ring G e a r..........................4 B 7 - -lnch Ring G e a r ................................. 4 B 7 - 5 S p e c ific a tio n s ....................................4 B 7- 9 Special T o o ls ....................................
Page 236 4B7-2 LOCKING DIFFERENTIALS 13" . P in io n T h ru s t W a s h e r 16. C am P late 7. P in io n G e ar 17. T h ru s t B lo c k -ln c h R in g G e a r .
Page 237 LOCKING DIFFERENTIALS 4B7-3 CAM UNIT ASSEMBLY - I V AND 8 V -INCH ADJUSTMENT OF THE DIFFERENTIAL • If it is necessary to replace the cam gear, the right + 4- Install or C onnect side gear, or the thrust block, the entire differential must be adjusted.
Page 238 4B7-4 LOCKING DIFFERENTIALS 11. If the backlash is too low, use a thinner thrust washer. Right Side Gear Backlash Adjustment 1. Assemble the clutch plates. • Alternate the plates as shown in figure 1. 2. Assemble the guide clips (19) to the plates. •...
Page 239 LOCKING DIFFERENTIALS 4B7-5 10. Right cam unit from the differential. 11. Right thrust washer (36). • Measure and record the overall length of the gear assembly from the front of the gear to the back of the thrust sleeve (35) including the side gear washer (36).
Page 240 4B7-6 LOCKING DIFFERENTIALS 35 36 43. G overnor and Latch ing Bracket 31. D iffe re ntia l Case Halves Plates Pinion T hru st W asher 44. Plates 32. Screw Pinion Gear 45. Side Gear T h ru st W asher 33.
Page 241 LOCKING DIFFERENTIALS 4B7-7 Figure 11— Removing the Thrust Sleeve Figure 13— Clamping the Cam Unit In Place • There are three adjustm ents to be made: (1) Left side gear backlash. (2) Right side gear backlash. (3) Thrust block clearance. Right Side Gear Blacklash Adjustm ent 1.
Page 242 4B7-8 LOCKING DIFFERENTIALS 8. Pull the pinion gear firm ly into its seat, and rotate the gear back and forth while reading the dial indicator. Record the reading. • Do not unseat the pinion yoke. This will make the backlash reading inaccurate. 9.
Page 243 LOCKING DIFFERENTIALS 4B7-9 5. Left side gear (46) . Case halves (31) together. . Latching bracket assem bly (43). • Hold the side gear in the left side case half. 7. Governor assembly (48). 9. Case screws (32). • The straight end of the latching bracket spring 10.
Page 244 4B7-10 LOCKING DIFFERENTIALS SPECIAL TOOLS Special Tools...
Page 245: Front Axle
4C1-1 SECTION 4C FRONT AXLE CONTENTS SUBJECT PAGE -lnch Ring Gear Front A x le ..............................4C 1-1 -lnch Ring Gear Front A x le ..............................4C 2-1 T Truck Front A x l e ..................................4C 3-1 K Truck Front A x l e ..................................4C 4-1 SECTION 4C1 8 1/2-INCH r in g g e a r...
Page 246: Disassembly
4C1-2 -INCH RING GEAR The front axle is sealed with a pinion seal, a seal at which are pressed onto the differential case. Two bearing each axle shaft, and by a gasket between the front cover caps are used to hold the differential into the front axle and the axle housing.
Page 247 -INCH RING GEAR 4C1-3 22. Side Gear 1. A xle H ousing 11. G asket 23. Ring Gear B olt 2. A ir Vent 12. Cover 24. D iffe re ntia l Case 4. C ollapsable Spacer 14. B olt 28.
Page 248 4C1-4 1/2-INCH RING GEAR A. S oft Drift F-04695 Figure 7— Removing the Drive Pinion • Work the cups out of the housing evenly, moving the punch back and forth between one side of the cup and the other. 20. Axle seals. F-04694 Figure 6 —...
Page 249: Cleaning And Inspection
-INCH RING GEAR 4C1-5 CLEANING AND INSPECTION CLEANING PINION AND RING GEAR • Inspect • Do not steam clean drive parts having ground and polished surfaces such as gears, bearings, and Pinion and ring gear teeth for cracking, chipping, scorring, or excessive wear. shafts.
Page 250: Assembly Of Axle
4C1-6 -INCH RING GEAR ASSEMBLY OF AXLE Figure 9— Front Pinion Bearing Cup Installation Im po rtant PINION DEPTH ADJUSTMENT Lubricate all seal lips, gears, and bearing surfaces Tools Required: with axle lubricant prior to assembly. J 8001 Dial Indicator Set J 21777-1 Arbor PINION BEARING CUP J 21777-29 Plate...
Page 251: Pinion Installation
1/2-INCH RING GEAR 4C1-7 PINION INSTALLATION Install or C o n n ect 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 252 4C1-8 1/2-INCH RING GEAR Dial in d ic a to r and arbor p o sitio n e d on the gage block. M easurem ent a fte r the arbor is moved o ff of the gage block. 1 F-04682 Figure 13—...
Page 253: Side Bearing Preload Adjustment
1/2-INCH RING GEAR 4C1-9 Figure 16— Checking Pinion Bearing Preload Figure 18— Installing the Ring Gear • Press the ring gear onto the case far enough SIDE BEARING PRELOAD to start the bolts using J 8107-4 to protect the ADJUSTMENT differential from the press ram (figure 18).
Page 254: Backlash Adjustment
4C1-10 1/2-INCH RING GEAR Figure 22— Measuring the Gage Plate Thickness Figure 20— Installing Side Bearing Gaging Tools • Push the feeler gage downward so that it • Support the case to keep it from falling into the contacts the shim at the top and bottom, and axle housing.
Page 255: Gear Tooth Contact Pattern Check
1 /2-INCH RING GEAR 4C1-11 T ig h te n thickness of the other shim by the same amount. This will maintain the correct front axle side bearing • The bolts to 80 N m (60 ft. lbs.) preload. 6. Check and record the backlash at three or four •...
Page 256: Final Assembly
4C1-12 1/2-INCH RING GEAR F-02018 Figure 26 — Gear Tooth Contact Pattern 4. Apply a load until a torque ot 54-70 N m (40-50 ft. Backlash is adjusted by means of the side bearing lbs.) is required to turn the pinion. adjusting shims which moves the entire case and ring gear assembly closer to, or farther from the drive pinion.
Page 257: Specifications
1/2-INCH RING GEAR 4C1-13 SPECIFICATIONS in c h r in g g e a r f r o n t a x l e 8 1 /2 TORQUE SPECIFICATIONS Fastener Ft. Lbs. Ring Gear Bolts. . . Bearing Cap Bolts. Axle Cover Bolts .
Page 258 4C1-14 1/2-INCH RING GEAR SPECIAL TOOLS J 8608 J 8611-01 ggll J 22888 J 8612-B J 22399 J 8092 J 22761 J 8001 J 22779 J 8609-01 J 5590 J 8614-01 J 8107-4 11. D iffe re ntia l Side Bearing In sta lle r 1.
Page 259 4C2-1 SECTION 4C2 9 3/4-INCH RING GEAR FRONT AXLE CONTENTS SUBJECT PAGE D escrip tion ......................................4 C 2 - 1 Disassembly of A x le ..................................4C 2- 2 In sp e ctio n ......................................4 C 2 - 2 D isassem b ly....................................4 C 2 - 2 Cleaning and In s p e c tio n ................................4 C 2 - 7 C le a n in g ......................................
Page 260: Disassembly Of Axle
4C2-2 9 /4-INCH RING GEAR FRONT AXLE DISASSEMBLY OF AXLE • Mark the bearings as left and right, and place INSPECTION them with the proper bearing caps and cups. 9. Differential shims (21). Perform the following checks before disassem bling the •...
Page 261 93/4-INCH RING GEAR FRONT AXLE 4C2-3 1. A x le H o u s in g 11. W a s h e r 22. D iffe re n tia l C ase 2. R ing G e a r and P in io n Set 12.
Page 262 4C2-4 93/4-INCH RING GEAR FRONT AXLE F-04756 Figure 3 — Removing the Bearing Cap F-04757 Figure 4— Spreading the Differential Case...
Page 263 /4-INCH RING GEAR FRONT AXLE 4C2-5 Figure 10— Removing the Pinion Gears Figure 13— Pinion Flange Removal...
Page 264 4C2-6 9 /4-INCH RING GEAR FRONT AXLE Figure 16— Removing the Pinion Inner Bearing...
Page 265: Cleaning And Inspection
93/4-INCH RING GEAR FRONT AXLE 4C2-7 CLEANING AND INSPECTION CLEANING PINION AND RING GEAR Inspect Do not steam clean drive parts having ground and polished surfaces such as gears, bearings, and shafts. Pinion and ring gear teeth for cracking, chipping, scoring, or excessive wear.
Page 266: Assembly Of Axle
4C2-8 9 /4-INCH RING GEAR FRONT AXLE ASSEMBLY OF AXLE Figure 19— Installing the Lock Pin Im p o rtan t 4. Pinion gears (24) to the differential w ithout the thrust washers (26). Lubricate all seal lips, bearings, gears, and bearing •...
Page 267: Determining Total Differential Shim Pack Size
93/4-INCH RING GEAR FRONT AXLE 4C2-9 Figure 20 — Installing the Ring Gear Bolts Figure 22— Determ ining Differential Shim Pack • Refer to “ Determ ining Total Shim Pack Size” in this 6. Force the differential assem bly in the opposite section.
Page 268 4C2-10 93/4-INCH RING GEAR FRONT AXLE Figure 26 — Scooter Gage on the Height Block • This reading indicates the am ount of shims needed for a nom inal p inion setting. The pinion marking may change the pinion depth by adding or deleting shim s from the nominal pinion setting.
