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GMC 1990 Light Truck Repair Manual

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G M C

T R U C K

1990

LIGHT TRUCK

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Page 1 G M C T R U C K 1990 LIGHT TRUCK...
Page 3 GMC Truck Division of General Motors dorp. This includes all text, illustrations, tables and charts.
Page 4 CAUTION To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed. Proper service and repair are important to the safety of the service technician and the safe, reliable operation of all motor vehicles. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part.
Page 5 TABLE OF CONTENTS 1990 SEC. SECTION NAME GENERAL INFORMATION AIR CONDITIONING 1B1 A6 Air Conditioning Compressor 1B2 V5 Air Conditioning Compressor 1B3 R-4 Air Conditioning Compressor 1B4 HR-6 Air Conditioning Compressor UNIT REPAIR 1B5 SD-709 Air Conditioning Compressor STEERING 3B2 Manual Steering Gear MANUAL 3B3 Power Steering AXLES...
Page 6 Mr. Goodwrench dealers you do the work yourself. selling Chevrolets, Pontiacs, Oldsmobiles, Buicks, IPIs&igimEl Cadillacs, GMC and Chevy Trucks. That's why Mr. Goodwrench wants to have a good in..stock of genuine GM Parts available. Everything from...
Page 7: Table Of Contents
GENERAL INFORMATION OA-1 SECTION OA GENERAL INFORMATION CONTENTS SUBJECT PAGE Service Parts Identification Label ......................... OA- 1 Vehicle Identification Number ..........................OA- 1 Certification Label ..............................OA- 1 Engine Identification Number ..........................OA- 2 "Transmission Identification Number ........................OA- 3 Model Reference ................................. OA- 3 Metric Fasteners .................................
Page 8: Vehicle Identification Number
1 Fort Wayne, IN B Chevrolet Incomplete 4 Two-OoorCab 0 Pontiac, Ml C Chevrolet Truck 5 Van 1 Oshawa, ON 0 GMC Incomplete Suburban 2 Moraine, OH J GMC Bus* 7 Motor Home Cnassis 3 Detroit. Ml Utility (Blazer/Jimmy) K GMC MPV...
Page 9: Transmission Identification Number
GENERAL INFORMATION OA-3 TRANSMISSION IDENTIFICATION NUMBER Refer to figures 10 through 13 for determining trans mission identification numbers and code meanings. MODEL REFERENCE Refer to figures 14 through 19 for determining vehi cle model. C, R, and S models are two wheel drive. K, V.and T models are four wheel drive.
Page 10 OA-4 GENERAL INFORMATION VIEW B 1. Engine I.D. Location F7554 Figure 9—6.2L Diesel Engine I.D. Location...
Page 11: Fastener Strength Identification
GENERAL INFORMATION OA-5 1. Transmission I.D. Location 1. Transmission I.D. Location F7573 F7572 Figure 11— Hydra-matic THM-180C (3L80/3I80-HD) Figure 10— Hydra-matic THM-700R4 (4L60) Transmission I.D. Location Transmission I.D. Location Metric and customary thread notation differ slightly. nut suppliers. In general, except for special applica The difference is shown in figure 21.
Page 12 ------------------------------------------------------------------------------ OA-6 GENERAL INFORMATION 1. Transmission I.D. Location BUILD DAY OF M O N TH MODEL YEAR 01 - 1ST DAY (0 - 19901 15 - 15TM DAY J j / o ' BUILD MONTH A * JANUARY B • FEBRUARY 1 HM-1 t7 | C - MARCH D - APRIL...
Page 13 GENERAL INFORMATION OA-7 R-V MODELS Suburban Pickup, Bonus/Crew Cab Utility Vehicle Jimmy (Blazer) F7558 Figure 14— RV Models...
Page 14 OA-8 GENERAL INFORMATION G VAN MODELS Rally (Sportvan) Vandura (Chevy Van) Cutaway Van Magnavan (Hi-Cube Van) & . . _ E IsQ f ’ lAOjj ------- — F7569 Figure 15—G Models...
Page 15 GENERAL INFORMATION OA-9 P MODELS Motor Home Chassis Value Van (Step Van) (Aluminum) Forward Control Chassis Value Van (Step Van) (Steel) r a g ) Cutaway Cab F7570 Figure 16— P Models CK Pickup Sportside CK Chassis Cab CK Pickup, Extended Cab CK Chassis, Extended Cab F4481 Figure 17—CK Models...
Page 16 0A-10 GENERAL INFORMATION S/T PICKUP, REGULAR CAB S/T CHASSIS CAB s fr UTILITY VEHICLE S/T PICKUP, EXTENDED CAB JIMMY (BLAZER) B6998 Figure 18—ST Models Passenger Van 1. Grade 2 (GM 200-M) 2. Grade 5 (GM 280-M) 3. Grade 7 (GM 290-M) Cargo Van 4.
Page 17 GENERAL INFORMATION OA-11 1. Customary B o lt— 1 /4-20 2. Metric B olt— M6.0x1 A. 1 /4-inch B. 6 mm C. 20 Threads Per Inch D. 1 Thread Per M illim eter (25.4 Threads Per Inch) _________________________________ F0705 Figure 21—Thread Notation E - External Drive B2221 Figure 22—Six Lobed Socket Head Fasteners...
Page 18 OA-12 GENERAL INFORMATION A. Metric Sizes 1. Top Lock Type 6. Nylon Strip Or Patch B. Inch Sizes 2. Center Lock 7. Nylon Washer Insert 3. Dry Adhesive Coating 8. Nylon Patch 4. Out Of Round Thread 9. Nylon Insert 5.
Page 19: Conversion Table
CONVERSION TABLE to get equivalent to get equivalent number of: Multiply Multiply____________ by__________ number of: LENGTH ACCELERATION Inch 25.4 millimeters (mm) Foot/sec2 0.304 8 meter/sec7 (m/s2 ) 0.304 8 Foot meters (m) Inch/sec2 0.025 4 meter/sec2 Yard 0.9144 meters TORQUE Mile 1.609 kilometers (km)
Page 20: Decimal And Metric Equivalents
OA-14 GENERAL INFORMATION DECIMAL AND METRIC EQUIVALENTS Fractions Decimal In. Metric mm Fractions Decimal In. Metric mm 1/64 0.015625 0.39688 33/64 0.515625 13.09687 1/32 0.03125 0.79375 17/32 0.53125 13.49375 3/64 0.046875 1.19062 35/64 0.546875 13.89062 1/16 0.0625 1.58750 9/16 0.5625 14.28750 5/64 0.078125...
Page 21 A-6 AIR CONDITIONING COMPRESSOR 1B1-1 SECTION 1 AIR CONDITIONING CONTENTS SUBJECT PAGE A-6 Air Conditioning Compressor........................1B1-1 V-5 Air Conditioning Compessor.........................1B2-1 R-4 Air Conditioning Compressor........................1B3-1 HR-6 Air Conditioning Compressor........................1B4-1 SD-709 Air Conditioning compressor........................ 1B5-1 SECTION 1B1 A-6 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE...
Page 22 1B1-2 A-6 AIR CONDITIONING COMPRESSOR 1. Nut 2. Clutch 3. Ring 4. Pulley Bearing Ring 5. Bearing 6. Pulley 7. Clutch Coil Ring 8. Coil 9. Shell 10. Sleeve Seal 11. Flat Seal 12. Ring 13. Seat Seal 14. Shaft Seal 15.
Page 23: Air Conditioning Compressor
A-6 AIR CONDITIONING COMPRESSOR 1B1-3 Illustrations used in describing these operations show the compressor removed from the vehicle to illus trate the various operations. When servicing the compressor, remove the compo nents that preliminary diagnosis indicates need servic ing. Refer to figure 1 for part name and location. Keep the work area, tools and parts clean.
Page 24 1B1-4 A-6 AIR CONDITIONING COMPRESSOR • Install J 9480-B on the threaded end of the shaft (figure 5). • Back off J 9480-B body to allow the center screw to be threaded against the end of the compressor shaft (39). •...
Page 25: A-6 Air Conditioning Compressor
A-6 AIR CONDITIONING COMPRESSOR 1B1-5 Retainer Ring • Drive the bearing (5) from the pulley (6) with J 9398 and J 8092. Install or Connect (Figures 1 and 10) Tools Required: J 6435 Snap Ring Pliers J 8092 Driver Handle J 9481-A Pulley Bearing and Pulley Installer •...
Page 26: Clutch Coil And Housing Assembly Replacement
1B1-6 A-6 AIR CONDITIONING COMPRESSOR Remove any adhesive around the three locator hole areas of the front head and around the three clutch coil locator protrusions at the rear of the clutch coil housing. Use a suitable solvent to clean the coil. Important Figure 11—Adhesive Fill Guide •...
Page 27: Major Repair To The Compressor
A-6 AIR CONDITIONING COMPRESSOR 1B1-7 J 21508 F1582 Figure 15— Removing/Installing the Shaft Seal and Seal Retaining Ring jo r” since the refrigeration system must be purged of refrigerant before proceeding. If servicing or replacing the internal cylinder and shaft assembly chain, measure and replace the oil with new 525 viscosity refrigerant oil.
Page 28 1B1-8 A-6 AIR CONDITIONING COMPRESSOR • Engage the tabs and lift the seal (14) out of the shaft (39) cavity. Hold J 22974 in place while removing the seal. 7. O-ring (15) with J 9553-01. Install or Connect (Figures 1, 13 through 16) Tools Required: J 5403 Snap Ring Pliers J 9392-01 Shaft Seal Remover and Installer...
Page 29: Pressure Relief \Falve Replacement
A-6 AIR CONDITIONING COMPRESSOR 1B1-9 • If the shaft has been pushed back in the axial plate (measurement greater than 1.9 mm (0.075-inch), disassemble the compres sor and replace the shaft and axial plate assembly, thrust races and thrust bearings. •...
Page 30 1B1-10 A-6 AIR CONDITIONING COMPRESSOR 49. Plate _________________________________ F1585 Figure 18—Removing the Rear Head Plate and Seal 9. Seal (36). 5. Seal (52). 10. Compressor to J 21352. 6. Rear discharge valve plate assembly (49) (figure 19). • Loosen the compressor from J 9396. •...
Page 31 A-6 AIR CONDITIONING COMPRESSOR 1B1-11 29. Front Cylinder Half 42. Rear Cylinder Half 66. Wood Block F1591 Figure — Separating the Cylinder Halves 12. Front seal (17). • Tap on the outside of the front head (16) with a plastic hammer to overcome the friction of the seal (17) between the fronthead (16) and the shell (9).
Page 32: Gaging Operation
1B1-12 A-6 AIR CONDITIONING COMPRESSOR Figure 25—Identifying the Notch at the Front of the Piston J 9432 Needle Bearing Installer J 21352-A Compressor Support Block 1. Needle bearing (21) to the front cylinder (29) with J 9432 (figure 27). • Support the cylinder half (29) on J 21352-A. •...
Page 33 A-6 AIR CONDITIONING COMPRESSOR 1B1-13 J 9397 F. Piston drive ball at the rear. 29. Cylinder (Front) G. Piston drive ball and a “zero” shoe disc at the front. 40. Race 29. Front cylinder half. 41. Bearing F1597 F1595 Figure 30—Installing the Piston during the Gaging Figure 28—Installing the Rear Thrust Races and Operation Bearing...
Page 34: Gaging Procedure
1B1-14 A-6 AIR CONDITIONING COMPRESSOR GAGING PROCEDURE Tools Required: J 8001 Dial Indicator Set J 9397 Compressing Fixture J 9402 Piston Assembly Tray J 9661 -01 Feeler Tension Gage Set Two gaging procedures provide the running toler ances. The first procedure determines the size shoe discs to provide at each piston a 0.041-0.061 mm (0.0016- 0.0024-inch) total preload between the seats and the axial plate at the tightest place through the 360 degree...
Page 35 A-6 AIR CONDITIONING COMPRESSOR 1B1-15 Select Position Position Position and Use Shoe No. Piston No. 1 .019" .0195" .019" Piston No. 2 .020" .020” .020" Piston No. 3 .021" .021" .022" T2500 SHOE DISC Identification Min. Feeler Part No. Gage Reading Stamp Ending In .0000...
Page 36: Piston Ring Replacement
1B1-16 A-6 AIR CONDITIONING COMPRESSOR • Transfer each of the piston, ball and shoe disc sets to J 9402. 13. Remove the rear outer "zero” thrust race (it will be on top) from the shaft and install the thrust race just selected in Steps 6 and 7 that is in J 9402.
Page 37: Compressor Assembly
A-6 AIR CONDITIONING COMPRESSOR 1B1-17 J 24608-5 24608-2 COMPRESSOR ASSEMBLY Assemble the cylinder assembly after performing the “ Gaging Procedure,” choosing the correct shoe discs and thrust races and installing any piston rings. Install new seals supplied in the service kit. 33.
Page 38 1B1-18 A-6 AIR CONDITIONING COMPRESSOR 27. Race 35. Seat 42. Cylinder (Rear) 28. Bearing 40. Race 46. Plate 34. Ball 41. Bearing F1626 F1628 Figure 40—Installing No. 1 Piston Figure Installing the Suction Crossover Tube 42— Plate • Lubricate all the moving parts with clean 525 viscosity refrigerant oil.
Page 39 A-6 AIR CONDITIONING COMPRESSOR 1B1-19 30. Sleeve 31. Seal F1629 Figure 45— Installing the Front Discharge Valve Figure 43— Installing the Discharge Crossover Tube Plate 21352 18. Discharge Plate 39. Shaft F1470 Figure 46— Installing the Front Head Figure 44— Installing the Front Suction Reed Plate...
Page 40 1B1-20 A-6 AIR CONDITIONING COMPRESSOR 16. Front Head 17. Seal F1635 L. Oil Sump Figure 47—Installing the Front Head Seal Area M. Oil Intake Important Tube Hole 9. Shell • Do not let the sealing area around the cen 17. Seal ter bore of the head touch the shaft as the head is lowered.
Page 41: Leak Testing
A-6 AIR CONDITIONING COMPRESSOR 1B1-21 26. Rear head (54) to the shell (9) (figure 51). • Align the two lower threaded compressor mounting holes with the compressor sump. • Do not let the suction screen (58) fall out of the rear head (54).
Page 42: Specifications
1B1-22 A-6 AIR CONDITIONING COMPRESSOR the test plate if the hoses have built-in 3. Connect the charging station “ high” and "low ” Schrader depressors. pressure lines to the correct fittings on J 9625-A, • Oil will drain out of the compressor suction using J5420 (7/16-inch) gage adapters.
Page 43: Special Tools
A-6 AIR CONDITIONING COMPRESSOR 1B1-23 SPECIAL TOOLS J9432 J 9459 & © J 9 4 8 0 ‘ 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 44 1B1-24 A-6 AIR CONDITIONING COMPRESSOR J 26549-B — f —..J 33011 19. Compressor Test Set 1. Oil Pickup Tube Remover 20. Compressor Support Block 2. Snap Ring Pliers 21. Oil Seal Protector 3. Goggles 22. Compressor Shaft Seal Installer 4.
Page 45 V5 AIR CONDITIONING COMPRESSOR 1B2-1 SECTION 1B2 V5 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE Description..................................1B2- 1 Theory of Operation..............................1B2- 1 Minor Repair to the Compressor..........................1B2- 2 Clutch Plate and Hub Assembly Replacement......................1B2- 2 Pulley and Bearing Assembly Replacement......................1B2- 4 Clutch Coil Replacem ent............................
Page 46: Minor Repair To The Compressor
1B2-2 V5 AIR CONDITIONING COMPRESSOR proper service. The compressor connections and the out side of the compressor should be cleaned before any “ on vehicle” repairs, or before removal of the compressor.The parts must be kept clean at all times and any parts to be C lutch Coil Terminals reassembled should be cleaned with Trichloroethane, nap- High Pressure Relief Valve...
Page 47 V5 AIR CONDITIONING COMPRESSOR 1B2-3 High Pressure Relief Valve High Side Low Pressure Valve High Side Cut-Off Switch Control Valve Shaft N ut C lutch Plate and Hub Assem bly Pulley Bearing Retainer Pulley Bearing Pulley C lutch Coil Assem bly Retainer Seal O-ring...
Page 48: Pulley And Bearing Assembly Replacement
1B2-4 V5 AIR CONDITIONING COMPRESSOR check that the shaft key (23) is properly in place • Back off J 33013-B body enough to allow the in the keyway, then install the clutch plate and center screw to be threaded agianst the end of hub assembly (22) to its final position.
Page 49 V5 AIR CONDITIONING COMPRESSOR 1B2-5 J-33013-B J-34992 22. Clutch Plate and Hub Assem bly A. A ir Gap 0.38-0.64 mm (.015-.025-inch) B. Bearing F-04540 Figure 7— Installing the Clutch Plate and Hub Figure 9— Installing the Pulley Rotor and Bearing Assembly Puller Guide Figure 8—Removing the Pulley Rotor and Bearing...
Page 50 1B2-6 V5 AIR CONDITIONING COMPRESSOR Figure 11 —Removing the Bearing from the Pulley Figure 12—Installing the Pulley Rotor Bearing Rotor Assembly J 33023-A Puller Pilot J 34992 Compressor Holding Fixture J 21352-A Support Block 1. Pulley (26) on J 21352-A (figure 12). NOTICE: Do not support the rotor by resting the pulley rim on a flat surface during bearing instal...
Page 51: Pressure Relief Valve Replacement
V5 AIR CONDITIONING COMPRESSOR 1B2-7 A. Stake Three Locations, 120° Apart B-06546 Figure 14—Bearing Stake Locations CLUTCH COIL ASSEMBLY REPLACEMENT 4--¥ Remove or Disconnect (Figures 3 and 16) Tools Required: J 8433 Puller Bar J 33023-A Puller Pilot J 33025 Clutch Coil Puller Legs Clutch plate and hub assembly (22).
Page 52: High-Side Pressure And High-Side Low Pressure Cutoff Switches Replacement
1B2-8 V5 AIR CONDITIONING COMPRESSOR J 33023-A J 8433 J 33025 A. Mark 27. Clutch Coil Assembly F-06455 Figure 16—Removing the Clutch Coil Assembly HIGH-SIDE PRESSURE AND HIGH-SIDE LOW-PRESSURE CUTOFF SWITCHES REPLACEMENT i- + Remove or Disconnect (Figures 1 and 3) Tool Required: J 5403 Snap Ring Pliers 1.
Page 53: Control Valve Replacement
V5 AIR CONDITIONING COMPRESSOR 1B2-9 CONTROL VALVE REPLACEMENT Remove or Disconnect (Figures 1 and 3) Tools Required: J 5403 Snap Ring Pliers 1. Retainer ring with J 5403. 2. O-ring seal (44). 3. Valve (5). -►+ Install or Connect (Figures 1 and 3) Tools Required: J 5403 Snap Ring Pliers 1.
Page 54 1B2-10 V5 AIR CONDITIONING COMPRESSOR J 23128-A A. Seal Retainer Ring J 5403 J 34992 J 34614 J 34992 — F-06457 Figure 21—Removing or Installing the Shaft Seal Retainer • Dip the new O-ring seal in clean 525 viscosity refriger ant oil.
Page 55 V5 AIR CONDITIONING COMPRESSOR 1B2-11 J 34993 J-33011 J-34992 35372 30. Shaft Seal Seat O-Ring A. Opening to Rear Suction Port F-04573 (12 O ’Clock Position Assembly Reference) B. Through Bolt Hole (6) Figure 24—Installing the Shaft Seal Seat O-Ring C.
Page 56: Leak Testing
1B2-12 V5 AIR CONDITIONING COMPRESSOR 7. Bearing (35) and thrust washers (36) in the same 2. Gasket (42) (figure 27). order as removed. • Place the elongated hole in the gasket over the rod at the upper left position. 8. Shim (34). 3.
Page 57: Specifications
V5 AIR CONDITIONING COMPRESSOR 1B2-13 SPECIFICATIONS Type — Harrison DA-V5............................Cylinder Axial Displacement................................9.2 Cu. In. Rotation..................................Clockwise 525 Viscosity Compressor Oil (Full C harge)......................227 g (8 oz.) TORQUE SPECIFICATIONS Compressor Suction and Discharge Connector B olt.................34 N-m (25 ft. lbs.) Shaft Nut..............................
Page 58: Special Tools
1B 2 -14 V5 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 5403 J 23128-A J 33022 J 33023-A J 6083 J 21352-A 29886 J 33011 J 33024 J 8433-1 J 33013-B J 33025 J 8433-3 J 34993 J 9398-A J 33017 J 34992 J 9481-A J 33019...
Page 59 R-4 AIR CONDITIONING COMPRESSOR 1B3-1 SECTION 1B3 R-4 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE R-4 Air Conditioning Compressor..........................1B3- 1 General Description..............................1B3- 1 Identification................................1B3- 2 Disassembly of The Drive Components........................1B3- 2 Clutch Drive H u b ................................ 1B3- 2 4 Pole Clutch Rotor And/Or Bearing-V-Groove......................
Page 60: Identification
1B3-2 R-4 AIR CONDITIONING COMPRESSOR Figure 1 —R-4 Compressor, V-Groove Pulley Type Figure 2—R-4 Compressor, Poly-Groove Pulley with 4 Pole Clutch and Driver Shown Type with 6 Pole Clutch and Driver Shown 30 ml (1 oz.) is drained from the compressor, add the same amount of new 525 viscosity oil to the overhauled assem...
Page 61: Pole Clutch Rotor And/Or Bearing
R-4 AIR CONDITIONING COMPRESSOR 1B3-3 J 25031 Rotor and Bearing Remover 4. File away the old staked metal to provide a clearance for the new bearing. J 29886 Driver Handle 1. Snap Ring with J 6038 (figure 8). • Mark the location of the clutch coil terminals. 6 POLE CLUTCH ROTOR AND/OR BEARING Important...
Page 62: Clutch Coil And/Or Pulley Rim
1B3-4 R-4 AIR CONDITIONING COMPRESSOR 5. The bearing from the hub using J 9398-A and J 29886 (figure 13). 6. The staking metal. CLUTCH COIL AND/OR PULLEY RIM V-GROOVE DRIVE Remove or Disconnect 1. Pulley rim mounting screws and washers. 2.
Page 63 R-4 AIR CONDITIONING COMPRESSOR 1B3-5 Figure 12—Pulley Rotor and Bearing Puller Installation SHAFT SEAL Remove or Disconnect (Figures 15 and 16) Tools required: J 5403 Snap Ring Pliers J 9553-01 O-ring Remover J 23128-A Seal Remover 1. Retainer ring using J 5403. 2.
Page 64: Disassembly Of The Compressor
1B3-6 R-4 AIR CONDITIONING COMPRESSOR DISASSEMBLY OF THE COMPRESSOR PRESSURE RELIEF VALVE Remove or Disconnect (Figure 17, 18 and 19) Remove or Disconnect (Figure 4) Tool Required: J 24896 Bearing Remover 1. Valve. 1. Head mounting screws (figure 17). 2. O-ring. 2.
Page 65: Discharge Valve Plate
R-4 AIR CONDITIONING COMPRESSOR 1B3-7 J 23128-A J 34614 F-01461 Figure 15—Removing the Shaft Seal with J 23128-A Figure 17—Removing the Front Head Mounting Screws F-06141 Figure 16—Removing and Installing the Shaft Seal Figure 18—Removing the Front Head Assembly DISCHARGE VALVE PLATE 2.
Page 66 1B3-8 R-4 AIR CONDITIONING COMPRESSOR Figure 19—Removing the Bearing from the Front Head 31. Valve Plate J 25008-A 33. Piston and Reed Assem bly 32. Retaining Strap F-01466 F-01793 Figure 20—Releasing the Shell Retaining Strap Figure 23—Replacing the Discharge Plate C.
Page 67: Cleaning And Inspection
R-4 AIR CONDITIONING COMPRESSOR 1B3-9 CLEANING AND INSPECTION CLEANING INSPECTION Clean Inspect The frictional surfaces of the clutch plate and the Front head for cracks or damage. Compressor shell for cracks or burrs. clutch rotor. Shaft seal area thoroughly. Staked areas for burrs. Cavity and O-ring groove for the high side high pres...
Page 68: High Side High Pressure Cutoff Switch
1B3-10 R-4 AIR CONDITIONING COMPRESSOR 8. O-ring into the groove of the front head (figure 18). 9. Front head aligning the marks made at disassembly. Figure 26—Replacing the Thrust and Belleville 10. Front head mounting screws (figure 17). Washers Tighten 3.
Page 69: Pole Clutch And/Or Bearing
R-4 AIR CONDITIONING COMPRESSOR 1B 3-11 J 26271-A F-06144 Figure 29—Installing the Rotor and Bearing Assembly — Poly-Groove Type • Make sure the protrusions on the rear of the coil align with the front head locator holes. 5. Clutch coil assembly using J 26271-A and J 29886 (figure 29).
Page 70: Pole Clutch Rotor And/Or Bearing-V-Groove
1B3-12 R-4 AIR CONDITIONING COMPRESSOR J 21352-A Support Block 4 POLE CLUTCH ROTOR AND/OR J 25008-A Holding Fixture BEARING-V-GROOVE J 29886 Driver Handle J 33019 Bearing Staking Tool *4 - Install or Connect (Figures 28 and 34) Pulley rotor on J 21352-A (Figure 30). Tools Required: NOTICE: Do not support the rotor by resting the J 6083 Snap Ring Pliers...
Page 71: Clutch Drive Hub
R-4 AIR CONDITIONING COMPRESSOR 1B3-13 6. Rotor Bearing 7. Rotor and Hub A ssem bly J 29886 J 9481-A C lutch Drive Rotor F-06152 B-08998 Figure 33—Installing the Clutch Rotor Bearing Figure 34—Installing the Shaft Key 6. Pulley rim mounting screws and washers. Do not tighten.
Page 72: Leak Testing
1B3-14 R-4 AIR CONDITIONING COMPRESSOR LEAK TESTING Tools Required: 12. Connect the charging station high pressure line or a high pressure gage and J 5420 to J 9625-A high side J 9625-A Pressure Test Set connector. J 5420 Straight Fitting J 25008-A Holding Fixture 13.
Page 73: Specifications
R-4 AIR CONDITIONING COMPRESSOR 1B3-15 SPECIFICATIONS Type Compressor..........................Harrison Radial 4 Cylinder Part N um bers................................1131593 ......1131610 ......1131611 ......1131616 ......1131623 ......3090927 ......3091278 ....10 cubic inches Displacement........Clockwise Rotation......0.5-1.0 mm (0.02-0.04 in.) Clutch Plate to Rotor Gap FASTENERS .
Page 74 1B3-16 R-4 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 4245 J 9399 J 5403 J 9480-B J 5420 J9481-A J 6083 J 9553-01 J 9625-A J 8398 J 21352-A J23128-A J 8433 J 24092 J 9398-A J 24895 1. Snap Ring Pliers (#23 Internal) 10.
Page 75 R-4 AIR CONDITIONING COMPRESSOR 1B3-17 J 24896 J 33019 J 25008-A J 33020 J 33027 J 25031 J 34614 J 26271-A J 37707 J 29886 J 33011 17. Bearing Remover 18. Compressor Shell Remover, Installer and Holding Fixture 19. Rotor and Bearing Puller with Guide 20.
Page 76 — I - --------...