Page 269: Pinion Installation
93/4-INCH RING GEAR FRONT AXLE 4C2-11 9. Measure each shim separately with a micrometer and add them together to obtain the total shim pack thickness. If a baffle (5) or slinger is used, these must also be measured and included in the shim pack (figure 28).
Page 270 4C2-12 9 /4-INCH RING GEAR FRONT AXLE Figure 34— Installing the Pinion Seal Figure 32— Checking the Pinion Preload specifications, change the shim pack by the torque of 1.13 N m (10 in. lbs.) to rotate the am ount the indicator needle is from the pinion pinion (figure 32).
Page 271 93/4-INCH RING GEAR FRONT AXLE 4C2-13 • Add shims to increase the preload. 5. With the force still applied to the differential case, set the dial indicator to zero. 6. Force the differential case away from the pinion ASSEMBLING THE gear to obtain an indicator reading.
Page 272: Checking Backlash
4C2-14 -INCH RING GEAR FRONT AXLE 4. High backlash is corrected by moving the ring gear • Use a rawhide hamm er to seat the differential closer to the pinion. assem bly in the axle housing (figure 40). 5. Low backlash is corrected by moving the ring gear 18.
Page 273 93/4-INCH RING GEAR FRONT AXLE 4C2-15 SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Ft. Lbs. Ring Gear B o lts............................Bearing Cap B o lts ............................Axle Cover B o lts ............................AVAILABLE SHIM SIZES Differential Bearing A djusting S h im ............................0.003-inch 0.005-inch 0.010-inch 0.030-inch...
Page 274 4C2-16 93/4-INCH RING GEAR FRONT AXLE SPECIAL TOOLS D-116-2 D-115-3 J-8092 D-116-1 J-5590 D-115 eggsssa 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. D iffe re ntia l Side Bearing Removal Plug 1. M aster D iscs (M iller) 10.
Page 275 T TRUCK FRONT AXLE 4C3-1 SECTION 4C3 T TRUCK FRONT AXLE CONTENTS SUBJECT PAGE D escrip tion ......................................4 C 3- Disassembly of A x le ..................................4C 3 - 2 In s p e c tio n ....................................4 C 3 - 2 D isassem b ly......................
Page 276: Disassembly Of Axle
4C3-2 T TRUCK FRONT AXLE DISASSEMBLY OF AXLE Bearing cups (33) and sleeves (32) from the case. INSPECTION • Turn the sleeves (32) using J 33792 until the cups are pushed out of the case (figure 8). Perform the following checks before disassem bling the Bearings (30) from the sleeves (32).
Page 277 T TRUCK FRONT AXLE 4C3-3 Figure 1— Axle Com ponents...
Page 278 4C3-4 T TRUCK FRONT AXLE 16. S p rin g 1. S h a ft 31. In s e rt 46. N u t 2. D e fle c to r 17. S h ift S h a ft and F o rk 32.
Page 279 T TRUCK FRONT AXLE 4C3-5 30. Bearing 32. Sleeve A. C arrier Pry Points F-01390 F-01782 Figure 6 — Separating the Carrier Case Halves Figure 9 — Remove the Sleeve Bearing 18. B olt 29. C arrier Case 19. Lock Tab 32.
Page 280 4C3-6 T TRUCK FRONT AXLE REMOVAL -33791-2 INSTALLATION J-33791-1 J-33791-3 J-33791-2 Figure 13— Removing the Inner Pinion Bearing Cup 95. C a rrie r A s s e m b ly F-01670 Figure 15— Replacing the Case Bushings...
Page 281: Cleaning And Inspection
T TRUCK FRONT AXLE 4C3-7 CLEANING AND INSPECTION CLEANING BEARINGS Inspect Do not steam clean drive parts having ground and polished surfaces such as gears, bearings, and shafts. • Bearings visually and by feel. The bearings should feel smooth when oiled and rotated while applying These parts should be cleaned in a suitable solvent.
Page 282: Assembly Of Axle
4C3-8 T TRUCK FRONT AXLE ASSEMBLY OF AXLE Im p o rtan t Lubricant all the seal lips, bearings, gears, and bearing surfaces with axle lubricant prior to assem bly. J 33790 DIFFERENTIAL CASE ASSEMBLY |-»<-| Install or C on n ect (F ig u res 1, 2 and 16) Tool Required: J 33790 Side Bearing Installer 1.
Page 283: Pinion Depth Adjustment
T TRUCK FRONT AXLE 4C3-9 PINION DEPTH ADJUSTMENT 1. Rotate the p inion w ith the torque w rench and observe the reading. 2. If th e p re lo a d to rq u e is b elo w s p e c ific a tio n s , Tools Required: c o n tin u e to r q u in g...
Page 284 4C3-10 T TRUCK FRONT AXLE A. B u tto n L o c a te d in B e a rin g B ore B. B u tto n M o ved O u t o f B e a rin g B ore F-05791 Figure 19—...
Page 285 T TRUCK FRONT AXLE 4C3-11 Figure 23— Installing the Sleeve Bearing 6. Turn the left adjusting sleeve IN one notch using J 33792. 7. Rotate the pinion several tim es to seat the bearings. 8. Install J 34047, J 25025-1 and J 8001-1 (figure 27). 9.
Page 286 4C3-12 T TRUCK FRONT AXLE A. M a rk L o c a tio n on th e C ase F-01830 Figure 26 — Marking Sleeve Location 10. Check and record the backlash at three or four points around the ring gear. •...
Page 287: Gear Tooth Contact Pattern Check
T TRUCK FRONT AXLE 4C3-13 ADJUSTMENTS AFFECTING TOO TH CONTACT Two adjustm ents can be made which will affect the tooth con tact pattern. These are backlash and the position 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 288 4C3-14 T TRUCK FRONT AXLE LOW FLANK CONTACT DECREASE PINION SHIM TOE CONTACT INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM F-02018 Figure 30— Gear Tooth Contact Pattern • Remove all oil and grease from the tube and carrier T ig h ten &...
Page 289 T TRUCK FRONT AXLE 4C3-15 Figure 32— Installing the Shift Figure 34— Installing the Thrust W asher Housing Seal T ig h ten • Bolts to 47 N m (35 ft. lbs.). 22. Bushings (48). Use J 33791 (figure 15). Inspect (F ig u re 35) Tool Required: J 33798 Engagem ent Tool...
Page 290: Specifications
4C3-16 T TRUCK FRONT AXLE . S h ift C a b le H o u s in g F-01668 Figure 35 — Checking the Shift Mechanism SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Ft. Lbs. In. Lbs. Cable Housing and Tube A ttaching B o lts ..............—...
Page 291: Special Tools
T TRUCK FRONT AXLE 4C3-17 SPECIAL TOOLS J-21551 J-33837 J-29763 J-33838 J-33782 J-33842 J-33785 J-33844 J-33788 J-33893 J-33790 J-34011 J-33792 J-29369-2 J-22912-01 J-8614-01 J-33799 J-23423A 1. O u tp u t S h a ft B e a rin g R e m o ve r 10.
Page 292 4C3-18 T TRUCK FRONT AXLE SPECIAL TOOLS J 29307 J 8001 J 33791 J 34037 J 33798 <$0 1. Slide Hammer 2. B ushing Remover 3. Dial Indicator Set 4. Dial Indicator 5. Dial Indicato r Stand (Part of J 25025-B) 6.
Page 293 4C4-1 SECTION 4C4 K TRUCK FRONT AXLE CONTENTS SUBJECT PAGE D escrip tion ......................................4 C 4- 1 Disassembly of A x le ..................................4 C 4 - 2 In s p ec tio n ...................................... 4 C 4 - 2 D is ass e m b ly ....................................4 C 4 - 2 Cleaning and In s p e c tio n ................................
Page 294 4C4-2 K TRUCK FRONT AXLE Figure 1— Front Axle Com ponents (K15-25 Models)
Page 295 K TRUCK FRONT AXLE 4C4-3 5. Sleeve (22), shift fork (18) and shaft (17) and spring (16). 6. Shim (20). 1. S h a ft 38. S h im 7. C arrier connector (9) with retainer ring (8) (K15-25 2. D e fle c to r 39.
Page 296 4C4-4 K TRUCK FRONT AXLE Figure 3— Front Axle Com ponents (K35 Models)
Page 297 K TRUCK FRONT AXLE 4C4-5 1. S h a ft 38. S h im 2. D e fle c to r 39. B ea rin g 3. Seal 40. S p a c e r 4. B e a rin g 41.
Page 298 4C4-6 K TRUCK FRONT AXLE 29. C a rrie r C ase 59. S h a ft F-01389 Figure 8 — Removing the Left Shaft Figure 9— Turning the Adjuster Sleeve...
Page 299 K TRUCK FRONT AXLE 4C4-7 Seal Figure 17— Removing the Side Bearings...
Page 300: Inspection
4C4-8 K TRUCK FRONT AXLE REMOVAL J36616 INSTALLATION J36616 F-05285 Figure 19— Replacing the Carrier Bushings CLEANING AND INSPECTION CLEANING • Bearing cup surfaces for nicks or burrs. Remove any burrs that are found. • Housing for cracks. Replace the housing if any •...
Page 301: Assembly Of Axle
K TRUCK FRONT AXLE 4C4-9 Sealing surface of the pinion flange for nicks, burrs, SHIMS, THRUST W ASHERS AND or rough tool marks which would cause dam age to ADJUSTER SLEEVES the seals’ inside diam eter and result in an oil leak. Inspect Replace all worn or broken parts.