Page 77: Air Conditioning Compressor
HR-6 AIR CONDITIONING COMPRESSOR 1B4-1 SECTION 1B4 HR-6 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE Description..................................1B4- 1 Minor Repair to the Compressor..........................1B4- 2 Clutch Plate and Hub Assembly Replacement....................1B4- 2 Pulley and Bearing Assembly Replacem ent......................1B4- 5 Clutch Coil and Housing Assembly Replacement....................
Page 78: Minor Repair To The Compressor
1B4-2 HR-6 AIR CONDITIONING COMPRESSOR Figure 1 — HR-6 Compressor, V-Groove Pulley MINOR REPAIR TO THE COMPRESSOR Illustrations show the compressor removed from the Inspect vehicle for easier viewing. Remove only the parts that need servicing. Refer to fig All parts and replace as necessary. ure 3 for part names and location.
Page 79 HR-6 AIR CONDITIONING COMPRESSOR 1B4-3 Shaft Nut Clutch Plate and Hub Assembly Puiley Bearing Retainer Pulley Bearing Pulley Clutch Coil Assembly Through Bolts (6) Shaft Seal Retainer Ring Shaft Lip Seal O-Ring Seal Front Head Head Gasket Valve Plate (Discharge) Suction Reed Plate Cylinder Seal Front Cylinder...
Page 80 1B4-4 HR-6 AIR CONDITIONING COMPRESSOR 2. C lutch Plate and Hub Assem bly 5. Pulley (Rotor) 21. Key 35. Keyway (Shaft) F-04459 Figure 5 — Removing the Shaft Nut Figure 7 — Positioning the Shaft Key, Clutch Plate, and Hub Assembly 2.
Page 81: Pulley And Bearing Assembly Replacement
HR-6 AIR CONDITIONING COMPRESSOR 1B4-5 PULLEY AND BEARING J 33023-A Puller Pilot J 8433-1 Puller Bar ASSEMBLY REPLACEMENT J 33026 Compressor Holding Fixture J 6083 Snap Ring Pliers Remove or Disconnect (Figures 4 ,9 ,1 0 ,1 1 and 12) Pulley (5) on J 21352-A.
Page 82 1B4-6 HR-6 AIR CONDITIONING COMPRESSOR Figure 14 — Staking the Pulley Bearing in the Rotor Bore Stake Three (3) Locations 120° Apart B-06546 Figure 15 — Staking Locations • Strike the staking pin with a hammer until a metal stake, similar to the original, is formed down to, but not touching the bearing.
Page 83: Clutch Coil And Housing Assembly Replacement
HR-6 AIR CONDITIONING COMPRESSOR 1B4-7 J-8433-3 J-33023-A J-8433-3 J-8433-1 J-33017 J-33026 J-33026 5. Pulley (Rotor) 6. Clutch Coil Assem bly A. Mark F-04522 B-06547 Figure 17 — Removing the Clutch Coil Assembly Figure 16 — Installing the Pulley Bearing Assembly —...
Page 84: Major Repair To The Compressor
1B4-8 HR-6 AIR CONDITIONING COMPRESSOR J-33026 6 6. Clutch Coil Assem bly A. Drift Punch 3 mm (1 /s inch) B. Stake in Front Head (3 Places) F-04523 Figure 19 — Staking the Clutch Coil Assembly to the Coil Head Figure 18 —...
Page 85: Shaft Seal Replacement
HR-6 AIR CONDITIONING COMPRESSOR 1B4-9 8. Seal Seat Retainer Ring A. Steel Shell B. Lip Seal B-06551 Figure 21 — Compressor Shaft Seal F-06509 SHAFT SEAL REPLACEMENT Remove or Disconnect (Figures 4, 22, 23 and 24) Figure 22 — Removing or Installing the Shaft Lip Seal Retaining Ring Tools Required: J 5403 Snap Ring Pliers...
Page 86 1B4-10 HR-6 AIR CONDITIONING COMPRESSOR 9. One-Piece Seal A. J 23128-A Seal Remover and Installer B. J 34614 Shaft Seal Protector F-06507 Figure 23 — Removing or Installing the Shaft Tip Seal 10. Shaft Seal Seat O-Ring J 33026 F-06511 Figure 24 —...
Page 87: Compressor Disassembly-Internal Cylinder And Shaft
HR-6 AIR CONDITIONING COMPRESSOR 1B4-11 A. Assem bly Alignm ent Marks 32. High Pressure Relief Valve B-06625 B-06626 Figure 27 — Compressor Alignment Marks Figure 26 — HR-6 Compressor Rear Head Detail COMPRESSOR D IS A S S E M B L Y - INTERNAL CYLINDER AND SHAFT Remove or Disconnect (Figures 4, 27, 28, 29 and...
Page 88: Compressor Assembly-Internal Cylinder And S H A Ft
1B4-12 HR-6 AIR CONDITIONING COMPRESSOR 14. Cylinder seal (15). 15. Suction reed plate (14). 16. Valve plate (13). 17. Head gasket (12). 18. Front head (11). Clean • All parts. Inspect All parts and replace as necessary. COMPRESSOR A SSEM B LY- INTERNAL CYLINDER AND SHAFT + + Install or Connect (Figures 4, 31 through 39)
Page 89 HR-6 AIR CONDITIONING COMPRESSOR 1B4-13 A. Suction Crossover Openings B. Through Bolt Hole (6) C. Suction Port (3) in Valve Plate D. Discharge Crossover Port E. Discharge Ports (In Valve Plate) B-06731 Figure 33 — Installing the Rear Valve Plate 4.
Page 90 1B4-14 HR-6 AIR CONDITIONING COMPRESSOR 52-A A. 12 o’clo c k Reference Position B. T ips o f S uction Reeds M ust Lo cate Above Recess in C ylinder at C. Discharge C rossover Opening 15. C ylinder Seal (Front) B-06735 Figure 36 —...
Page 91: Leak Testing
HR-6 AIR CONDITIONING COMPRESSOR 1B4-15 • Leak test the compressor. • Refer to “ Leak Testing.” 14. Clutch coil assembly (6). 15. Pulley (5). 16. Clutch plate and hub assembly (2). 33026 B-06717 Figure 39 — Installing the Compressor to J 33026 LEAK TESTING Tools Required: •...
Page 92: Specifications
1B4-16 HR-6 AIR CONDITIONING COMPRESSOR indicate one or more suction and/or discharge valves suction port adapter if the compressor is positioned leaking, an internal leak, or an inoperative valve. Dis with the suction port downward. assemble the compressor and repair as necessary. •...
Page 93: Special Tools
HR-6 AIR CONDITIONING COMPRESSOR 1B4-17 J21352-A J 5403 J 33020 J 6083 J 23128-A @ > J 33022 (S Jfo J 33023-A J 8092 J 33024 J 23500-01 J 33025 J 8433-1 J 8433-3 29886 J 8389 J 33011 J 9398-A J 33013-B J 9481-A J 33016...
Page 94 1B4-18 HR-6 AIR CONDITIONING COMPRESSOR 15. Pulley and Bearing Assembly Installer 1. Snap Ring Pliers 16. Hub and Drive Plate Remover and Installer 2. Snap Ring Pliers 3. Driver Handle 17. Cylinder Alignment Rods 18. Pulley and Bearing Assembly Installer 4.
Page 95 SD-709 AIR CONDITIONING COMPRESSOR 1B5-1 SECTION 1B5 SD-709 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE Description................................... 1B5-1 Inspection..................................1B5-1 Compressor Replacem ent............................1B5-1 Disassembly of the Clutch and Shaft S eal.........................1B5-1 Assembly of the Clutch and Shaft S e a l........................1B5-4 Disassembly of the Cylinder Head and Valve Plate....................
Page 96 1B5-2 SD-709 AIR CONDITIONING COMPRESSOR Figure 1 —Date Code Figure 3—Removing the Nut 14. Seal 21. Seal Cage Snap Ring Coil Lead Wire Screw 15. Cylinder Head 22. Shaft O-Ring Seal Clutch Plate and Coil Lead Wire Clamp 16. Cap 23.
Page 97 SD-709 AIR CONDITIONING COMPRESSOR 1B5-3 1. Hex nut using a 19 mm socket. 3. Shaft key (27) by lightly tapping it loose with a slot screw driver and hammer (figure 5). 2. Clutch front plate using J 36045 (figure 4). •...
Page 98: Assembly Of The Clutch And Shaft Seal
1B5-4 SD-709 AIR CONDITIONING COMPRESSOR J 29886 J 37795 F-06174 Figure 9—Removing the Coil Snap Ring Figure 8—Removing the Bearing • Turn the puller center bolt to the right with a ASSEMBLY OF THE socket wrench until the rotor pulley is free (fig CLUTCH AND ure 7).
Page 99 SD-709 AIR CONDITIONING COMPRESSOR 1B5-5 Figure 10—Removing the Felt Ring Metal Retainer J 29886 Driver Handle J 37796 Shaft Protector J 37791 Clutch Front Plate Spanner 1. Field coil and snap ring retainer. • The coil flange protrusion must match the hole in the front housing to prevent coil movement and to correctly place the lead wire.
Page 100: Disassembly Of The Cylinder Head And Valve Plate
1B5-6 SD-709 AIR CONDITIONING COMPRESSOR J 29886 J 37795 F-06180 Figure 14—Installing the Rotor Bearing J 29886 J 37795 Tighten & • Nut the 36 N m (27 ft. lbs.). • Check the air gap with a feeler gauge. It should be 0.49 to 0.79 mm (0.016 to 0.031 inch).
Page 101: Specifications
SD-709 AIR CONDITIONING COMPRESSOR 1B5-7 4. Clean refrigerant oil to the top of the valve plate. 5. Clyinder head (15) and cap screws (11). Tighten & • Screws to 32 N-m (24 ft. lbs.) using the star configuration as shown in figure 17. Figure 17—Torque Sequence F-06182 Figure 16—Loosening the Valve Plate...
Page 102: Special Tools
1B5-8 SD-709 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 37792 J 8433 J 9553 01 J 37793 J 37794 J 29640 J 29886 J 37795 J 36045 J 37796 J 37791 Puller Set 2. O-Ring Hook Shaft Protector Driver Handle Front Plate Puller 6.
Page 103 MANUAL STEERING 3B2-1 SECTION 3B2 MANUAL STEERING GEAR CONTENTS SUBJECT PAGE Description .................................3B2- 1 Saginaw Model 525 ............................3B2- 2 Saginaw Model 535 ............................3B2- 6 Specifications ..............................3B2-10 Adjustment ..............................3B2-10 Fastener Torque ............................3B2-10 Special Tools..............
Page 104 1 - N U T , W O R M B R G . A D J U S T E R LO C K 1 4 - B U SH IN G O R N E E D L E B R G . P IT M A N S H A F T 2 - A D J U S T E R , W O R M T H R U S T B R G .
Page 105 MANUAL STEERING 3B2-3 1. REMOVE AND INSTALL WORM SHAFT SEAL GEAR ASSEMBLED REMOVE IN S T A L L 1. Wrap 0.1 mm to 0.2 mm 1. Install parts a s shown. (.005* to .008*) shim stock around shaft and insert between shaft and seal.
Page 106 3B2-4 MANUAL STEERING REMOVE INSTALL DISASSEMBLE ASSEMBLE L o o s e n lock nut U se p u nch Install parts as sho w n Pry lower bearing retainer P ress cup into adjuster a g a in st e d g e o f slot using Tool A.
Page 107 MANUAL STEERING 3B2-5 6. ADJUST WORM BEARING PRELOAD 7. ADJUST “OVER CENTER” PRELOAD T igh ten w orm b e a rin g ad ju ste r until it bo tto m s then lo o sen o n e-q u arte r turn B a c k o f t p r e l o a d...
Page 108 3B2-6 MANUAL STEERING 1. Worm Bearing Adjuster Locknut 2. Worm Bearing Adjuster Lower Worm Bearing Cup Lower Worm Bearing Lower Bearing Retainer Ball Nut 7. Worm Shaft 8. Upper Worm Bearing Upper worm Bearing Cup Pitman Shaft Seal Housing Worm Shaft Seal 13.
Page 109 MANUAL STEERING 3B2-7 1. REMOVE AND INSTALL WORM SHAFT SEAL GEAR ASSEMBLED REMOVE INSTALL 1. Wrap 0.1 mm to 0.2 mm 1. Install parts as shown. (.005" to 008") shim stock around shaft and insert between shaft and seal. 1" S O C K E T Pry seal out.
Page 110 3B2-8 MANUAL STEERING 3. REMOVE AND INSTALL WORMSHAFT 4. DISASSEMBLE AND ASSEMBLE WORM AND BALL NUT BEARING ADJUSTER REMOVE INSTALL DISASSEMBLE ASSEMBLE 1 . L o o sen lock nut. U se punch 1. Install parts a s shown. Pry lower bearing retainer P ress cup into adjust again st e d g e of slot.
Page 111 MANUAL STEERING 3B2-9 6. REMOVE AND INSTALL PITMAN SHAFT 7. ADJUST WORM BEARING PRELOAD SEALS AND BEARING 1. Tighten worm bearing adjuster until it bottoms then REMOVE loosen one-quarter turn. INSTALL 2. Carefully turn the wormshaft all the way to end of travel 1.
Page 112 3B2-10 MANUAL STEERING SPECIFICATIONS ADJUSTMENT Adjustment Torque to Turn Worm Shaft In. Lbs. Worm Bearing......................... 0.6-1.0 Over Center Preload...................... 0.5-1.2 4-10 In Excess of Worm Bearing Preload Total Steering Gear Preload..................16 max. FASTENER TORQUE SAGINAW MODEL 525 Manual Steering Gear Ft.
Page 113 MANUAL STEERING 3B2-11...
Page 115 POWER STEERING 3B3-1 SECTION 3B3 POWER STEERING CONTENTS SUBJECT PAGE Description ........................3B3- 1 Saginaw Integral Power Steering Gear— RV, G, P, ST, M ........3B3- 1 3B3- 3 Disassembly ........................3B3- 5 Cleaning and Inspection .................... Assembly ........................3B3- 5 Saginaw Integral Power Steering Gear—...
Page 116 3B3-2 POWER STEERING 203. Nut 204. Spring Washer 205. Retaining Ring 207. Washer 208. Seal 209. Bearing 210. Screw 211. Clamp 212. Ball Guide 213. Balls 214. Rack Piston 215. Plug 216. Seal 217. Ring 218. Seal 219. Plug 220. Retaining Ring 221.
Page 117 POWER STEERING 3B3-3 A. Hammer B. Punch 220. Retaining Ring F1805 Figure 2— Unseating the Retaining Ring Figure 5— Removing the Pitman Shaft Bearing equivalent should be used. DO NOT use brake fluid, automatic transmission fluid, or other non-approved flu ids.
Page 118 3B3-4 POWER STEERING Assembly ___________________________________ B6502 Figure 8—Removing the Needle Bearing • Hold the tool against the worm and turn the stub shaft to the left. The rack piston (214) will be forced onto the tool. • Hold the tool and pull the rack piston toward the handle until it is against the flange on the Valve Assembly tool.
Page 119 POWER STEERING 3B3-5 — Adjuster screw (222) threads for wear. The adjuster screw must be free to turn with no V FT H end play. 2. Rack piston. — Worm (248) and rack piston (214) grooves and all balls (213) for scoring. BOTH MUST BE REPLACED as a matched assembly.
Page 120 3B3-6 POWER STEERING A. Mark B. Adjuster Hole A. Guide Halves 213. Balls 251. Stub Shaft B. Petroleum Jelly B6518 B6532 Figure 13—Retaining the Balls In the Ball Guide Figure 16—Marking the Housing • Retain the balls in the guide with petroleum jelly.
Page 121 POWER STEERING 3B3-7 Figure 17— Remarking the Housing Seals A. Torque Wrench B. 12 Point Socket 2 2 2 227. Nut 222. Adjusting Screw 251. Stub Shaft B — F4929 Figure 21— Aligning the Over-Center Preload Figure 18—Aligning the Adjuster Hole with the Second Mark N.
Page 122 3B3-8 POWER STEERING wrench near vertical while turning the wrench The ball nut and control rings (seals) generally need to the left at an even rate (figure 19). If the not be replaced unless cut or damaged. If cut or dam reading is less than 0.45 N-m (4 in.
Page 123 Kty M o. K«r Mo. Nam* P»rt Mam* Kay No. F*rt Mam* 1 — HO U S IN G , STEERING GEAR IB _ PLUG. ADJUSTER — SCREW ASM . LOCKWASHER * (2) 2 — RACE. THRUST BEARING (WORM) 20 — BEARING. NEEDLE —...
Page 124 3B3-10 POWER STEERING REMOVE AND INSTALL PITMAN SHAFT AND SIDE COVER REMOVE INSTALL If pitman shaft and If removed, install side cover are to be gasket seal by separated, remove bending tabs around preload ad|uster nut cover e d ge s Rotate stub shaft to Install parts center gear, then...
Page 125 POWER STEERING 3B3-11 4. REMOVE AND INSTALL ADJUSTER PLUG . 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 Install parts as Use punch against as shown.
Page 126 3B3-12 POWER STEERING 9. REMOVE AND INSTALL PITMAN SHAFT . DISASSEMBLE AND ASSEMBLE RACK PISTON SEALS AND BEARING REMOVE INSTALL DISASSEMBLE ASSEMBLE 1. Coat seal lip and washer face 1. Clean end of housing with anhydrous calcium grease. 1. D isassem ble parts Assem b le parts thoroughly to prevent dirt from entering and be...
Page 127 POWER STEERING 3B3-13 PITMAN SHAFT “OVER-CENTER' 10. REMOVE AND INSTALL CHECK SECTOR ADJUSTMENT VALVE REMOVE I N S T A L L 1 . R em o ve p a rts a s sh o w n . 1. Install parts a s sh o w n With sm all screw d river, pry c h e c k valve from h ou sin g C a r e sh o u ld b e taken not to...
Page 128 3B3-14 POWER STEERING A. Used On Some Models Housing Sleeve Dowel Pin O-Ring Seal Pressure Plate Spring O-Ring Seal Pressure Plate Dowel Pin Vane Rotor Pump Ring O-Ring Seal Thrust Plate Thrust Plate Retaining Ring Return Tube Drive Shaft Seal Drive Shaft Bearing Retaining Ring...
Page 129 POWER STEERING 3B3-15 REMOVING SEAL INSTALLING SEAL 16. Drive Shaft Seal Figure 31—Removing the Fitting, Control Valve, H. Suitable Socket and a Press Spring and Seal F1881 Figure 34— Remove and Install Driveshaft Seal E. Note the position of the large lug. 17.
Page 130 3B3-16 POWER STEERING Vane 13. Thrust Plate 1. Housing Rotor 14. Thrust Plate Retaining Ring 2. Sleeve Pump Ring 3. Dowel Pin 15. Return Tube O-Ring Seal 4. O-Ring Seal 5. Pressure Plate Spring 6. O-Ring Seal 7. Pressure Plate, 8.
Page 131 POWER STEERING 3B3-17 6. O-ring seal (6) (figure 42). 7. Pressure plate (7). Mark top of pressure plate L. Mark Top of directly over the pin hole in the plate. Pressure Plate 8. Dowel pin (8). 6. O-Ring Seal 7. Pressure Plate Important •...
Page 132 3B3-18 POWER STEERING Drive Shaft Seal O-Ring Seal Housing O-Ring Seal Thrust Plate F iller Cap Flow Control Valve Flow Control Spring O-Ring Seal Pump Rotor Shaft Retainer Ring Vane Pump Ring Pressure Plate Pressure Plate Spring 67. Housing End Plate 68.
Page 133 POWER STEERING 3B3-19 14. Pressure plate spring (66). 17. Seal (69). 18. Reservoir (70). 15. End plate (67). 19. Bolt (71). 16. End plate retaining ring (68). 20. Fitting (73). SPECIFICATIONS FASTENER TORQUE Integral Power Steering Gear Pitman Shaft Over Center Preload..................0.6-1.2 N m (6-10 in. lbs.) Pitman Shaft Preload Adjuster Screw Jam Nut..............
Page 134 **1 r ■ » & •■ / : ■ w & - •-, <mv > ■ & * 'v. m m *' ,v - ■ •;< .*•. ■ v*--- •»■ •**»*, « w « i ^ & ant* »r» twe$...
Page 135: Rear Axle
AND 7s/s-INCH RING GEAR AXLES 4B1-1 SECTION 4B REAR AXLE CONTENTS SUBJECT PAGE and 7 /s-inch Ring Gear Axles..........................4B1-1 7 1 / 2 -inch Ring Gear A xle............................... 4B2-1 -inch Ring Gear A xle............................... 4B3-1 -inch Ring Gear A xle............................. 4B4-1 1 0 1 Dana Rear A xles..
Page 136: And 7 5 /S-Inch Ring Gear Axles
4B1-2 7*/2 AND 7 /s-INCH RING GEAR AXLES • Mark the races and the shims as left and right, CHECKING THE AXLE and place them with the bearing caps. BEFORE DISASSEMBLY 11. Differential side bearings using J 8107-2 and J 22888 (figure 3). Inspect •...
Page 137 71 fe AND 7s/s-INCH RING GEAR AXLES 4B1-3 21 22 25 24 / 1 i y f 2123 20 i /I < ® \ 1. Brake Drum 19. Shim 2. Axle Shaft 20. Pinion and Ring Gear Set 3. “ C” Lock 21.
Page 138: Inspection
4B1-4 71 fe AND 7 /a-INCH RING GEAR AXLES Figure 5—Pinion Collapsable Spacer 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. •...
Page 139: Assembly Of The Rear Axle
71/2 AND 75/s-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 which would cause damage to the seals’...
Page 140 4B1-6 7’ fe AND 7s/s-INCH RING GEAR AXLES DIFFERENTIAL CASE ASSEMBLY Tighten £ ♦«- Install or Connect (Figure 1) • Stud nut to 2.2 N m (20 in. lbs.). 6. Rotate the gage plate and bearings several Tools Required: complete revolutions to seat the bearings. J 25299 Differential Side Bearing Installer 7.
Page 141 71/2 AND 7s/s-INCH RING GEAR AXLES 4B1 -7 Figure 10—Checking Pinion Depth • Production shims are cast iron and are not to be 1. Place the case with the bearing cups installed into reused. Measure the production shims and spacers the axle housing (figure 1).
Page 142 4B1-8 71/z AND 7%-INCH RING GEAR AXLES 4.32 MM (0.170-INCH) SERVICE SPACER Total Thickness of Total Thickness of Both Prod. Shims Service Shims To Be Used As A Starting Point Removed 1.52 mm (0.060-inch) 10.57 mm (0.420-inch) 1.78 mm (0.070-inch) 10.92 mm (0.430-inch) 2.03 mm (0.080-inch) 11.18 mm (0.440-inch)
Page 143 71 / 2 AND 7 /8-INCH RING GEAR AXLES 4B1-9 Figure 17—Installing the Differential Bearing Preload Shim 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 144: Gear Tooth Pattern Check
7 1/2 4B1-10 AND 7s/ 8-INCH RING GEAR AXLES 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 means of the side bearing adjusting shims which move the entire case and ring gear assembly closer to, or farther from, the drive pinion.
Page 145: Specifications
71 / 2 AND 7 /s-INCH RING GEAR AXLES 4B1-1 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 71/2 AND 75/s-INCH RING GEAR AXLE FASTENER FT.
Page 146: Special Tools
4B1-12 71 / 2 AND 7%-INCH RING GEAR AXLES SPECIAL TOOLS J 7817 J 23911 J 25299 J 7818 J 8107-2 J 25320 J 8092 10 . J 8614-01 J 8001 J 22888 J 5590 1. Front Pinion Bearing Cup Installer 2.
Page 147 -INCH RING GEAR 4B2-1 SECTION 4B2 8 V 2 -INCH r i n g g e a r CONTENTS SUBJECT PAGE Description....................4B 2- 1 Checking the Axle Before Disassembly..........4B2- 1 Disassembly of the Rear A xle.............. 4B 2- 1 C le a n in g ....................
Page 148 4B2-2 1 / 2-INCH RING GEAR 1. Axle Housing 21. Pinion Gear 22. Side Gear 2. A ir Vent 23. Ring Gear Bolt 3. Plug 24. Differential Case 4. Collapsable Spacer 5. Inner Pinion Bearing 25. Nut 6. Shim 26. Washer 27.
Page 149 -INCH RING GEAR 4B2-3 • Refer to “ Checking the Axle Before Disassembly” in Insoect this section. • Drive pinion bearing preload (figure 4). 4. Pinion shaft lock screw (15). • For looseness of pinion assembly by moving it 5. Pinion shaft (17). back and forth.
Page 150 4B2-4 'fe-INCH RING GEAR Figure 5—Removing the Drive Pinion Nut 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 151 -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 Inspect Pinion and ring gear teeth for cracking, chipping, scoring, or excessive wear.
Page 152 4B2-6 -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 153 -INCH RING GEAR 4B2-7 A. Dial indicator and arbor positioned on the gage block. B. Measurement after the arbor is moved off of the gage block. ^ A F-04682 Figure 13—Checking Pinion Depth Tighten tightening. Each tightening increases the bearing preload by several pounds. If the The nut until the pinion end play is just taken bearing preload is exceeded, the pinion will up.
Page 154 4B2-8 1 / 2-INCH RING GEAR Tighten DIFFERENTIAL CASE ASSEMBLY • The ring gear bolts in sequence to 80 N m (60 Install or Connect (Figure 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 155 -INCH RING GEAR 4B2-9 Figure 19—Installing the Side Bearing Figure 21—Measuring Side Bearing Shim Requirements • 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.
Page 156 4B2-10 -INCH RING GEAR 11. For an initial backlash setting, move the ring gear 8. If the backlash is not within specifications, move the 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 thickness of one shim , and decreasing the to the shim pack on the opposite side.
Page 157 -INCH RING GEAR 4B2-11 ADJUSTMENTS AFFECTING TOOTH CONTACT Two adjustments 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 158 4B2-12 1 / 2-INCH RING GEAR SPECIFICATIONS 81/2-INCH RING GEAR AXLE FASTENER FT. LBS. Ring Gear Bolts..........................Bearing Cap Bolts........................Axle Cover B olts........................SPACER AND SHIM SIZES SIZE Differential Side Bearing Spacer..........................0.170-inch Differential Side Bearing Shim K its......................0.064-0.070-inch 0.072-0.078-inch 0.080-0.086-inch 0.088-0.094-inch...
Page 159 1 / 2-INCH RING GEAR 4B2-13 SPECIAL TOOLS J 8611-01 J 8608 J 22888 r v > l 1 i J8612-B J 22399 J 8092 10 . J 22761 J 8001 J 8609-01 J 22779 J 5590 J 8614-01 J 8107-4 11.
Page 161 -INCH RING GEAR 4B3-1 SECTION 4B3 9 1 /2-INCH r in g g e a r CONTENTS SUBJECT PAGE Description..................................4B3- 1 Checking the Axle Before Disassembly........................ 4B3- 1 Disassembly of the Rear Axle..........................4B3- 1 Cleaning..................................4B3- 4 Inspection.................................. 4B3- 4 Assembly of the Rear A x le .............................
Page 162 4B3-2 -INCH RING GEAR 26. Ring Gear Bolt 1. Brake Drum 27. D ifferential Case 14. Shim 2. Wheel Stud 28. Pinion Shaft 15. Ring and Pinion Gear Set 3. Axle Shaft 29. Pinion Shaft Lock Screw 16. A djusting Nut Lock 4.