Page 302 4C4-10 K TRUCK FRONT AXLE PINION INSTALLATION J 36598-3 (K15-25) Install or C on n ect (F ig u res 1 th ro u gh 4 and 11, 23 and 24) Tools Required: J 35512 Bearing Installer (K15-25 Models) J 36614 Bearing Installer (K35 Models) J 8614-01 Pinion Flange Remover J 36333 Seal Installer 1.
Page 303 K TRUCK FRONT AXLE 4C4-11 J 36601-4 (K15-25) J 36601-3 (K35) B u tto n L o ca te d In B ore B e a rin g S w u n g O u t o f B ore N u t W a sh e r P ilo t...
Page 304 4C4-12 K TRUCK FRONT AXLE J 35512 (K15-25) J 8092 J 36614 (K35) J 22761 (K15-25) J 29710 (K35) F-05870 Figure 23— Installing the Pinion Bearing F-05871 Figure 26— Installing the Differential Side Bearing • Rotate the pinion gears toward the opening just en ough to p e rm it th e s lid in g in of the th ru s t washers.
Page 305 K TRUCK FRONT AXLE 4C4-13 J 8092 J 36603 F-05873 Figure 30— Installing the Side Bearing Cups • Turn the left sleeve (32) (K15-25 models) or a d ju s te r plu g (61) (K35 m o d e ls) in u n til backlash is felt between the ring and pinion.
Page 306: Gear Tooth Contact Pattern C H E C
4C4-14 K TRUCK FRONT AXLE J 8001-1 F-05874 F-05875 Figure 31 — Measuring Backlash at the Ring Gear Figure 32— Measuring Backlash at the Pinion Flange 7. Rotate the pinion several tim es to seat the bearings. MEASURING BACKLASH (ALTERNATE METHOD) 1.
Page 307 K TRUCK FRONT AXLE 4C4-15 T he p o s itio n of th e d riv e p in io n is a d ju s te d 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 d iffe re n tia l to c o m p ensate for m anufacturing tolerances.
Page 308 4C4-16 K TRUCK FRONT AXLE iB M } V LOW FLANK CONTACT DECREASE PINION SHIM TOE CONTACT . / ; INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM F-02018 Figure 34— Gear Tooth Contact Pattern AXLE TUBE ASSEMBLY 1.
Page 309: Final Assembly
K TRUCK FRONT AXLE 4C4-17 OUTPUT SHAFT SHIM SELECTION 2. Move the shaft (1) back and forth and read the • Refer to figures 1 through 4. end play. Correct end play is 0.03-0.51 mm • It is necessary to select the proper size output shaft (0.001-0.020-inch).
Page 310 4C4-18 K TRUCK FRONT AXLE ■d$L ¥ C. M easure w ith Axle S haft Forced O utboard 1. Shaft 5. Tube 9. C arrier C o n n e cto r 23. O u tp u t Shaft 29. C arrier Case F-05877 Figure 37 —...
Page 311 K TRUCK FRONT AXLE 4C4-19 MEASURING DIMENSION “A” MEASURING DIMENSION “B” (K15-25 SHOWN) F-05878 Figure 38— Measuring to Calculate Shim Size...
Page 312 4C4-20 K TRUCK FRONT AXLE SPECIFICATIONS TORQUE SPECIFICATIONS Ft. Lbs. In. Lbs. FASTENER — Ring Gear Bolts . . . — C arrier Case Bolts . — Axle Tube Bolts..— A ctuator....— Front Axle Switch . . —...
Page 313: Special Tools
K TRUCK FRONT AXLE 4C4-21 SPECIAL TOOLS J 36609 J 29307 J-36599 J 36612 J 29369-1 J 36613 J 29369-2 J 36601 J 8092 J 33842 J 29763 J 8107-2 J 34011 J 36597 J 34037 J8612-B J 35512 J 36606 J 36614 J 8614-01 J 34672...
Page 314 4C4-22 K TRUCK FRONT AXLE...
Page 315 SECTION 5 BRAKES The following notice applies to one or more steps in the assembly procedure of com ponents in this portion of the manual as indicated at appropriate locations by the term inology NOTICE: See ‘N otice’ on page 5-1 of this section. NOTICE: This fa ste n e r is an im p o rta n t a tta c h in g p a rt in th a t it c o u ld a ffe c t the p e rfo rm a n c e o f vita l c o m p o n e n ts and system s, a n d /o r c o u ld re s u lt in m a jo r re p a ir expense, it m u s t be re p la c e d w ith one o f the same p a rt n u m b e r o r w ith an e q u iv a le n t p a rt if re p la c e m e n t b e co m e s necessary.
Page 316 5-2 BRAKES 16. C over 17. B ra c k e t 18. N u t 19. B o o t . O -R ing 20. Pedal Rod 7. S p rin g 21. Pin . H o u s in g 22.
Page 317 • E ye le t to th e re q u ire d le n g th . R e fe r to BRAKES (SEC. 5) in the 1988 Light Duty Truck Service Manual. J-24551 (JB 8 , JF9) 8. H ousing j .
Page 318: Master Cylinders
5-4 BRAKES MASTER CYLINDERS In sp ect COMPOSITE MASTER CYLINDER Diaphragm for cuts, cracks, or a swollen condition. The Delco-M oraine Com posite Master C ylinder has C ylinder bore for scoring or corrosion. If corrosion is identifying inform ation stam ped into the front outlet tube. present, replace the cylinder.
Page 319 BRAKES 5-5 Figure 9— Com posite Master Cylinder Components jjjl CAUTION: In the following step if air pressure is Clean used to remove the secondary piston, place the All the metal parts in denatured alcohol. open end of the cylinder bore approxim ately 25 All the rubber parts in clean brake fluid.
Page 320: Bendix Master Cylinder
5-6 BRAKES C over Diaphragm Reservoir G rom m et Q uick Take-Up Valve Spring S pring R etainer Primary Seal Secondary Piston Secondary Seal Snap Ring Prim ary Piston A ssem bly Body 9. Tube seats (if removed). • Seat the tube seats with a spare brake tube nut (figure 18).
Page 321 BRAKES 5-7 Bail Cover D iaphragm Body Spring Spring Retainer Prim ary Seal Secondary Piston Secondary Seals Prim ary Piston A sse m bly Snap Ring F-00774 Figure 14—Cast Iron Master Cylinder Com ponents CAUTION: In the following step if air pressure is *"►...
Page 322 5-8 BRAKES 4. Primary piston assembly (51) and snap ring (52). • The prim ary piston m ust be depressed to Body install the snap ring. Spring Secondary Piston 5. O-ring (55) and springs (47). Prim ary Piston A sse m bly .
Page 323: Vacuum Boosters
BRAKES 5-9 41. Cover 42. Diaphragm — 42 43. F ilte r 44. R eservoir 45. C om pe n satin g Valve Seal 46. Valve Poppet 47. Spring . — 44 48. S econdary Spring 49. S econdary P iston __ 55 50.
Page 324 5-10 BRAKES 1. B o o t 2. S ile n c e r 3. V a c u u m c h e c k Valve 4. G r o m m e t 5. F ro n t H o u s in g Seal 6.
Page 325: Tandem Diaphragm Vacuum Booster
BRAKES 5-11 F-05891 Figure 24 — Gaging the Piston Rod 11. Front housing seal (5). 12. Silencer (2) and boot (1). • Gage the piston rod using J 22647 (figure 24). If not within limits, obtain a service adjustable piston rod. Lubricate the inside and outside diameters of the grom met and front housing seal with a thin layer of silicone.
Page 326 5-12 BRAKES B o ot S ile n c e r V a cu u m C h e c k Valve G r o m m e t F ront H o u s in g Seal P rim ary P is to n B e a rin g Rear H o u s in g Front H o u s in g Return S p rin g...
Page 327 BRAKES 5-13 12. P is to n Rod (G aged) 13. R e a c tio n R e ta in e r 14. P o w e r H ead S ile n c e r 15. D ia p h ra g m R e ta in e r 16.
Page 328: Specifications
5-14 BRAKES J 28458 A. D ia p h ra g m L ip S e c o n d a ry P is to n B e a rin g 20. S e c o n d a ry D ia p h ra g m H o u s in g D iv id e r 21.
Page 329: Special Tools
BRAKES 5-15 SPECIAL TOOLS J 22647 J 23456 J 24551-A J 26889 J 25083 J 6217 1. P ow er B rake P ush R od H e ig h t G age 2. P is to n Seal P ro te c to r 3.
Page 330 5-16 BRAKES...
Page 331 6A-1 SECTION 6 ENGINE CONTENTS SUBJECT PAGE G en eral E ngine M e c h a n ic a l.................................6 A - 1 2 .5 L iter L 4 ......................................6 A 1 - 1 2 .8 L iter V 6 ...................................... 6 A 2 - 1 4 .3 L ite r V 6 ......................................6 A 3 - 1 4 .8 L ite r L 6 ......................................6 A 4 - 1 V 8 E n g in e ..............................I .......
Page 332: 6A-2 General Engine Mechanical
6A-2 GENERAL ENGINE MECHANICAL GENERAL INFORMATION USING RTV SEALER STATEMENT ON 1. Do not use RTV when extreme tem peratures are CLEANLINESS AND CARE expected, such as exhaust manifold, head gasket or where gasket elim inator is specified. • An engine is a com bination of many machined, 2.
Page 333: Cylinder Bores, Pistons, Rings, And Connecting Rods
GENERAL ENGINE MECHANICAL 6A-3 CYLINDER BORES, PISTONS, RINGS, AND CONNECTING RODS MEASURING CYLINDER BORE TAPER AND OUT-OF-ROUND (ALL MODELS) Tool Required: J 8087 C ylinder Bore Gage (or equivalent) • If one or more cylinder bores are rough, scored or worn beyond limits, it will be necessary to smooth or true up such bores to fit new pistons.