Page 163 9V2-INCH RING GEAR 4B3-3 NOTICE: Do not pry the ring gear from the case. This w ill damage the ring gear and the differential case. 15. Ring gear (15) from the differential. • Drive the ring gear off with a brass drift if necessary.
Page 164 4B3-4 -INCH RING GEAR INSPECTION It is very important to carefully and thoroughly inspect all drive unit parts before reassembly. Thorough inspection of the drive parts for wear or stress and subsequent replacement of worn parts will eliminate costly drive component repair after reassembly. AXLE HOUSING Inspect •...
Page 165 /2-INCH RING GEAR 4B3-5 Figure 9—Instaiiing the Front Pinion Bearing Cup • 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 166 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 number on the dial indicator and not the number which represents how far the needle travels.
Page 167 9V2-INCH RING GEAR 4B3-7 Figure 14—installing the Pinion Inner Bearing PINION INSTALLATION Install or Connect Tools Required: J 22388 Pinion Oil Seal Installer J 22804-1 Pinion Oil Seal Spacer J 5590 Rear Pinion Bearing Cone Installer • The bearing cups should have been installed in “...
Page 168 4B3-8 9 fe-INCH RING GEAR tightening. Each tightening increases the bearing preload by several pounds. If the bearing preload is exceeded, the pinion will have to be removed, and a new collapsible spacer installed. • Once the preload has been obtained, rotate the pinion several times to assure that the bearings have seated.
Page 169 /2-INCH RING GEAR 4B3-9 8. Differential case (27) to the axle housing. Refer to BACKLASH ADJUSTMENT “ Side Bearing Preload Adjustment” in this section. 1. Install a dial indicator to the case using a magnetic base. SIDE BEARING PRELOAD ADJUSTMENT 2.
Page 170 4B3-10 91 / 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 means of the side bearing adjusting shims which move the entire case and ring gear assembly closer to, or farther from, the drive pinion.
Page 171 -INCH RING GEAR 4B3-11 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 172 4B3-12 9 /2-INCH RING GEAR SPECIFICATIONS 91/2-INCH RING GEAR AXLE FASTENER FT. LBS. Ring Gear Bolts.... Bearing Cap Bolts..Axle Cover B o lts..Adjusting Nut Lock Bolt SPACER AND SHIM SIZES SIZE Differential Side Bearing Spacer 0170 ■inch 0.040-0.044 -inch Differential Side Bearing Shim Kits 5 59 mm (0.220- nch) 5.64 mm (0.222- nch)
Page 173 91 / 2-INCH RING GEAR 4B3-13 SPECIAL TOOLS J-8107-3 J-8092 J-8001-M J-22804-1 J-24429 J-29710 10 . J-22912-01 J-22888 11 . J-24433 J-5590 J-7817 J-22388 J-8614-01 1. Differential Side Bearing Plug 2. Pinion Oil Seal Spacer Refer to Figure 53 for these tools: 3.
Page 174 ......—...
Page 175 /2-INCH RING GEAR 4B4-1 SECTION 4B4 1 0 1/2-INCH RING GEAR CONTENTS SUBJECT PAGE D escrip tion ................................4B4- 1 Checking the Axle Before Disassembly........................ 4B4- 1 Disassembly of the Rear A xle..........................4B4- 2 C le a n in g ..................................4B4- 2 Inspection..................................
Page 176: 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). |<"»| Remove or Disconnect (Figure 1) •...
Page 177 10 1 -INCH RING GEAR 4B4-3 Pinion Pilot Bearing Axle Vent Tube Axle Housing Differential Side Bearing Bearing Adjusting Nut Bearing Cap Adjusting Nut Lock Bolt Gasket Cover Bolt Brake Line Clip Washer Bolt Side Gear Side Gear Thrust Washer Pinion Gear Thrust Washer 32.
Page 178 4B4-4 101 / 2-INCH RING GEAR Figure 4—Removing the Pinion Cage Figure 7—Pressing the Drive Pinion from the Cage...
Page 179: Assembly Of The Rear Axle
/2-INCH RING GEAR 4B4-5 BEARINGS PINION AND RING GEAR Inspect Inspect Bearings visually and by feel. Pinion and ring gear teeth for cracking, chipping, scoring, or excessive wear. The bearings should feel smooth when oiled and rotated while applying as much hand pressure as Pinion splines for wear.
Page 180 4B4-6 101 / 2-INCH RING GEAR PINION INSTALLATION 2. Outer pinion bearing cup (6) using J 8608 and J 8092. Install or Connect 3. Inner pinion bearing cup (13) using J 24432 and Tools Required: J 8092. J 34943 Pinion Pilot Bearing Installer 4.
Page 181 10 1 -INCH RING GEAR 4B4-7 Figure 16—Installing the Ring Gear to Case 2. Differential side gears (29) and thrust washers (30) to the differential case halves in their original C O D E NUMBER O N ORIGINAL PINION locations. 3.
Page 182 4B4-8 -INCH RING GEAR T ighten • Do not tighten. Tighten the right adjusting nut firmly to force the • The ring gear bolts in sequence to 163 N-m case into solid contact with the left adjusting nut. (120 ft. lbs.). Rotate the pinion several times to seat the bearings.
Page 183: Gear Tooth Pattern Check
lO ’ fe-INCH RING GEAR 4B4-9 4. Expand the brake shoes until a torque of 40 to 50 ft. 5. If the reading is too high, remove the adjusting nut lbs. is required to turn the pinion. locks, and loosen the right nut one slot, and tighten A test made without loading the gears will not give a the left nut one slot (figure 18).
Page 184 4B4-10 101 / 2-INCH RING GEAR 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 185: Specifications
-INCH RING GEAR 4B4-11 SPECIFICATIONS 10V2-INCH RING GEAR AXLE (CORPORATE) FASTENER FT. LBS. Ring Gear Bolts.......................... Bearing Cap Bolts........................Axle Cover B olts........................Adjusting Nut Lock B o lts ......................SPACER AND SHIM SIZES SIZE Pinion Bearing Shims................0.006- nch 0.007- nch 0.008- nch...
Page 186: Special Tools
4B4-12 101 /2-INCH RING GEAR SPECIAL TOOLS J 8614-01 J 8092 J 22888 J 24433 J 8608 J 24429 1. Pinion Flange Remover 2. Side Bearing Remover 3. Rear Pinion Bearing Cup Installer 4. Driver Handle 5. Rear Pinion Bearing Cone Installer 6.
Page 187 DAN A REAR AXLES 4B5-1 SECTION 4B5 DANA REAR AXLES CONTENTS SUBJECT PAGE -lnch Ring G e a r..............................4B5- 1 Description................................4B5- 1 Checking the Axle Before Disassembly........................ 4B5- 1 Diassembly of the Rear Axle........................... 4B5- 2 Cleaning..................................4B5- 2 Inspection..................................
Page 188: Cleaning
4B5-2 DANA REAR AXLES Determine the cause of the axle problem before 12. Lock pin (29) from the differential using a hammer and a punch (figure 8). disassembly if possible. 13. Pinion shaft (28) using a hammer and a brass drift DISASSEMBLY OF THE (figure 9).
Page 189 DANA REAR AXLES 4B5-3 . Axle Housing . Washer . D ifferential Case 23. Ring Gear Bolt . Ring Gear and Pinion Set . Pinion Nut 24. Pinion Gear 3. Inner Pinion Bearing 14. Cover 16. Plug 25. Side Gear 4.
Page 190 4B5-4 DANA REAR AXLES Figure 4—Spreading the Differential Case Figure 7—Removing the Ring Gear...
Page 191 DANA REAR AXLES 4B5-5 F-04762 Figure —Removing the Drive Pinion Nut Figure 9—Removing the Pinion Shaft Figure 13—Removing the Pinion Flange Figure 10—Removing the Pinion Gears...
Page 192 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 193: Assembly Of The Rear Axle
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 . New ring gear bolts (23) (figure 19). • Shims for cracks and chips. Damaged shims should •...
Page 194 4B5-8 DANA REAR AXLES 2. Mount a dial indicator having a minimum travel of PINION DEPTH ADJUSTMENT -inch with a magnetic base on the ring gear Tools Required: bolt side of the housing (figure D-120 Master Pinion Block (Miller) 3. Force the differential assembly as far as possible in D-116-1 Pinion Height Block (Miller) the direction towards the indicator.
Page 195 DANA REAR AXLES 4B5-9 Figure 24—Pinion Height Block Figure 27—Measuring the Shims . Record the reading at the point of greatest deflection (when the dial indicator needle is centered between movement to the left and to the right). • This reading indicates the amount of shims needed for a nominal pinion setting.
Page 196 4B5-10 DANA REAR AXLES F-04719 Figure 30—Installing the Inner Bearing Drive the inner bearing cup into the axle assembly 9. Pinion depth checking tools D-116-1, D-116-2, using D-111 and C-4171. The cup must be seated on D-115-3, and D-115 to the top of the pinion. the shims (figure 28).
Page 197 DANA REAR AXLES 4B5-11 Figure 32—Checking the Pinion Depth Setting ASSEMBLING THE DIFFERENTIAL TO THE AXLE • Remove the pinion nut ( ), washer ( ), pinion HOUSING flange (10), slinger ( ) and bearing cone (7). Tools Required: 10. Preload shims ( J 23690 Differential Side Bearing Installer •...
Page 198 4B5-12 DANA REAR AXLES 7. Remove the indicator and the differential case from 12. Assemble J 24385-01 to the axle housing as shown the carrier. in figure 38. 13. Assemble the dial indicator as shown in figure 38. . Remove the master bearings from the differential Preset the gage at least 0.020-inch, and then rotate case.
Page 199: Description
DANA REAR AXLES 4B5-13 Figure 41—Installing the Axle Cover Figure 40—Measuring Backlash . To adjust the backlash, the differential case must be Tighten removed from the housing, then the differential • The bearing cap bolts (19) to 115 N m (85 ft. bearings removed, and the proper number of shims lbs.).
Page 200 4B5-14 DANA REAR AXLES 30. Bolt 16. Plug . Axle Housing 31. Nut 17. Bolt . Ring and Pinion Gear Set 32. Hub Seal 18. Bearing Cap 3. Bearing 33. Bearing 19. B olt 4. Shims 34. Bearing . Bearing 5.
Page 201: Disassembly Of The Rear Axle
DANA REAR AXLES 4B5-15 Figure 44— Removing the Bearing Cap All Dana axles are identified by the part number on the 3. Bearing cap bolts (19) (figure 44). right axle tube next to the carrier. The model number is 4. Bearing caps (18). •...
Page 202 4B5-16 DANA REAR AXLES Figure 46—Removing the Differential Lock pin (29) from the differential using a hammer 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.
Page 203 DANA REAR AXLES 4B5-17 F-04762 F-04693 Figure 53—Removing the Drive Pinion Nut Figure 50—Removing the Pinion Shaft 17. Pinion flange (10) using J 8614-01 (figure 54). 18. Pinion (2) from the carrier using a rawhide hammer to tap the pinion (figure 55). 19.
Page 204: Cleaning
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 disassembled before cleaning. Parts should be thoroughly dried immediately after cleaning.
Page 205 DANA REAR AXLES 4B5-19 Figure 59—Installing the Lock Pin 3. Pinion gears (24) to the differential without the thrust BEARINGS 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 206 4B5-20 DANA REAR AXLES Figure 60—Installing the Ring Gear Bolts DETERMINING TOTAL DIFFERENTIAL SHIM 7. Remove the dial indicator from the axle. PACK SIZE — B OR U MODEL . Remove the differential case from the axle housing. 1. Assemble the differential case (22) to the axle •...
Page 207 DANA REAR AXLES 4B5-21 Figure 65—Pinion Height Block Figure 63—Master Pinion Block D-115 Scooter Gage (Miller) . 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.
Page 208 4B5-22 DAN A REAR AXLES • This reading indicates the amount of shims Drive the inner bearing cup into the axle assembly needed for a nominal pinion setting. The using C-4204 and C-4171. The cup must be seated pinion marking may change the pinion depth on the shims (figure 69).
Page 209 DANA REAR AXLES 4B5-23 F-04721 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 amount the indicator needle is from the pinion times to seat the bearings and assure a more marking.
Page 210 4B5-24 DANA REAR AXLES . Force the differential case away from the pinion • Remove shims to increase the preload. gear to obtain an indicator reading. Repeat this • Add shims to decrease the preload. action until a consistant reading is obtained. 7.
Page 211 DANA REAR AXLES 4B5-25 . Place the proper shims on the differential side bearing hub (opposite the ring gear) and drive the differential bearing onto the hub using J 23690 and J 8092. • If installing a new bearing, be certain that it is the same width as the old bearing.
Page 212 4B5-26 DAN A REAR AXLES 1. Assemble the differential case (22) with master 20. Drive the outboard spacers (43) into the proper bearings installed to the axle housing. The pinion sides using C-4205 and C-4171. must be installed. 21. Remove the spreader. 2.
Page 213 DANA REAR AXLES 4B5-27 SPECIFICATIONS 93/4-INCH r in g g e a r a x l e FASTENER FT. LBS. Ring Gear Bolts..........................Bearing Cap Bolts......................... Axle Cover B o lts........................... SIZE Differential Bearing Adjusting S h im ......................... 0.003-inch 0.005-inch -inch 0.030-inch...
Page 214 4B5-28 DANA REAR AXLES SPECIAL TOOLS D-116-2 < g = ® 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 ifferential Side Bearing Removal Plug 1. Master Discs (Miller) 10. Rear Pinion Bearing Cup Installer 2.
Page 215 DANA REAR AXLES 4B5-29 SPECIAL TOOLS 10 . D-116-2 J-8107-3 D-115-3 11 . J-8092 D-116-1 J-7817 D-115 J-5590 D-136 or D-117 J-8614-01 (Heavy Duty Axles) D-120 J-23690 C-4204 J-29721 C-4171 J-24385-01 4205 J-29721-70 10. D ifferential Side Bearing Remover Plug 1.
Page 216 -----...
Page 217 12-INCH RING GEAR (ROCKWELL) 4B6-1 SECTION 4B6 12-INCH RING GEAR (ROCKWELL) CONTENTS SUBJECT PAGE Description................................4B6- 1 Disassembly of the Rear Axle..........................4B6- 1 Cleaning..................................4B6- 5 Inspection.................................. 4B6- 5 Assembly of the Rear A x le............................. 4B6- Specifications................................4B6-10 Special Tools................................4B6-11 The differential is used to allow the wheels to turn at DESCRIPTION different rates of speed while the rear axle continues to...
Page 218 4B6-2 12-INCH RING GEAR (ROCKWELL) Figure 1—Rear Axle Components...
Page 219 12-INCH RING GEAR (ROCKWELL) 4B6-3 . Bolt . Axle Vent 43. Side Gears . Washer 23. Bolt 44. Bolt 3. Hub Cap 24. Washer 45. Washer 4. Gasket 25. Bearing Cap 46. Carrier 5. Axle Shaft 26. Nut 47. Bolt .
Page 220 4B6-4 12-INCH RING GEAR (ROCKWELL) F-04758 F-04770 Figure —Removing the Bearing Cap F-04766 Figure 7—Removing the Differential Figure 10—Removing the Differential Side Bearing...
Page 221 12-INCH RING GEAR (ROCKWELL) 4B6-5 Figure 13—Removing the Pinion Cage 16. Pinion shaft nut (62) and washer (61) using J 3453 CLEANING to hold the pinion yoke (figure 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 222: Assembly Of The Rear Axle
4B6-6 12-INCH RING GEAR (ROCKWELL) 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 223 12-INCH RING GEAR (ROCKWELL) 4B6-7 Figure 18—Removing the Pinion Nut 12. Pinion washer (61) and a new nut (62) using J 3453 — Divide the diameter by 2 to find the radius in to hold the pinion (figure 17). inches. —...
Page 224 4B6-8 12-INCH RING GEAR (ROCKWELL) Figure 20—Differential Components 3. Cage bolts (56). Tighten • Bolts (44) to 61 N-m (45 ft. lbs). Tighten • Check that the mating surfaces of the differential • Bolts to 48 N-m (35 ft. lbs.). case and the ring gear are clean and burr free.
Page 225 12-INCH RING GEAR (ROCKWELL) 4B6-9 • Press the bearings on using a suitable tool. DIFFERENTIAL INSTALLATION |-»<-| Install or Connect 1. Bearing cups (33) to the carrier (36). 2. Adjusting nuts (32). 3. Bearing caps (25). 4. Cap bolts (23). Tighten •...
Page 226: Specifications
4B6-10 12-INCH RING GEAR (ROCKWELL) 2. Drive axles. Refer to the proper service manual. FINAL ASSEMBLY 3. The axle housing to the v ehicle. Refer to the proper -n - Install or Connect service manual. 4. Lubricant to the rear axle. 1.
Page 227: Special Tools
12-INCH RING GEAR (ROCKWELL) 4B6-11 SPECIAL TOOLS Special Tools...
Page 228 rO'&ta&i ocmi-...
Page 229 4B7-1 SECTION 4B7 LOCKING DIFFERENTIAL CONTENTS SUBJECT PAGE Locking Differentials..............................4B7- 1 -lnch Ring G ear........................4B7- 1 -lnch Ring G e a r..............................4B7- 5 1 0 1 Specifications................................4B7- 9 Special Tools................................4B7-10 LOCKING DIFFERENTIALS CAM UNIT DISASSEMBLY - 91 /2-INCH 7 1/2, 81/2 AND 91/2-INCH 7 5ls,...
Page 230 4B7-2 LOCKING DIFFERENTIALS Pinion Thrust Washer Cam Plate Pinion Gear Thrust Block -lnch Ring Gear Side Gear Thrust Washer Pinion Shaft -lnch Ring Gear Clutch Plates Guide Clip -lnch Ring Gear Side Gear Guide Clip . D ifferential Case Latching Bracket Side Cam Gear 2.
Page 231 LOCKING DIFFERENTIALS 4B7-3 CAM UNIT ASSEMBLY - 71 /2 AND 8 V -INCH ADJUSTMENT OF THE DIFFERENTIAL • If it is necessary to replace the cam gear, the right Install or Connect side gear, or the thrust block, the entire differential must be adjusted.
Page 232: 010 -Inch
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 233 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 234 4B7-6 LOCKING DIFFERENTIALS 37. Plates 43. Governor and Latching Bracket 31. D ifferential Case Halves 44. Plates 32. Screw 38. Pinion Thrust Washer 39. Pinion Gear 45. Side Gear Thrust Washer 33. Cam Plate 34. Guide Clip 40. Side Cam Gear 46.
Page 235 LOCKING DIFFERENTIALS 4B7-7 • There are three adjustments to be made: (1) Left side gear backlash. (2) Right side gear backlash. (3) Thrust block clearance. Right Side Gear Blacklash Adjustment 1. Install the cam unit and thrust washer (36) to the right case half.
Page 236 4B7-8 LOCKING DIFFERENTIALS . Pull the pinion gear firmly 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 237: Lubricant
LOCKING DIFFERENTIALS 4B7-9 5. Left side gear (46) . Case halves (31) together. . Latching bracket assembly (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 238 4B7-10 LOCKING DIFFERENTIALS SPECIAL TOOLS Special Tools...
Page 239: Front Axle
4C1-1 SECTION 4C FRONT AXLE CONTENTS SUBJECT PAGE -lnch Ring Gear Front Axle............................. 4C1-1 -lnch Ring Gear Front Axle............................. 4C2-1 T Truck Front A x le ................................4C3-1 K Truck Front A x le ................................4C4-1 L Van Front A x le .................................4C5-1 SECTION 4C1 8 V 2 -INCH RIN G G E A R CONTENTS...
Page 240: Disassembly Of Axle
4C1-2 1/2-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 241 -INCH RING GEAR 4C1-3 . Side Gear . Axle Housing 11. Gasket 23. Ring Gear Bolt . A ir Vent 12. Cover 24. D ifferential Case 4. Collapsable Spacer 14. Bolt 28. Axle Shaft Seal 5. Inner Pinion Bearing 15. Pinion Shaft Lock Screw 35.
Page 242 4C1-4 1/2-INCH RING GEAR • 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. Figure 6—Pinion Flange Removal...
Page 243: Cleaning And Inspection
1 /2-INCH RING GEAR 4C1-5 CLEANING AND INSPECTION PINION AND RING GEAR CLEANING Inspect • Do not steam clean drive parts having ground and Pinion and ring gear teeth for cracking, chipping, polished surfaces such as gears, bearings, and scorring, or excessive wear. shafts.
Page 244: Assembly Of Axle
4C1-6 -INCH RING GEAR ASSEMBLY OF AXLE Figure 9 —Installing Front Pinion Bearing Cup Important 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 INSTALLATION...
Page 245: Pinion Installation
-INCH RING GEAR 4C1-7 PINION INSTALLATION Install or Connect Tools Required: J 8609-01 Rear Pinion Bearing Cone Installer J 22388 Pinion Oil Seal Installer J 8614-01 Pinion Flange Remover J 5590 Rear Pinion Bearing Cone Installer • The bearing cups should have been installed in “...
Page 246 4C1-8 1/2-INCH RING GEAR Dial indicator and arbor positioned on the gage block. Measurement after the arbor is moved o ff of the gage block. L____ F-04682 Figure 13—Checking Pinion Depth J 22761 Differential Side Bearing Installer • Rotate the pinion gears toward the differential Lubricate all parts with rear axle lubricant.
Page 247: Side Bearing Preload Adjustment
-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). 7.
Page 248: Backlash Adjustment
4C1-10 1/2-INCH RING GEAR Figure 20—Installing Side Bearing Gaging Tools Figure 22—Measuring the Gage Plate Thickness • Support the case to keep it from falling into the • Push the feeler gage downward so that it axle housing. contacts the shim at the top and bottom, and then contacts the axle housing.
Page 249: Gear Tooth Contact Pattern Check
-INCH RING GEAR 4C1-11 thickness of the other shim by the same amount. Tighten 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 250: Final Assembly
4C1-12 -INCH RING GEAR LOW FLANK CONTACT DECREASE PINION SHIM TOE CONTACT INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM F-02018 Figure 26—Gear Tooth Contact Pattern 4. Apply a load until a torque of 54-70 N-m (40-50 ft. Backlash is adjusted by means of the side bearing lbs.) is required to turn the pinion.
Page 251: Fastener N-M Ft. Lbs
-INCH RING GEAR 4C1-13 SPECIFICATIONS 81/2 INCH RING GEAR FRONT AXLE TORQUE SPECIFICATIONS Fastener Ft. Lbs. Ring Gear B olts... Bearing Cap Bolts. Axle Cover Bolts .. AVAILABLE SHIM AND SPACER SIZES Differential Side Bearing Spacer......................0.170-inch-0.172-inch Differential Side Bearing Kits.........................0.064 - 0.070-inch 0.040 - 0.044-inch 0.046 - 0.050-inch 0.052 - 0.056-inch...
Page 252: Special Tools
4C1-14 1/2-INCH RING GEAR SPECIAL TOOLS J 8608 J 8611-01 J 22888 J 8612-B J 22399 J 8092 10 . J 22761 J 8001 J 22779 J 8609-01 J 5590 J 8614-01 J 8107-4 11. Differential Side Bearing Installer 1. Front Pinion Bearing Cup Installer 12.
Page 253 4C2-1 SECTION 4C2 9 3/4-INCH r in g g e a r f r o n t a x le CONTENTS SUBJECT PAGE Description....................................4C2- 1 Disassembly of A x le ................................4C 2- 2 inspection.................................... 4C 2- 2 Disassem bly..................................4C 2- 2 Cleaning and Inspection...............................4C 2- 7 C le a n in g ....................................4C 2- 7 Inspection.....................................4C 2- 7...
Page 254: 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 disassembling the •...
Page 255 /4-INCH RING GEAR FRONT AXLE 4C2-3 1. Axle Housing 11. Washer 22. D ifferential Case 2. Ring Gear and Pinion Set 12. Pinion Nut 23. Ring Gear Bolt 3. Inner Pinion Bearing 14. Cover 24. Pinion Gear 4. Shims 15. Spacer 25.
Page 256 4C2-4 93/4-INCH RING GEAR FRONT AXLE F-04756 Figure 4—Spreading the Differential Case Figure 7—Removing the Ring Gear...
Page 257 /4-INCH RING GEAR FRONT AXLE 4C2-5 Figure 13—Pinion Flange Removal Figure 10—Removing the Pinion Gears...
Page 258 4C2-6 9 /4-INCH RING GEAR FRONT AXLE Figure 16—Removing the Pinion Inner Bearing...
Page 259: Cleaning And Inspection
/4-INCH RING GEAR FRONT AXLE 4C2-7 CLEANING AND INSPECTION PINION AND RING GEAR CLEANING Inspect Do not steam clean drive parts having ground and Pinion and ring gear teeth for cracking, chipping, polished surfaces such as gears, bearings, and shafts. scoring, or excessive wear.
Page 260: Lubricant
4C2-8 93/4-INCH RING GEAR FRONT AXLE ASSEMBLY OF AXLE F-05783 Figure 17—Installing the Axle Shaft Seals Figure 19—Installing the Lock Pin Important 4. Pinion gears (24) to the differential without the thrust washers (26). Lubricate all seal lips, bearings, gears, and bearing •...
Page 261: Determining Total Differential Shim Pack Size
/4-INCH RING GEAR FRONT AXLE 4C2-9 Figure 22—Determining Differential Shim Pack Figure 20—Installing the Ring Gear Bolts 6. Force the differential assembly in the opposite • Refer to “ Determining Total Shim Pack Size” in this direction as far as it will go. Repeat this step until section.
Page 262 4C2-10 9 /4-INCH RING GEAR FRONT AXLE • This reading indicates the amount of shims needed for a nominal pinion setting. The pinion marking may change the pinion depth by adding or deleting shims from the nominal pinion setting. • A positive ( + ) pinion marking indicates that the distance between the ring gear centerline and the pinion head must increase by the number of thousandths marked on the pinion.
Page 263: Pinion Installation
/4-INCH RING GEAR FRONT AXLE 4C2-11 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 264 4C2-12 93/4-INCH RING GEAR FRONT AXLE torque of 1.13 N-m (10 in. lbs.) to rotate the specifications, change the shim pack by the pinion (figure 32). Rotate the pinion several amount the indicator needle is from the pinion times to seat the bearings and assure a more marking.
Page 265 /4-INCH RING GEAR FRONT AXLE 4C2-13 Figure 38—Installing the Differential Bearings 5. With the force still applied to the differential case, • Add shims to increase the preload. set the dial indicator to zero. 6. Force the differential case away from the pinion ASSEMBLING THE gear to obtain an indicator reading.
Page 266: Checking Backlash
4C2-14 9 /4-INCH RING GEAR FRONT AXLE Figure 39—Mounting the Carrier Spreader • Use a rawhide hammer to seat the differential 4. High backlash is corrected by moving the ring gear assembly in the axle housing (figure 40). closer to the pinion. 5.
Page 267: Differential Bearing Adjusting S H Im
/4-INCH RING GEAR FRONT AXLE 4C2-15 SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Ft. Lbs. Ring Gear Bolts..........................Bearing Cap Bolts......................... Axle Cover B o lts........................... AVAILABLE SHIM SIZES . .0.003- nch Differential Bearing Adjusting S h im ......................0.005- nch 0.010- nch 0.030- nch .