Page 334: Cylinder Bore Reconditioning (2.8 L Engines)
6A-4 GENERAL ENGINE MECHANICAL 6. If honing is not required, the cylinder bores should be cleaned with a hot water and detergent wash. Apply clean engine oil to the bore after cleaning. CYLINDER BORE RECONDITIONING (ALL EXCEPT L AND 2.8 L ENGINES) 1.
Page 335: Honing
GENERAL ENGINE MECHANICAL 6A-5 boring bar may be tilted which would result in the 6. By measuring the piston to be installed at the sizing rebored cylinder wall not being at right angles to the point specified in the proper section, and adding the crankshaft.
Page 336 GENERAL ENGINE MECHANICAL 2. Connecting rod bearing inserts. If the inserts are to be reused, place them in a rack so they can be installed in their original connecting rod and cap. 3. Snap rings. Use snap ring pliers. 4. Piston pin. Slide the pin from the piston. 5.
Page 337 GENERAL ENGINE MECHANICAL 6A-7 B-04981 Figure 8— Measuring Piston Pin Diameter CLEANING AND INSPECTION -04980 Clean Piston. Figure 9— Piston Pin Hole Diam eter — Remove all varnish and carbon deposits. DO NOT USE A WIRE BRUSH. M easu re (F ig u re s 8 and 10) —...
Page 338: Piston Selection (2.5 L And 2.8 L Engines)
GENERAL ENGINE MECHANICAL • R e fe r to “ S p e c ific a tio n s ” in th e p ro p e r A. 6 5 m m (2 1 /2 -in c h e s ) section.
Page 339 GENERAL ENGINE MECHANICAL 6A-9 • The piston must be installed with the piston cro w n in d e n t on th e sa m e sid e as th e connecting rod bearing tang slots (figure 14). 2. Piston pin. Apply engine oil to the pin and push into place.
Page 340 6A-10 GENERAL ENGINE MECHANICAL In sp ect (F ig u res 17) Ring fit as follows: 1. Fit each com pression ring to the piston on w hich it is going to be used. 2. Slip the outer surface of the top and second com pression ring into the respective piston ring groove (figure 17), to make sure that the ring is free.
Page 341 GENERAL ENGINE MECHANICAL 6A-11 The top com pression ring is a keystone type. The oil ring is a two-piece type, consisting of an expander and a scraper ring. M easu re (F ig u res 7 and 16) Ring end gap as follows: 1.
Page 342: Camshaft Bearing
6A-12 GENERAL ENGINE MECHANICAL CAMSHAFT BEARINGS ilililililililil'M 'l'l'l'l'lil 'l 'l 'l'i r A. B earing Tool C. N u t B. P ilo t D. P u lle r S crew B-05276 Figure 19— Removing or Installing the Inner Figure 20— Removing or Installing the Outer Camshaft Bearings Camshaft Bearings •...
Page 343: In Sp Ection B Efore D Is A S S E M B
GENERAL ENGINE MECHANICAL 6A-13 1. Outer cam shaft bearings. Drive the bearings into Holding the puller screw with a wrench, turn place using J 6098-01 (figure 20). the nut w ith a second wrench to pull the cam shaft bearing into place. Im p o rta n t Remove the puller screw, pilot, and bearing tool.
Page 344 6A-14 GENERAL ENGINE MECHANICAL 223 225 230 221 3j W ) ^(“| j ^ ( — TLfl I (9 222 224 226. P lu n g e r 221. L ifte r B o dy 227. M e te rin g Valve 222.
Page 345 GENERAL ENGINE MECHANICAL 6A-15 Figure 26— Removing the Check Ball Retainer (Typical) clean, lint-free shop rags. Work with clean hands, on a clean work surface. 1. C heck ball (225) to the small hole in the bottom of the plunger (226). 2.
Page 346 6A-16 GENERAL ENGINE MECHANICAL Adjust the ram (with the w eight arm clear of the ram) so that the point is positioned on the set line (marked “ S ” ). Tighten the jam nut to m aintain the setting. Operate the lifter through full travel of the plunger by pum ping the weight arm to fill the lifter with test fluid and force out air.
Page 347 GENERAL ENGINE MECHANICAL 6A-17 B-04519 Figure 30— Cleaning the Combustion Chambers Figure 3 2 — Measuring Stem to Bore Clearance (Typical) (Typical) • Move the stem of the valve from side to side REPAIR using light pressure to obtain a clearance reading.
Page 348 6A-18 GENERAL ENGINE MECHANICAL Regardless of what type of equipm ent is used, however, it is essential that valve guide bores be free from carbon or dirt to ensure proper centering of the pilot in the guide. Refer to “’S pecifications” in the proper section for valve seat angle specifications.
Page 349 GENERAL ENGINE MECHANICAL 6A-19 Figure 36 — Reaming the Valve Guides (Typical) MEASURING MAIN BEARING CLEARANCE Main bearings are of the precision insert type and do not use shim s for adjustment. If clearances are found to be excessive, new upper and lower inserts will be re quired.
Page 350 6A-20 GENERAL ENGINE MECHANICAL 2. On the edge of the gaging plastic envelope there is a graduated scale. W ithout removing the gaging plastic, measure its com pressed width (at the w idest point) with the graduations on the gaging plastic en velope (figure 38).
Page 351 GENERAL ENGINE MECHANICAL 6A-21 A. M easure W id e s t P o in t o f G a gin g P la s tic w ith G rad ua te d Scale B-04997 Figure 3 9 — Placing the Gaging Plastic on the Figure 4 0 —...
Page 352: Special Tools
6A-22 GENERAL ENGINE MECHANICAL SPECIAL TOOLS J 8087 J 5790 J 25220 J 8089 J 24086 J 8101 J 29134-A J 8001 J 8056 J 6098-01 J 29664 C y lin d e r B ore G age R ing E x p a n d e r P is to n Pin R e p la c e r Set P is to n Pin C lip In s ta lle r C a m s h a ft B e a rin g R e p la c e r...
Page 353 6A1-1 SECTION 6A1 2.5 LITER L4 ENGINE CONTENTS SUBJECT PAGE D escription.......6A1 Engine Lubrication.... .6A1 Disassembly of the Engine. .6A1 Tools and Shop E quipm ent........................| ....... 6A 1- .6A1 Accessory R em o val..........................C le a n in g ..............................6A1 Parts Identification..................................
Page 354 6A1-2 2.5 LITER L4 ENGINE CONTENTS (CONT.) SUBJECT PAGE Assembly of Engine Cont. Oil Pan Installation..................................6 A 1 -2 7 Oil Pump Driveshaft In stallatio n ............................6 A 1 -2 7 Cylinder Head In stallatio n ................................ 6 A 1 -2 7 Valve Train Com ponent In stallatio n .............................
Page 355 2.5 LITER L4 ENGINE 6A1-3 A. Oil Pum p Drive Gear O iling B. Oil Pressure S ending U nit C. Splash O iling D. Full Flow Oil F ilte r E. F ilte r Bypass System B-07950 Figure 1— Engine Lubrication Diagram...
Page 356 41-4 2.5 LITER L4 ENGINE DISASSEMBLY OF THE ENGINE 34. Valve Stem Oil Shield 1. O uter Engine Heat Stove 17. C ylinder Head Gasket 18. Intake Valve 35. Valve Spring 2. Bolt 36. Intake Valve Stem Seal 3. Stud 19.
Page 357 2.5 LITER L4 ENGINE 6A1-5 Figure 3— Cylinder Head, Manifolds, and Com ponents...
Page 358 6A1-6 2.5 LITER L4 ENGINE 102. F ront Cover 50. Push Rod Cover 77. Oil Pum p 103. Screw 51. P iston and Pin 78. Nut 104. C am shaft Gear 52. Piston Rings 79. Pin 105. C am shaft T h ru s t Bearing 53.
Page 359 2.5 LITER L4 ENGINE 6A1-7 Figure 5 — Block and Components...
Page 360 6A1-8 2.5 LITER L4 ENGINE 37. W a s h e r 38. B o lt 42. S tu d 43. In ta k e M a n ifo ld 44. G a sk e t F-01984 Figure 6 — Intake Manifold Com ponents 2.
Page 361 2.5 LITER L4 ENGINE 6A1-9 22 m m (7/s") 55 m m (21 /s") 40 m m (1 V ") 10 m m (3/s") 25 m m (1 ") D eep H o le s fo r P u s h ro d s 22 m m (7/s") D rill 25 m m (1 ") D eep H o le s fo r Valve...
Page 362 6A1-10 2.5 LITER L4 ENGINE 31. B olt 32. R ocker Arm Ball 17. Head G asket 33. R ocker Arm 24. C ylin d e r Head 45. Push Rod G uide 25. Head B olt (Stud) 47. Push Rod 27.
Page 363 2.5 LITER L4 ENGINE 6A1-11 89. Key 94. B olt 95. C rankshaft Pulley 96. B olt 97. C rankshaft and Power Steering Pulley 98. B olt 99. W asher 100. C rankshaft Pulley Hub F-01992 Figure 14—Tim ing Gear Cover and Com ponents OIL PAN REMOVAL PISTON AND CONNECTING ROD REMOVAL...
Page 364 6A1-12 2.5 LITER L4 ENGINE markings, to insure proper reassembly. Use a silver pencil to mark the parts if necessary. • To avoid m ism atching the connecting rods and c o n n e c tin g rod c a p s , re m o v e o n ly one connecting rod cap at a time.
Page 365 2.5 LITER L4 ENGINE 6A1-13 Figure 20— Removing the Camshaft Thrust Plate Bolts CRANKSHAFT REAR OIL SEAL REMOVAL (WITHOUT REMOVING CRANKSHAFT) R em ove or D isco n n ec t (Figure 5) NOTICE: Care m u s t be taken n o t to dam age th e cra n k s h a ft o u ts id e d ia m e te r surfa ce w ith the p ry tool.
Page 366 6A1-14 2.5 LITER L4 ENGINE A. T im in g M a rk s 87. C ra n k s h a ft G e a r 103. T h ru s t P late B o lts 104. C a m s h a ft G ear 105.
Page 367 2.5 LITER L4 ENGINE 6A1-15 1 1 3/l 6 -Inch Figure 22— Checking the Block Gasket Surface must be flat within 0.10 mm (0.004-inch) to assure that the gasket will provide a tight seal between the cylinder head and the block. B ore G a g in g P o in t CYLINDER BORES P is to n G a g in g P o in t...
Page 368 6A1-16 2.5 LITER L4 ENGINE 108. C a m s h a ft F-01998 Figure 27— Measuring Cam shaft Thrust Plate Figure 25— Measuring Camshaft Journal Runout Clearance (Camshaft End Play) INTAKE AND EXHAUST journals. If runout exceeds 0.020-inch, the cam shaft MANIFOLDS is excessively bent and should be replaced, along with the cam shaft bearings.
Page 369 2.5 LITER L4 ENGINE 6A1-17 A. A rb o r Press B. Press Tool 104. C am shaft Gear 105. T h ru s t Plate 108. C am shaft F-02027 Figure 29— Installing the Camshaft Gear A. B e aring Tool B.
Page 370 6A1-18 2.5 LITER L4 ENGINE P u m p B o d y S p rin g R e ta in in g S p rin g C o ve r S c re w s C o ve r a 80 C o ve r G a s k e t P re ssu re R e lie f Valve...
Page 371 2.5 LITER L4 ENGINE 6A1-19 Drive gear and shaft (128) for looseness in the pump VALVE TRAIN COMPONENTS body (77). Inside of the cover (82) for wear that would perm it oil PUSHRODS, PUSHROD GUIDES, to leak past the ends of the gears. ROCKER ARMS AND BALLS T h e p u m p g e a rs and b o d y are not s e rv ic e d separately.
Page 372 6A1-20 2.5 LITER L4 ENGINE 18. In ta ke Valve 19. E x h a u s t Valve 28. Valve S p rin g C ap 29. Valve S te m O il Seal 30. Valve K e e p e rs 34.
Page 373 2.5 LITER L4 ENGINE 6A1-21 Make sure that the keepers seat properly in the groove. Repeat the preceding steps on the rem aining valves. Check each valve seal using J 22330. Wet the suction cup portion of the tool lightly with engine oil.
Page 374 6A1-22 2.5 LITER L4 ENGINE • M ount the crankshaft in V-blocks or between centers. • Use a dial indicator as shown. • If the main bearing journals are misaligned, the crankshaft is bent and must be replaced along with the main bearings. Figure 38 —...
Page 375 2.5 LITER L4 ENGINE 6A1-23 A. A lig n m e n t H ole in C rankshaft B. D ust Lip C. Dowel Pin D. C o lla r E. M andrel F. Screws 71. C rankshaft Rear Oil Seal F-02029 Figure 41—...
Page 376 6A1-24 2.5 LITER L4 ENGINE T im in g M a rks MAIN BEARING INSTALLATION 87. C ra n k s h a ft G ear (WITHOUT REMOVING THE T h ru s t P late B o lts CRANKSHAFT) C a m s h a ft G ear T h ru s t P late C a m s h a ft...
Page 377 2.5 LITER L4 ENGINE 6A1-25 CRANKSHAFT PULLEY HUB INSTALLATION -►+ Install or C o n n ec t (F ig u res 5 and 47) 1. C rankshaft pulley and hub. Slide the hub on the crankshaft until it bottoms against the crankshaft gear.
Page 378 6A1-26 2.5 LITER L4 ENGINE 89. Key 94. Bolt 95. C rankshaft 96. B olt 97. C rankshaft 98. Bolt 99. W asher 100. C rankshaft F-01992 Figure 4 7 — Timing Gear Cover and Com ponents FINAL ASSEMBLY OIL PUMP INSTALLATION Install or C o n n ect (F ig u re 5) Install or C o n n ect (F ig u re 5) •...
Page 379 2.5 LITER L4 ENGINE 6A1-27 ^ X \ T ig h te n • Oil pan bolts to 10.0 N m (90 in. lbs.). OIL PUMP DRIVESHAFT INSTALLATION Install or C o n n ec t (F ig u res 5 and 52) 1.
Page 380 6A1-28 2.5 LITER L4 ENGINE • C ylinder head bolts should be w ashed in solvent and dry at the tim e of installation. All residual oil should be wiped from the cylinder head mating surfaces. • C o at the th re a d s of b o lt 9 w ith s e a lin g c o m p o u n d (P a rt N u m b e r...
Page 381 2.5 LITER L4 ENGINE 6A1-29 VALVE TRAIN COMPONENT INSTALLATION +<• Install or C o n n e c t (F ig u res 3, 5, 54, 55 and 56) • Lubricate the hydraulic lifters (121) with Engine Oil S u p p le m e n t (G M p a rt n u m b e r 1 0 5 1 3 9 6 ) o r equivalent.
Page 382 6A1-30 2.5 LITER L4 ENGINE INTAKE MANIFOLD INSTALLATION -►+ Install or C o n n e ct (F ig u re 59) 1. Gasket. • Apply sealant to the bolts indicated in figure 59. 2. Intake manifold. 3. Intake manifold bolts and washers. T ig h ten •...
Page 383 2.5 LITER L4 ENGINE 6A1-31 Figure 59— Intake Manifold Installation Tightening Sequence T ighten b o lts in num ber sequence as show n. Or, “ A” group b o lts can be tig h te n e d first, then “...
Page 384 6A1-32 2.5 LITER L4 ENGINE 5. Listen for im properly adjusted valves or sticking 2. Fill the crankcase with the proper quantity and lifters, or other unusual noises. grade of oil. Refer to the proper Truck Service 6. Check for oil and coolant leaks while the engine is Manual or O w ner’s and D river’s Manual for this running.
Page 385 2.5 LITER L4 ENGINE 6A1-33 SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherwise noted. GENERAL DATA: Type Displacem ent 2.5L Bore 4.00 Stroke 3.00 Com pression Ratio 8.3:1 Firing Order 1-3-4-2 Oil Pressure 36-41 psi @ 2000 RPM CYLINDER BORE: Diameter 4.000...
Page 386 6A1-34 2.5 LITER L4 ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) All specifications are in INCHES unless otherwise noted. CRANKSHAFT: 2.300 Diameter 0.0005 Main Taper 0.0005 Journal Out of Round 0.0005-0.0022 Main Bearing C learance 0.0035-0.0085 Crankshaft End Play 2.000 Diameter 0.0005 Crankpin Taper Out of Round...
Page 387 2.5 LITER L4 ENGINE 6A1-35 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Item Ft. Lbs. In. Lbs. Main Bearing Cap B o lt s ........................95 — Connecting Rod N u t s ..........................44 — Oil Pan Bolts (A ll).............................10.0 — Oil Pump to Block B o lt s ........................30 —...
Page 388 6A1-36 2.5 LITER L4 ENGINE SPECIAL TOOLS J-21882 J-8037 J-34995 J-34144-A J-34924-A J-8080 J-22330 J-8062 J-33049 J-3049 1. P is to n R in g C o m p re s s o r 2. F ro n t C ra n k s h a ft Seal In s ta lle r 3.
Page 389 6A2-1 SECTION 6A2 2.8 LITER V-6 CONTENTS SUBJECT PAGE D escrip tion ......................................6 A 2 - 2 Engine Lubrication..................................6 A 2 - 2 D isassem bly..........................................6 A 2 - 6 Tools and Shop Equipm ent. .6A 2 - 6 .6 A 2 - 6 Accessory R e m o v a l....
Page 390: Subject Page
6A2-2 2.8 LITER V CONTENTS (CONTINUED) SUBJECT PAGE Assembly of Engine (Continued) Torsional Damper In stallatio n ..............................6A 2-21 Piston and Connecting Rod In s ta lla tio n ..........................6 A 2 -2 2 Oil Pump In s ta lla tio n ................................. 6 A 2 -2 3 Oil Pan Installation..................................
Page 391 2.8 LITER V 6A2-3 Figure 1— Engine Lubrication Diagram...
Page 392 6A2-4 2.8 LITER V Figure 2— Engine Lubrication Diagram...
Page 393 2.8 LITER V 6A2-5 A. L u b ric a tio n B e g in s B. 189° D u ra tio n O f L u b ric a tio n C. End O f L u b ric a tio n D.
Page 394: Disassembly
6A2-6 2.8 LITER V B-09312 Figure 4— Engine Lubrication Diagram DISASSEMBLY ACCESSORY REMOVAL TOOLS AND SHOP EQUIPMENT This manual assumes that the engine accessories have A clean, well lit work area should be available. Other been removed. These accessories may include one or necessary equipm ent includes: A suitable parts cleaning more of the following: tank, com pressed air supply, trays to keep parts and...