Page 268: Special Tools
4C2-16 9 /4-INCH RING GEAR FRONT AXLE SPECIAL TOOLS D-116-2 D-115-3 J-8092 D-116-1 J-5590 D-115 J-8614-01 J-23690 D-117 J-29721 D-120 J-24385-01 D-111 J-29721-70 C-4171 J-8107-03 J-7818 9. Differential Side Bearing Removal Plug 1. Master Discs (Miller) 10. Rear Pinion Bearing Cup Installer 2.
Page 269 T TRUCK FRONT AXLE 4C3-1 SECTION 4C3 T TRUCK FRONT AXLE CONTENTS SUBJECT PAGE Description..................................4C3- 1 Disassembly of A x le ..............................4C3- 2 Inspection.................................. 4C3- 2 Disassembly................................4C3- 2 Cleaning and Inspection..............................4C3- 7 Cleaning..................................4C3- 7 Inspection.................................. 4C3- 7 Assembly of Axle................................
Page 270: 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 disassembling the Bearings (30) from the sleeves (32).
Page 271 T TRUCK FRONT AXLE 4C3-3 Figure 1—Axle Components...
Page 272 4C3-4 T TRUCK FRONT AXLE 1. Shaft 16. Spring 31. Insert 46. Nut 2. D eflector 17. Shift Shaft and Fork 32, Sleeve 47. Plug 3. Seal 18. Bolt 33. Side Bearing 48. Bushing 4. Bearing 19. Lock Tab 34. Bolt 49.
Page 273 T TRUCK FRONT AXLE 4C3-5 30. Bearing 32. Sleeve J-21551 F-01782 Figure 9—Remove the Sleeve Bearing Figure 6—Separating the Carrier Case Halves Figure 7—Removing the Lock Tabs F-05788 Figure 10—Removing the Pinion Nut Figure 8—Removing the Side Bearing Cup...
Page 274 4C3-6 T TRUCK FRONT AXLE J-33791-2 Figure 13—Removing the Inner Pinion Bearing Cup 95. Carrier Assembly F-01670 Figure 15—Replacing the Case Bushings...
Page 275: Cleaning And Inspection
T TRUCK FRONT AXLE 4C3-7 CLEANING AND INSPECTION BEARINGS CLEANING Inspect Do not steam clean drive parts having ground and • Bearings visually and by feel. The bearings should polished surfaces such as gears, bearings, and shafts. feel smooth when oiled and rotated while applying These parts should be cleaned in a suitable solvent.
Page 276: Assembly Of Axle
4C3-8 T TRUCK FRONT AXLE ASSEMBLY OF AXLE Important • Lubricant all the seal lips, bearings, gears, and bearing surfaces with axle lubricant prior to assem bly. J 33790 DIFFERENTIAL CASE ASSEMBLY -► «- Install or Connect (Figures 1, 2 and 16) Tool Required: J 33790 Side Bearing Installer 1.
Page 277: Pinion Depth Adjustment
T TRUCK FRONT AXLE 4C3-9 1. Rotate the pinion with the torque wrench and PINION DEPTH ADJUSTMENT observe the reading. 2. If the preload torque is below specifications, Tools Required: continue to rq u in g the pinion nut in sm all J 33838 Pinion Depth Setting Gage increm ents.
Page 278 4C3-10 T TRUCK FRONT AXLE A. Button Located in Bearing Bore B. Button Moved Out of Bearing Bore F-05791 Figure 19—Measuring Pinion Depth...
Page 279 T TRUCK FRONT AXLE 4C3-11 J 33785 J 33788 F-01789 " F-01791 Figure 20—Installing the Pinion Bearing Figure 23—Installing the Sleeve Bearing 6. Turn the left adjusting sleeve IN one notch using F-01781 J 33792. 7. Rotate the pinion several times to seat the bearings. Figure 24—Adjusting the Sleeve 8.
Page 280 4C3-12 T TRUCK FRONT AXLE Carrier Case Sleeve Mark Location on the Case F-01830 Figure 26—Marking Sleeve Location 10. Check and record the backlash at three or four points around the ring gear. • The pinion must be held stationary when checking backlash.
Page 281: Gear Tooth Contact Pattern Check
T TRUCK FRONT AXLE 4C3-13 ADJUSTMENTS AFFECTING TOOTH CONTACT Two adjustments can be made which will affect the tooth contact 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 282 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 Tighten 14. Thrust washer (20). Use grease to hold it in place. 15.
Page 283 T TRUCK FRONT AXLE 4C3-15 Figure 33—Installing the Differential Pilot Bearing ( P I Inspect (Figure 35) Tool Required: J 33798 Engagement Tool • Operation of the shift mechanism. Insert J 33798 into the shift fork. Turn the axle shaft while engaging and disengaging the shift mechanism with the tool.
Page 284: Specifications
4C3-16 T TRUCK FRONT AXLE 11. S hift Cable Housing F-01668 Figure 35—Checking the Shift Mechanism SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Ft. Lbs. In. Lbs. Cable Housing and Tube Attaching Bolts............— Left Hand Output Shaft Cover Bolts............... — Carrier Case Bolts..................... —...
Page 285: Special Tools
T TRUCK FRONT AXLE 4C3-17 SPECIAL TOOLS 10 . J-21551 J-33837 J-29763 J-33838 12 . -33782 J-33842 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-23423-A 1. Output Shaft Bearing Remover 10. Pinion Bearing Cup Remover and Installer 2.
Page 286 4C3-18 T TRUCK FRONT AXLE SPECIAL TOOLS J 29307 J 8001 3® J 25025-1 J 33791 J 34037 J 33798 1. Slide Hammer 2. Bushing Remover 3. Dial Indicator Set 4. Dial Indicator 5. Dial Indicator Stand (Part of J 25025-B) 6.
Page 287 K TRUCK FRONT AXLE 4C4-1 SECTION 4C4 K TRUCK FRONT AXLE CONTENTS SUBJECT PAGE Description..................................4C4- 2 Disassembly of A xle.................................4C4- 2 Inspection..................................4C4- 2 Disassembly................................. 4C4- 2 Cleaning and Inspection..............................4C4- 9 Cleaning..................................4C4- 9 Inspection..................................4C4- 9 Assembly of A x le ................................4C4-10 Pinion Bearing Cup Installation..........................4C4-10 Pinion Depth Adjustment............................
Page 288: Description
4C4-2 K TRUCK FRONT AXLE DESCRIPTION The front axle on K model vehicles has a center discon transmit the driving force. This prevents tire scuffing when nect feature which, under most conditions, allows shifting going around corners and prevents premature wear on into and out of four wheel drive when the vehicle is in internal axle parts.
Page 289 K TRUCK FRONT AXLE 4C4-3 Figure 1—Front Axle Components (K-15-25 Models)
Page 290 4C4-4 K TRUCK FRONT AXLE 22. Sleeve(s) (32) and side bearing (33) cups (right side only on K35). • Turn the sleeve(s) to push the bearing cup(s) out of the bore(s). Use J 36599 (figure 9). Shaft 32. Sleeve 23. Adjuster plug (61) with side bearing cup (33) and O- Deflector 33.
Page 291 K TRUCK FRONT AXLE 4C4-5 Figure 3—Front Axie Components (K35 Models)
Page 292 4C4-6 K TRUCK FRONT AXLE 37. Ring and Pinion 1. Shaft 2. Deflector Gears 3. Seal 38. Shim 39. Bearing 4. Bearing 40. Spacer 5. Tube 6. Bolt 41. Bearing 7. Thrust Washer 42. Seal 43. Deflector 10. Solenoid 11. Washer 44.
Page 293 K TRUCK FRONT AXLE 4C4-7 Figure 9—Turning the Adjuster Sleeve...
Page 294 4C4-8 K TRUCK FRONT AXLE Seal Figure 17—Removing the Side Bearings Figure 14—Removing the Pinion Bearing...
Page 295: Cleaning And Inspection
K TRUCK FRONT AXLE 4C4-9 Figure 18—Removing the Pin (K15-25 Models) CLEANING AND INSPECTION • Bearing cup surfaces for nicks or burrs. Remove CLEANING any burrs that are found. • Housing for cracks. Replace the housing if any • Do not steam clean drive parts having ground and cracks are found.
Page 296: Assembly Of Axle
4C4-10 K TRUCK FRONT AXLE SHIMS, THRUST WASHERS AND Sealing surface of the pinion flange for nicks, burrs, or rough tool marks which would cause damage to ADJUSTER SLEEVES the seals’ inside diameter and result in an oil leak. Inspect Replace all worn or broken parts.
Page 297: Pinion Installation
K TRUCK FRONT AXLE 4C4-11 PINION INSTALLATION 36598-3 (K15-25) < J 36598-4 (K35) I * * ! Install or Connect (Figures 1 through 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 298 4C4-12 K TRUCK FRONT AXLE J 36601-4 (K15-25) J 36601-3 (K35) A. Button Located In Bore B. Bearing Swung Out of Bore C. Nut D. Washer E. Pilot F. Flats 39. Bearing (Inner Pinion) J 21777-35 (K15-25) J 29763 41. Bearing (Outer Pinion) J 21777*8 (K35) F-5869 Figure 22—Measuring Pinion depth...
Page 299 K TRUCK FRONT AXLE 4C4-13 Figure 25—Measuring Pinion Preload install them on the same side from which they were removed. 2. Pinion gears (56). • Position one pinion gear (56) between the side gears and rotate the gears until the pinion gear is directly opposite the opening in the case.
Page 300: Adjusting Backlash
4C4-14 K TRUCK FRONT AXLE F-5873 Figure 30—Installing the Side Bearing Cups 2. New O-ring (62) to the adjuster plug (61) (K35 models). 3. Sleeves (32) and/or adjuster plug (61) to the carrier case (29). F-5857 • K15-25 models: Use J 36599 (figure 28). •...
Page 301 K TRUCK FRONT AXLE 4C4-15 J 8001-1 F-5874 F-5875 Figure 32—Measuring Backlash at the Pinion Flange Figure 31—Measuring Backlash at the Ring Gear s p e c ific a tio n 0.13-0.18 1. Refer to figures 1 through 4. 2. Tighten the right sleeve (32) to 140 N m (100 ft. lbs.). (0.005-0.007-inch).
Page 302: Gear Tooth Contact Pattern Check
4C4-16 K TRUCK FRONT AXLE A test made without loading the gears will not give a satisfactory pattern. Turn the companion flange with a wrench so that the ring gear rotates one full revolution then reverse the rotation so that the ring gear rotates one revolution in the opposite direction.
Page 303: Axle Tube Assembly
K TRUCK FRONT AXLE 4C4-17 LOW FLANK CONTACT DECREASE PINION SHIM TOE CONTACT INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM F-2018 Figure 34—Gear Tooth Contact Pattern 3. Left seal (3). Use J 36600 (K15-25 models) or •...
Page 304: Final Assembly
4C4-18 K TRUCK FRONT AXLE • If the figure obtained in step 5 was 3.53 mm, use a 3.30 mm shim. • If the figure obtained in step 5 was 3.30 mm, use a 2.70 mm shim (K15-25 models) or 2.80 mm shim (K35 models).
Page 305 K TRUCK FRONT AXLE 4C4-19 C. Measure w ith Axle Shaft Forced Outboard 1. Shaft 5. Tube 9. Carrier Connector 23. O utput Shaft 29. Carrier Case F-5877 Figure 37—Measuring to Calculate Shim Size...
Page 306 4C4-20 K TRUCK FRONT AXLE MEASURING DIMENSION “A’ MEASURING DIMENSION “ B” (K15-25 SHOWN) F-5878 Figure 38—Measuring to Calculate Shim Size Tighten Bolts (6) to 40 N-m (30 ft. lbs.). Inspect (Figure 40) • Shift mechanism operation. Insert a drift into the actuator hole in the axle tube.
Page 307: Drive Axle Assembly
K TRUCK FRONT AXLE 4C4-21 Figure 40—Checking the Shift Mechanism DRIVE AXLE ASSEMBLY Tools Required: OUTER DEFLECTING RING J 8059 Snap Ring Pliers REPLACEMENT J 35910 Seal Clamp Tool J 36652 Swage Clamp Tool ««* Remove or Disconnect (Figures 41,42 and 43) 1.
Page 308 4C4-22 K TRUCK FRONT AXLE 1. Tri-pot Housing Assembly 2. Shaft Retaining Ring 3. Tri-pot Joint Spider 4. Needle Retainer Ring 5. Needle Retainer 6. Tri-pot Joint Ball 7. Needle Roller 8. Spacer Ring 9. Swage, Ring 10. Tri-pot Joint Seal 15.
Page 309 K TRUCK FRONT AXLE 4C4-23 “ ►+ Install or Connect Small seal-retaining clamp (11) on the neck of the new seal (13). Do not crimp. Slide the seal (13) onto the axle shaft (12) and position the neck of the seal in the seal groove on the axle shaft.
Page 310: Outer Joint Assembly Replacement
4C4-24 K TRUCK FRONT AXLE MAKE SURE SWAGE RING AND SWAGE SWAGE CLAMP SIZE CHART RING CLAMP ARE IN PROPER ALIGNMENT APPLICATION DESCRIPTION TOOL NO. Split Plate Swage Clamp K 10/20 J 36652-1 Split Plate Swage Clamp K 30 (Outboard) J 36652-2 K 30 (Inboard) J 36652-3...
Page 311: Inner Tripot Seal Replacement
K TRUCK FRONT AXLE 4C4-25 9 Important Be sure that the retaining ring side of the inner race (16) face the axle shaft (12). HAMMER Perform steps 1 through 3 in “ Outer Joint Seal Replacement” Install or Connect. BRASS DRIFT INNER TRI-POT SEAL REPLACEMENT...