Page 395: Cleaning
2.8 LITER V 6A2-7 75. Nut A. Front 76. A ir Injection Pipe 80. Bolt 81. EGR Valve 82. Gasket B-09406 B-09442 Figure 5— Air Injection Tube Figure 6— EGR Valve CLEANING EGR VALVE REMOVAL Remove the engine accessories before cleaning, to R em o ve or D isco n n ect (F ig u re 6) provide better access to engine exterior surfaces.
Page 396: Valve Train Component Removal
6A2-8 2.8 LITER V Figure 7— Exhaust Manifold Installation 1. Nuts (6), balls (8), rocker arm s (7), and pushrods (9). VALVE TRAIN COMPONENT • Every effort should be made to insure that REMOVAL th e se m a tin g p a rts are in s ta lle d in th e ir original locations during assembly.
Page 397: Front Cover And Water Pump Removal
2.8 LITER V 6A2-9 Figure 11— Removing the Hydraulic Lifter (Typical) FRONT COVER AND WATER PUMP REMOVAL +-► R em ove or D isco n n ect 1. Water pump. 2. Front cover bolts. 3. Front cover. 4. Gasket. the same place for future reference. Num ber one cylinder reference is the first clockwise mark from the keyway OIL PAN REMOVAL when viewing the engine from the front.
Page 398: Camshaft Removal
6A2-10 2.8 LITER V A. F ro n t 40. B o lt 41. O il P um p 42. S h a ft B-09432 Figure 12— Oil Pump Installation Figure 13— Replacing the Camshaft (Typical) 3. Connecting rod and piston (figure 15). CAMSHAFT REMOVAL •...
Page 399: Flywheel Removal
2.8 LITER V 6A2-11 Figure 15— Replacing the Piston and Connecting Rod (Typical) A. Front FLYWHEEL REMOVAL 85. Bolt 86. Main Bearing Cap R em o ve or D isco nn ect 87. Bearing Insert 88. Oil Seal 1. Bolts. B-09405 2.
Page 400: Cleaning, Inspection, And Repair
6A2-12 2.8 LITER V Figure 17— Removing or Installing the Main Bearing Insert CLEANING, INSPECTION, AND REPAIR — The area w here th e main bearing inserts A solvent tank, large enough to hold the larger engine parts, will be needed along with various bristle brushes co n ta ct the m ain b e a rin g bore sh o uld be and a gasket scraper.
Page 401: Piston And Connecting Rod A S S E M B Lie
2.8 LITER V 6A2-13 PISTON AND CONNECTING ROD ASSEMBLIES Refer to GENERAL ENGINE MECHANICAL (SEC. 6A) and perform the following: ❖ D isassem b le Com ponents as required. Clean Com ponents as outlined. Inspect C om ponents as outlined. M easu re Piston pin diameter and clearance.
Page 402: Camshaft
6A2-14 2.8 LITER V Figure 19— Checking the Camshaft Journals CAMSHAFT Im p o rtan t • W henever the cam shaft needs to be replaced, a new set of lifters must also be installed. Inspect Cam shaft lobes and journals for scratches, pitting, scoring, and wear.
Page 403: W Ater P U M
2.8 LITER V 6A2-15 Install or C on n ect Tool Required: J 35468, Seal Installer New seal so that the open end of the seal is toward the inside of the cover. — Drive the seal into position with J 35468. —...
Page 404: Valve Train Components
6A2-16 2.8 LITER V • Pushrods for bending. Roll the pushrod on a flat T ig h ten su rfa c e to d e te rm in e if it is bent. R e pla ce if • Screws to 9.0 N m (80 in. lbs.). necessary.
Page 405 2.8 LITER V 6A2-17 20. Intake Valve 21. Exhaust Valve 22. Valve Keepers 23. Valve Cap 24. Oil Shedder 90. R ocker Arm Stud 25. Seal 91. Pushrod G uide 26. O-Ring B-09444 B-09551 Figure 23 — Valves and Com ponents Figure 25—...
Page 406: Therm Ostat And W Ater O U Tle
6A2-18 2.8 LITER V A. Grind out th is portio n . B-05248 Figure 26— Scale for Checking Valve Spring Installed Height • C o m p re ss th e valve sp rin g using J 8062 (figure 24). Com press the spring enough so the lower valve stem groove can be seen clearly.
Page 407 2.8 LITER V 6A2-19 • Crankshaft run-out. • Mount the crankshaft in V-blocks or between centers. • Use a dial indicator. • If the main journals are m isaligned more than 0.025 mm, the crankshaft is bent and must be replaced, along with the main bearing.
Page 408: Rear Crankshaft Oil Seal In S Ta Lla Tio
6A2-20 2.8 LITER V A. A lig n m e n t H o le In C ra n k s h a ft 7. Main bearing caps with arrows pointing toward the B. D u st Lip front of the engine. C.
Page 409: Camshaft, Timing Chain And Sprocket Installation
2.8 LITER V 6A2-21 be replaced to insure durability of the cam shaft lobes and lifter feet. 1. Camshaft. Im p o rtan t • All cam shaft bearing journals are the same d ia m e te r and care m u st be exercised in in s ta llin g th e c a m s h a ft to avo id b e a rin g damage.
Page 410: Piston And Connecting Rod In S Ta Lla Tio
6A2-22 2.8 LITER V The torsional dam per has three tim ing notches on the inertia ring. The number one cylinder tim ing reference ENGINE LEFT ENGINE FRONT ENGINE RIGHT mark will be identified by a dab of white paint. If a new dam per assem bly is installed, mark the new assembly in the same place for future reference.
Page 411: Oil Pan Installation
2.8 LITER V 6A2-23 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 tra nsp o se d from one block or c y lin d e r to another, new connecting rod bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder...
Page 412: Valve Train Com Ponent In Stallatio
6A2-24 2.8 LITER V VALVE TRAIN COMPONENT INSTALLATION If lifter replacem ent is necessary, use new lifters with a narrow flat along the lower of the body length. This provides additional oil to the cam lobe and lifter surfaces. Figure 3 8 — Oil Pan Installation Im p o rta n t Replace all hydraulic lifters if a new cam shaft was T ig h ten...
Page 413: Valve Adjustment
2.8 LITER V 6A2-25 INTAKE MANIFOLD INSTALLATION Install or C o n n e ct (Figure 42) 1. RTV to the front and rear sealing surfaces on the block. Apply a 5 mm (3/ie-inch) bead of RTV (part num ber 1052917 or equivalent) to the front and rear of the block as shown.
Page 414: Exhaust Manifold In S Ta Lla Tio
6A2-26 2.8 LITER V 2. R e in fo rc e m e n ts 4. G a s k e t 3. R o c k e r A rm C o v e r 5. S tu d s B-09303 Figure 43 —...
Page 415: Air Injection Tube Installation
2.8 LITER V 6A2-27 Figure 44 — Exhaust Manifold Installation AIR INJECTION TUBE Im p o rta n t INSTALLATION • If a new cam shaft or hydraulic lifters were installed, add Engine Oil S upplem ent (GM Part No. 1051396) or equivalent to the engine |*H"| Install o r C on n ect (F ig u re 5) oil.
Page 416 6A2-28 2.8 LITER V SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in MILLIMETERS unless otherwise noted. G E N E R A L D A TA : Type 2.8L D isplacem ent 89.0 Bore 76.0 Stroke 8.9:1 C om pression R atio 1-2-3-4-5-6 Firing O rder 69 kPa fa 500 R PM ;...
Page 417 2.8 LITER V 6A2-29 SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) All s p e cific atio n s are in M IL L IM E T E R S unless o th erw ise noted. C R A N K S H A F T D ia m e te r - 3 D o ts 67.241-67.249 D ia m e te r - 2 D o ts...
Page 418 6A2-30 2.8 LITER V SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Ft. Lbs. Item Rocker Arm Cover B o lts .......................... Intake Manifold Bolts..........................Exhaust Manifold B o lts ..........................C ylinder Head B o lts ..........................Torsional Damper B olt..........................Tim ing Chain D am per................
Page 419: Special Tools
2.8 LITER V 6A2-31 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. H ydrau lic L ifte r Rem over (Plier Type) 2. C ra nksh a ft S procket In s ta lle r 3.
Page 420 6A2-32 2.8 LITER V-6...
Page 421 6A3-1 SECTION 6A3 4.3 LITER V-6 CONTENTS SUBJECT PAGE D escription......................................6 A 3 - 2 Engine Lubrication..................................6 A 3 - 2 D isassem bly.......................................6 A 3 - 5 Tools and Shop Equipm ent..............................6 A 3 - 5 Accessory R e m o v a l..................................6 A 3 - 5 C le a n in g ......................................
Page 422: Subject Page
6A3-2 4.3 LITER V CONTENTS SUBJECT PAGE Assembly of Engine (Continued) Front Cover Installation................................6 A 3 -1 8 Torsional Damper Installation..............................6 A 3 -1 8 Piston and Connecting Rod In s ta lla tio n ..........................6 A 3 -2 0 Oil Pump In sta lla tio n .................................
Page 423 4.3 LITER V 6A3-3 B-07857 Figure 1— Engine Lubrication Diagram...
Page 424 6A3-4 4.3 LITER V A. R egu lator Valve (Shown In O pen Position) B. S uction C. Oil Pressure Sw itch D. Valve L ifter G allery E. Main Oil G allery F. B ypass Valve Front V iew Rear V iew Show ing Path O f Oil To Tim in g C hain.
Page 425: Disassembly
4.3 LITER V 6A3-5 DISASSEMBLY Cooling Fan Distributor Carburetor TBI Unit It is beyond the scope of this section to detail the many different accessory installations. Refer to the proper Truck Service Manual for this inform ation. Diagram s of em ission and vacuum hose routings, w iring harness routing, accessory drive belt layout, etc., should be made before removing accessories.
Page 426: Rocker Arm Cover Removal
6A3-6 4.3 LITER V 40. B olt 41. R etainer 42. N uts 43. Balls 44. R ocker A rm s 45. P ushrods 46. R e s tric to r 47. H yd ra u lic L ifte r B-07611 Figure 4—...
Page 427: Cylinder Head Removal
4.3 LITER V 6A3-7 CYLINDER HEAD REMOVAL R em o ve or D isco nn ect 1. Spark plugs. 2. C ylinder head bolts. 3. C ylinder heads. 4. Head gaskets. TORSIONAL DAMPER REMOVAL 4- + R em o ve or D isco nn ect (F ig u re 5) Tool Required: 70.
Page 428: Piston And Connecting Rod Removal
6A3-8 4.3 LITER V 87. T h ru s t P late 88. S cre w B-07615 Figure 7— Camshaft and Com ponents • Place a cloth on top of the piston. PISTON AND CONNECTING ROD • Perform the cutting operation with a ridge REMOVAL ream er (figure 9).
Page 429: Flywheel Removal
4.3 LITER V 6A3-9 CRANKSHAFT REMOVAL |+ + | R em ove or D isco n n ect • Check the main bearing clearance before removing A. G u ide Rod the crankshaft. Refer to “ C rankshaft and Main Bearing Installation”...
Page 430: Main Bearing Removal (W Ithout Removing C Ra N K S H A
6A3-10 4.3 LITER V MAIN BEARING REMOVAL (WITHOUT REMOVING CRANKSHAFT) R em o ve or D isco nn ect Tool Required: J 8080, Main Bearing Remover/Installer 1. Main bearing caps. • Check the main bearing caps for location markings. Mark the caps if necessary. The ca ps m ust be re tu rn e d to th e ir o rig in a l locations during assembly.
Page 431: Intake And Exhaust Manifolds
4.3 LITER V 6A3-11 M easu re A lignm ent of m anifold flanges. Use a straight edge and feeler gage. If the flanges do not align, the Piston pin diam eter and clearance. manifold is warped and should be replaced. Piston to bore clearance, and fit pistons as outlined.
Page 432: Front Cover
6A3-12 4.3 LITER V Install or C on n ect Tool Required: J 35468, Seal Installer New seal so that the open end of the seal is toward the inside of the cover. — Drive the seal into position with J 35468. —...
Page 433: Valve Train Components
4.3 LITER V 6A3-13 NOTICE: Be c a re fu l o f tw is tin g , s h e a rin g o r c o lla p s in g the p ip e w h ile in s ta llin g the p u m p . 7.
Page 434 6A3-14 4.3 LITER V CLEANING AND INSPECTION OF COMPONENTS 2 0 . Valve K eeper Refer to GENERAL ENGINE MECHANICAL (SEC. 6A) 21. Cap and perform the following. 2 2 . S hield r j i C lean 23. O-Ring Seal 24.
Page 435 4.3 LITER V-6 6A3-15 1. Valves (27 and 29). • Lubricate the valve stems with engine oil. • Insert the valves into the proper seats. 2. Seal (24) (intake valve only). • Install the seal over the valve stem and seat it against the head.
Page 436: Therm Ostat And W Ater O U Tle
6A3-16 4.3 LITER V-6 • C o m p re ss the valve sp rin g using J 8062 (figure 20). Com press the spring enough so the lower valve stem groove can be seen clearly. • Push a new O-ring seal (23) onto the valve stem.
Page 437: Rear Crankshaft Oil Seal Retainer In S Ta Lla Tio
4.3 LITER V-6 6A3-17 ASSEMBLY OF ENGINE PRIOR TO ASSEMBLY The im portance of cleanliness during the assembly p ro ce d u re ca n n o t be o ve rstre sse d . D irt w ill cause prem ature wear of the rebuilt engine.
Page 438: Rear Crankshaft Oil Seal In S Ta Lla Tio
6A3-18 4.3 LITER V-6 • T ig h te n th e s c re w s s e c u re ly w ith screwdriver. This will ensure that the seal is A. Rear o f Block installed squarely over the crankshaft. 80.
Page 439 4.3 LITER V-6 6A3-19 87. T hrust Plate 88. Screw B-07615 Figure 29 —Cam shaft and Com ponents N O T IC E : The in e rtia w e ig h t s e c tio n o f th e to rs io n a l d a m p e r is a s s e m b le d to th e h u b w ith ru b b e r type m a te ria l.
Page 440: Piston And Connecting Rod In S Ta Lla Tio
6A3-20 4.3 LITER V-6 A. Oil Ring Rail G aps B. 2nd C om pressio n Ring G ap C. N otch In Piston D. Oil Ring S p a c e r G ap (Tang In H o le O r S lot W ith Arc) E.
Page 441: Oil Pump Installation
4.3 LITER V-6 6A3-21 • Locate the piston ring end gaps as shown in figure 33. Lubricate the piston and rings with engine oil. • W ithout disturbing the ring end gap location, install J 8037 over the piston (figure 34). •...
Page 442 6A3-22 4.3 LITER V-6 A-Forward 70. Gasket B-Sealant 71. R einforcem ent F-04488 Figure 37— Oil Pan Installation...
Page 443: Valve Train Com Ponent In Stallatio
4.3 LITER V-6 6A3-23 (Even numbered cylinders are in the right bank; odd num bered cylinders are in the left bank, when viewed from the rear of the engine). 3. Back out the adjusting nut until lash is felt at the pushrod then turn in the adjusting nut until all lash is removed.
Page 444: Egr Valve In Stallatio
6A3-24 4.3 LITER V-6 40. Bolt 41. R etainer 42. Nuts 43. Balls 44. R ocker Arm s 45. Pushrods 46. R estrictor 47. H ydraulic Lifter B-07611 Figure 39— Valve Train Com ponents FLYWHEEL INSTALLATION • Bolts on front and rear exhaust tubes to 28 N m (20 ft.
Page 445: Engine Set-Up And T E S Tin
4.3 LITER V-6 6A3-25 C. Port B lo ckin g Plate D. RTV Sealant F-05521 Figure 40— Intake Manifold Installation ENGINE SET-UP AND TESTING 1. After overhaul, the engine should be tested before installation in the vehicle. If a suitable test stand is not available, the following procedure can be used after the engine is installed in the vehicle.
Page 446 6A3-26 4.3 LITER V-6 installed, add Engine Oil S upplem ent (GM part no. 1051396) or equivalent to the engine oil. 3. Fill the cooling system with the proper coolant. 4. With the ignition “ OFF,” or disconnected, crank the engine several times.
Page 447 4.3 LITER V-6 6A3-27 SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherwise noted. GENERAL DATA: Type 4.3L (262 Cu. In.) Displacement 4.00 Bore 3.48 Stroke 9.3:1 Compression Ratio 1 - 6 - 5 - 4 - 3 - 2 Firing Order 10 psi 500 RPM;...
Page 448 6A3-28 4.3 LITER V-6 SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) All specifications are in INCHES unless otherwise noted. DISPLACEMENT: 4.3L CRANKSHAFT: 2.4484-2.4493 Diameter #2, #3 2.4481-2.4490 2.4479-2.4488 Production 0.0002 (Maximum) Main Taper Journal Service Limit 0.001 (Maximum) Production 0.0002 (Maximum) Out Of Round Service Limit 0.001 (Maximum)
Page 449 4.3 LITER V-6 6A3-29 SPECIFICATIONS (CONTINUED) TORQUE SPECIFICATIONS IN. LBS. ITEM FT. LBS. Rocker Arm Cover B o lt s ......................10.2 — Intake Manifold B o lts ........................ 48 Exhaust Manifold Bolts Center Two B o lts ........................ 36 All O t h e r s ........................
Page 450 6A3-30 4.3 LITER V-6 SPECIAL TOOLS J-23523-E J-5802-01 -------------- J-5715 J-6036 J-8062 J-6880 J-35468 J-5825-A J-8080 J-8037 J-5590 J-5239 J-35621 J-23738-A 1. Torsional D am per Remover and In sta lle r 8. Stud Rem over 2. Valve S pring C om pre ssor 9.
Page 451 6A4-1 SECTION 6A4 4.8 LITER L6 CONTENTS SUBJECT PAGE D escription......................................6 A 4 - 2 D isassem bly.......................................6 A 4 - 4 Tools and Shop E quipm ent..............................6 A 4 - 4 Accessory R e m o v a l..................................6 A 4 - 4 C le a n in g ......................................6 A 4 - 4 Parts Id entification..................................
Page 452 6A4-2 4.8 LITER L6 CONTENTS (CONTINUED) SUBJECT PAGE Assem bly of Engine (Cont.) Oil Pan Installation..................................6 A 4 -2 8 Cylinder Head In s ta lla tio n ................................6 A 4 -2 9 Valve Train Com ponent In stallatio n ............................. 6 A 4 -2 9 Valve A djustm ent..................................
Page 453: Liter L6
4.8 LITER L6 6A4-3 A. O il P ressure S e n d in g U nit B. D is trib u to r S h aft O ilin g C. S plash O ilin g D. F ilte r B ypass S ystem E.
Page 454: Disassembly
6A4-4 4.8 LITER L6 DISASSEMBLY 41. Stud 21. Pushrod 1. Oil Cap 42. Intake Valve 22. Bolt 2. C lip 43. Exhaust Valve 3. Screw 23. Bolt 44. S w itch 4. R einforcem ent 24. W asher 45. Plug 5.
Page 455 4.8 LITER L6 6A4-5 1 4 — B-07997 Figure 4 — Cylinder Head, Manifolds, and Com ponents...
Page 456 6A4-6 4.8 LITER L6 112 <T|^108 I ft*-109 129+&/ B-05056 Figure 5— Block and Com ponents...
Page 457 4.8 LITER L6 6A4-7 145. B o lt 93. S c re w 146. O il Pan 94. C a m s h a ft G e a r 147. F ro n t O il Pan Seal 95. T h ru s t P late 148.
Page 458: Draining The Engine
6A4-8 4.8 LITER L6 DRAINING THE ENGINE □ R em o ve or D is c o n n e c t (F ig u re 5) — Oil pan drain plug (144). Allow the oil to drain. — Oil filter (174). —...
Page 459: Thermostat Housing Removal
4.8 LITER L6 6A4-9 " > A. 22 mm (7/s” ) B. 55 mm (2-1/s” ) C. 40 mm (I-V ” ) D. 10 mm (3/8” )d rill 25 m m (1” )deep H ole s fo r P ushrods E.
Page 460: Cylinder Head Removal
6A4-10 4.8 LITER L6 Figure 15— Removing the Torsional Damper CYLINDER HEAD REMOVAL |+ + | R em o ve or D isco nn ect (F ig u re 4) 1. Bolts (21). 2. C ylinder head (26). Use care when handling the B-05064 cylinder head to prevent dam age to the gasket surfaces.
Page 461: Timing Gear Cover Removal
4.8 LITER L6 6A4-11 • Using the m anufacturer’s directions, install a ridge ream er into the top of the cylinder (figure 16). Perform the cutting operation. • A fter the ridge and/or deposits are removed, remove the ridge reamer. Turn the crankshaft until the piston is at the top of its stroke.
Page 462: Crankshaft Removal
6A4-12 4.8 LITER L6 Figure 18— Flywheel Installed Figure 19— Removing the Lower Seal Half 4. Bolts (122). CRANKSHAFT REAR OIL SEAL REMOVAL (WITHOUT 5. Flywheel (118). REMOVING CRANKSHAFT) CRANKSHAFT REMOVAL R em o ve or D is co n n ec t (F ig u re s 5, 19, and 20) The main bearings and rear oil seal can be replaced 1.
Page 463: Camshaft Removal
4.8 LITER L6 6A4-13 • Use a small brass drift and hammer. Tap on the insert, on the side opposite the bearing tang, until the insert rotates out of position (figure 21). • Use a pair of pliers with the jaw s taped to prevent dam age to the crankshaft.
Page 464: Cleaning, Inspection, And Repair
6A4-14 4.8 LITER L6 CLEANING, INSPECTION, AND REPAIR A solvent tank, large enough to hold the larger engine The area where the main bearing inserts (130, parts, will be needed along with various bristle brushes 133, 136, and 153) contact the main bearing and a gasket scraper.
Page 465: Cylinder B O R E
4.8 LITER L6 6A4-15 PISTON AND CONNECTING ROD ASSEMBLIES Refer to GENERAL ENGINE M ECHANICAL (SEC. 6A) and perform the following: D isassem b le Com ponents as required. C lean Com ponents as outlined. In sp ect C om ponents as outlined. M easu re •...
Page 466: Camshaft
6A4-16 4.8 LITER L6 A. In d ic a to r B. C h e c k in g F ix tu re B-04578 182. C a m s h a ft Figure 26— Measuring Camshaft Journal Runout A ssem b le (F ig u re 4) 1.
Page 467: Camshaft Bearings
4.8 LITER L6 6A4-17 TIMING GEAR COVER Clean Old gasket from the gasket surfaces. • Place the cam shaft (182) in a press. Support L«| the cam shaft gear. DO NOT support the thrust In sp ect plate (95). — Tim ing tab for damage. —...
Page 468: Oil Pan And Rocker Arm Cover
6A4-18 4.8 LITER L6 • Do not remove the pick-up screen and pipe 201. Pressure R elief Valve unless replacem ent is required. 202. S pring • The pick-up pipe is a press fit in the pump 203. S pring R etaining body (209).
Page 469: Valve Train Components
4.8 LITER L6 6A4-19 B-09438 Figure 33 — Installing the Oil Pump Screen and Pipe VALVE TRAIN COMPONENTS PUSHRODS, ROCKER ARMS, BALLS, AND NUTS IQ * C lean • Parts in solvent. Blow dry with com pressed air. Make sure the oil passages in the pushrods are clear. In sp ect (F ig u re 4) —...
Page 470 6A4-20 4.8 LITER L6 ASSEMBLY 5. Valves (42 and 43). Place them in a rack so they can be returned to their original position at assembly. A ssem b le (F ig u re s 34, 3 5 , and 39) CLEANING AND INSPECTION OF COMPONENTS Tools Required: Refer to GENERAL ENGINE MECHANICAL (SEC.
Page 471: Thermostat And Housing
4.8 LITER L6 6A4-21 |'ii|i|i|n'm'JTT r n|M T " A. G rind out th is portion. B-05248 Figure 40 — Scale for Checking Valve Spring Installed Height t j j M easu re (F ig u re s 3 4 , 4 0 , and 41) •...
Page 472: Torsional Damper
6A4-22 4.8 LITER L6 D isassem b le (F ig u re 4) 1. Bolts (55). 2. W ater outlet (54). 3. Therm ostat (52). 4. Gasket (53). In sp ect (F ig u re 4) W ater outlet (54) and housing (50) for cracks or damage.
Page 473: Oil Filter Relief Valve R E P La C E M E N
4.8 LITER L6 6A4-23 VALVE REMOVAL VALVE INSTALLATION B-03497 Figure 4 5 — Replacing the Oil Filter Bypass Valve A ssem b le (F ig u re 44) Tool Required: J-5590 Gear Installer Crankshaft gear, using J-5590. Make sure the tim ing mark faces outside. OIL FILTER RELIEF VALVE REPLACEMENT D isassem b le (F ig u re 45)
Page 474 6A4-24 4.8 LITER L6 0 ( \ 1 1 5 in the block. The installation tool must remain in p o sitio n until the seal half is p ro p e rly positioned with both ends flush with the block. •...
Page 475: Main Bearing Installation (With Crankshaft In S Ta Lle
4.8 LITER L6 6A4-25 MAIN BEARING INSTALLATION (WITH CRANKSHAFT INSTALLED) Refer to “ Crankshaft and Main Bearing Installation,” later in this section for main bearing insert sizing information. Install o r C on n ect (F ig u re s 5 and 21) Tool Required: J-8080 Main Bearing Remover/Installer 1.
Page 476: Cam Shaft In Stallatio
6A4-26 4.8 LITER L6 Figure 50—Measuring Crankshaft End Play £ Tighten Tighten • All bolts (138 and 139) EXCEPT THE REAR • Screws (93) to 9.0 N m (80 in. lbs.). MAIN BEARING CAP BOLTS to 90 N m (65 ft. lbs.).
Page 477: Torsional Damper Installation
4.8 LITER L6 6A4-27 Figure 54— Piston Ring Gap Location i - + R em o ve or D is c o n n e c t (F ig u re 5) PISTON AND CONNECTING ROD INSTALLATION J-35468 from the seal (158). TORSIONAL DAMPER CONNECTING ROD BEARING SELECTION Connecting rod bearings are of the precision insert type...
Page 478: Oil Pump In Stallatio
6A4-28 4.8 LITER L6 Measure • C onnecting rod bearing clearance. Refer to GENERAL ENGINE M ECHANICAL (SEC. 6A). Then apply engine oil to the connecting rod bearing. • W ith the connecting rod cap removed, install J-5329 onto the connecting rod studs (69). 4.
Page 479: Cylinder Head In S Ta Lla Tio
4.8 LITER L6 6A4-29 CYLINDER HEAD INSTALLATION Figure 59—Timing Marks (Typical) Clean (Figures 4 and 5) VALVE TRAIN — Gasket surfaces on the block (115) and cylinder COMPONENT INSTALLATION head (26). — Threads for cylinder head bolts in the block (115). Important Replace all hydraulic lifters if a new cam shaft was |-n-| Install or Connect (Figures 4, 5 and 58)
Page 480: Checking Valve T Im In
6A4-30 4.8 LITER L6 5. The following chart shows indicator readings with gears properly indexed for 4.8L engines and the indicator readings resulting from im properly indexed gears. Engine 4.8L Camshaft Part Number 3848000 Valve Lift 0.405" Dial Gears Properly Indexed 0.016"...
Page 481: Intake And Exhaust Manifold Installation
4.8 LITER L6 6A4-31 INTAKE AND EXHAUST ENGINE SET-UP AND TESTING MANIFOLD INSTALLATION 1. A fter overhaul, the engine should be tested before installing in the vehicle. If a suitable test stand is not Install or C o n n e c t (F ig u re 4) available, the following procedure can be used after the engine is installed in the vehicle.
Page 482: S P E C Ific A Tio N
6A4-32 4.8 LITER L6 SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherwise noted. GENERAL DATA: In Line Type 4.8L (292 Cu. In.) Displacement No. Of Cylinders 3.876 Bore 4.12 Stroke 8.0:1 Compression Ratio 1 - 5 - 3 - 6 - 2 - 4 Firing Order 16 psi @ 700 RPM;...
Page 483 4.8 LITER L6 6A4-33 SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) All specifications are in INCHES unless otherwise noted. CRANKSHAFT: Diameter 2.2979 2.2994 Main Production 0.0002 (Maximum) Taper Journal Service Limit 0.001 (Maximum) Out of Production 0.0002 (Maximum) Round Service Limit 0.001 (Maximum) #1-#6: 0.0010-0.0024 Main Production...

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Chevrolet 1988 Light Duty Truck Repair Manual

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