Page 312 4C4-26 K TRUCK FRONT AXLE 4. Shaft retaining ring (2) in the groove of the axle shaft SPIDER ASSEMBLY (12) with J 8059. • Slide the tri-pot spider (3) towards the end of the shaft (12) and reseat the spacer ring (8) in the groove on the axle.
Page 313: Specifications
K TRUCK FRONT AXLE 4C4-27 Important Make sure that the seal (10), housing (1) and swage ring (9) all remain in alignment (figure 47). — Continue to tighten each bolt 180° at a time, alternating until both sides are bottomed. Remove the axle assembly from the tool.
Page 314 4C4-28 K TRUCK FRONT AXLE J 29307 J 36616 J 36612 J 22761 J 36613 J 29710 J 22888 J 8092 J 36609 J 8107-2 J 36597 J 29369-1 J3612-B J 29369-2 J 36606 J 33842 J 8614-01 J 34011 1.
Page 315 K TRUCK FRONT AXLE 4C4-29 J 34037 J 35512 J 36614 J 34672 J 36366 J 36600 J 22833 J 36615 J 36598 J 8001 J 34047-3 J-36599 J 36601 J 8059 J 29763 J 35910 J 36603 Depth Gage 19.
Page 317 L-VAN FRONT AXLE 4C5-1 SECTION 4C5 L-VAN FRONT AXLE CONTENTS SUBJECT PAGE . 4C5- 1 Description Disassembly of Axle . 4C5- 1 Inspection 4C5- 1 , 4C5- 3 Disassembly , 4C5- 3 Cleaning and Inspection . 4C5- 3 Cleaning . 4C5- 4 Inspection , 4C5- 6 Assembly of Axle...
Page 318 4C5-2 L-VAN FRONT AXLE Figure 1— L-Van Front Axle...
Page 319 L-VAN FRONT AXLE 4C5-3 1. Shaft 31. Insert 45. Washer 58. Bolt 2. Deflector 32. Sleeve 46. Nut 59. Shaft 33. Side Bearing 47. Plug 3. Seal 34. Bolt 48. Bushing 4. Bearing 5. Tube 35. Differential Case 49. Vent Hose 6.
Page 320 4C5-4 L-VAN FRONT AXLE Figure 5—Separating the Carrier Case Halves Seal Stlf 29. Carrier Case 59. Shaft 18. Bolt 29. Carrier Case 19. Lock Tab 32. Sleeve F1780 Figure 6—Removing the Lock Tabs F1389 Figure 4— Removing the Axle Shaft Parts should be thoroughly dried immediately after cleaning.
Page 321 L-VAN FRONT AXLE 4C5-5 30. Bearing 32. Sleeve F1782 Figure &—Removing the Sleeve Bearing J 33837-1 J 33837-3 44. Flange F7549 Figure 10—Removing the Pinion Flange AXLE HOUSING Inspect • Carrier bore for nicks or burrs that would prevent Bearing cup surfaces for nicks or burrs. Remove the outer diameter of the pinion seal from sealing.
Page 322 4C5-6 L-VAN FRONT AXLE • Pinion splines for wear. • Pinion flange splines for wear. • Fit of the pinion flange on the pinion. • Sealing surface of the pinion flange for nicks, burrs, or rough tool marks which would cause damage to the seal’s inside diameter and result in an oil leak.
Page 323 L-VAN FRONT AXLE 4C5-7 3. Thrust washers (55). • Rotate the pinion gears toward the opening just enough to permit the sliding in of the thrust wash ers. 4. Shaft (52) and bolt (36). 5. Ring gear (37) onto the differential case (35). J 33790 6.
Page 324 4C5-8 L-VAN FRONT AXLE A. Button Located in Bearing Bore B. Button Moved Out of Bearing Bore F5791 Figure 18— Measuring Pinion Depth...
Page 325 L-VAN FRONT AXLE 4C5-9 1. Shim (38) to the pinion gear (37). • The shim must be of the proper size, as select ed previously. 2. Bearing (39) onto the pinion gear (37) using J 33785 (figure 19). 3. New spacer (40) onto the pinion gear (37). 4.
Page 326 4C5-10 L-VAN FRONT AXLE 29. Carrier Case 32. Sleeve A. Mark Location on the Case F1830 Figure 22— Installing the Sleeve Bearing Figure 25—Marking Sleeve Location 6. Four bolts (28) (figure 24). • Bolts (28) to 50 N-m (37 ft. lbs.). ADJUSTING BACKLASH Tools Required: J 33792 Side Bearing Adjuster Wrench...
Page 327 L-VAN FRONT AXLE 4C5-11 verify the correct running position of the ring gear and the drive pinion. Gear sets which are not positioned properly may be noisy, or have a short life, or both. The best contact between the ring gear and the drive pinion for low noise level and long life can be assured with a pattern check.
Page 328 4C5-12 L-VAN FRONT AXLE LOW FLANK CONTACT DECREASE PINION SHIM TOE CONTACT INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM F2018 Figure 28—Gear Tooth Contact Pattern 3. Bolts (18) and locks (19). FINAL ASSEMBLY Tighten Remove or Disconnect (Figures 1, 2 and 24) •...
Page 329 L-VAN FRONT AXLE 4C5-13 2. Small seal-retaining clamp (12) on axle shaft with side cutter and discard. 3. Separate joint seal (14) from C/V joint race (20) at large diam eter and slide seal away from joint along axle shaft (13). 4.
Page 330 4C5-14 L-VAN FRONT AXLE 1. Tri-Pot Housing Assembly 2. Shaft Retaining Ring 3. Tri-Pot Joint Spider 4. Needle Retainer Ring 5. Needle Retainer 6. Tri-Pot Joint Ball 7. Needle Roller 8. Spacer Ring 9. Seal Retaining Clamp (Service Only) 10. Retaining Clamp Protector 16.
Page 331 L-VAN FRONT AXLE 4C5-15 SPREAD RETAINING RING EARS AND SLIDE C/V JOINT OFF AXLE SHAFT 16. Race Retaining Ring 20. C/V Joint Outer Race F7485 Figure 33— Separating C/V Joint and Axle PUSH C/V JOINT ASSEMBLY ONTO AXLE SHAFT UNTIL RETAINING RING IS SEATED IN GROOVE ON AXLE SHAFT SQUARE UP DEFLECTOR RING AND TIGHTEN...
Page 332 4C5-16 L-VAN FRONT AXLE MAKE SURE SWAGE RING AND SWAGE RING CLAMP ARE IN PROPER ALIGNMENT F7488 Figure 36— Installing Swage Ring GENTLY TAP ON CAGE UNTIL TILTED ENOUGH TO REMOVE FIRST BALL. REMOVE OTHER BALLS IN SIMILAR MANNER. 6. Cage (19) and inner race (18) from outer race (20). 7.
Page 333 L-VAN FRONT AXLE 4C5-17 PIVOT CAGE AND INNER RACE AT 90° TO CENTER LINE OF OUTER RACE WITH CAGE WINDOWS ALIGNED WITH LANDS OF OUTER RACE. LIFT OUT CAGE AND INNER RACE. SLIDE SPACER RING AND SPIDER ASSEMBLY BACK ON SHAFT.
Page 334 4C5-18 L-VAN FRONT AXLE Important • Handle the tri-pot spider assembly with care. Tri-pot balls and needle rollers may separate from spider trunnions. 8. Remove spacer ring (8) and seal (11) from axle shaft (13). 9. Flush grease from tri-pot housing (1). Inspect Joint seal Spider...
Page 335 L-VAN FRONT AXLE 4C5-19 14. Retaining clamp protector (10) over larger seal retaining clamp (9) and snap into position. | ? I Important • Due to possible road hazards, a retaining clamp protector (10) must be installed when inboard seal or clamp is serviced. SPECIFICATIONS TORQUE SPECIFICATIONS Ft.
Page 336: Special Tools
4C5-20 L-VAN FRONT AXLE SPECIAL TOOLS J 8614-01 J 21551 J 29763 J 33844 J 33782 J 33893 J 33785 J 29369-2 J 33788 J 29307 J 33790 J 33791 J 33792 J 8001 J 22912-01 J 25025-1 J 23423-A J 36652 J 33837 11 .
Page 337 SECTION 5 BRAKES The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology NOTICE: See ‘Notice’ on page 5-1 of this section. N O T IC E : T h is fa s te n e r Is a n 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 th e p e rfo rm a n c e o f v ita l c o m p o n e n ts a n d s y s te m s , a n d /o r c o u ld re s u lt In m a jo r re p a ir e x p e n s e , It m u s t b e re p la c e d w ith o n e o f th e s a m e p a rt n u m b e r o r w ith a n e q u iv a le n t p a rt If re p la c e m e n t b e c o m e s n e c e s s a ry .
Page 338 5-2 BRAKES 16. Cover 17. Bracket 18. Nut 6. O-Ring 19. Boot 7. Spring 20. Pedal Rod 8. Housing 21. Pin 9. Bolt 22. Piston Assem bly 10. Seal 23. Seal 27 26 1. Retainer 11. Accum ulator Valve 24. Retainer 2.
Page 339 BRAKES 5-3 Figure 4—Removing the Accumulator Valve Figure 7—Installing the Piston Assembly Tighten • Bolts to 30 N m (22 ft. lbs.). 9. Bracket (17) and nut (18). Tighten • Nut to 149 N m (110 ft. lbs.). 10. Boot (19). 11.
Page 340 5-4 BRAKES MASTER CYLINDERS Inspect COMPOSITE MASTER CYLINDER Diaphragm for cuts, cracks, or a swollen condition. The Delco-Moraine Composite Master Cylinder has Cylinder bore for scoring or corrosion. If corrosion is identifying information stamped into the front outlet tube. present, replace the cylinder. Do not attempt to hone The first and second digits are the build code.
Page 341 BRAKES 5 -5 1. Cover 2. Diaphragm 3. Reservoir 4. Grommet 5. Quick Take-Up Valve 6. Spring 7. Spring Retainer 8. Primary Seal 9. Secondary Piston 10. Secondary Seal 11. Snap Ring 12. Primary Piston Assembly 13. Body F-00769 Figure 9—Composite Master Cylinder Components CAUTION: In the following step if air pressure is used to remove the secondary piston, place the All the metal parts in denatured alcohol.
Page 342 5-6 BRAKES 1. Cover 2. Diaphragm 3. Reservoir 4. Grommet 5. Q uick Take-Up Valve 6. Spring 7. Spring Retainer 8. Primary Seal 9. Secondary Piston 10. Secondary Seal 9. Tube seats (if removed). • Seat the tube seats with a spare brake tube nut (figure 18).
Page 343 BRAKES 5-7 Bail Cover Diaphragm Body Spring Spring Retainer Primary Seal Secondary Piston Secondary Seals Primary Piston Assem bly Snap Ring F-00774 Figure 14—Cast Iron Master Cylinder Components CAUTION: In the following step if air pressure is + + Remove or Disconnect (Figure 19) used to remove the secondary piston, place the 1.
Page 344 5-8 BRAKES Figure 17—Removing Tube Seats 4. Primary piston assembly (51) and snap ring (52). • The primary piston must be depressed to install the snap ring. 5. O-ring (55) and springs (47). Primary Piston Assem bly 6. Valve poppets (46) and compensating valve seals Snap Ring (45).
Page 345 BRAKES 5-9 Cover Diaphragm Filter Reservoir Com pensating Valve Seal Valve Poppet Spring Secondary Spring Secondary Piston Piston Return Spring Primary Piston Snap Ring Body Bolts O-Ring F-00775 Figure 19—Bendix Master Cylinder Components VACUUM BOOSTERS Delco-Moraine Vacuum Boosters have a build date on a means 1986).
Page 346 5-10 BRAKES 1. Boot 2. Silencer 3. Vacuum check Valve 4. Grommet 5. Front Housing Seal 6. Power Piston Bearing 7. Rear Housing 8. Front Housing 9. Return Spring 10. Piston Rod (Gaged) 11. Reaction Retainer 12. Filter 13. Diaphragm Retainer 14.
Page 347 BRAKES 5-11 3 7 8 3 9 Figure 24—Gaging the Piston Rod 11. Front housing seal (5). 12. Silencer (2) and boot (1). • Gage the piston rod using J 37839 (figure 24). If not within limits, obtain a service adjustable piston rod. •...
Page 348 5-12 BRAKES Boot S ile n c e r Va cu u m C h e c k Valve Gro m m e t Front H o u s in g Seal Prim ary P isto n Bearing Rear H o u s in g Front H o u s in g Return Spring Pisto n Rod (Gaged)
Page 349 BRAKES 5-13 8. Primary Piston Bearing 9. Rear H ousing 10. Front H ou sing 11. Return Spring 38. Power Piston Group Piston Rod (Gaged) Reaction Retainer Power Head Silencer Diaphragm F-05823 Retainer Primary Diaphragm Figure 26—Booster Inner Components Primary Support Plate Secondary Piston Bearing •...
Page 350 5-14 BRAKES J 28458 J 28458 A. Diaphragm Lip Secondary Piston Bearing 20. Secondary Diaphragm Housing Divider 21. Secondary Support Plate Secondary Diaphragm 41. Power Piston Assem bly Power Piston Assem bly F-05894 F-05895 Figure 28—Assembling the Secondary Diaphragm Figure 29—Assembling the Housing Divider and Support SPECIFICATIONS Ft.
Page 351 BRAKES 5-15 SPECIAL TOOLS 3 7 8 3 9 J 23456 L H ATy J 24551-A J 26889 J 25083 J 6217 1. Power Brake Push Rod Height Gage 2. Piston Seal Protector 3. Piston Seal Protector J 28458 4. Power Brake Booster Disassem bly and Reassembly Tool 5.
Page 352 ----------------- — V . IM S L A-f58£2 t \ rsa t...
Page 353: General Engine Mechanical
6A-1 SECTION 6 ENGINE CONTENTS SUBJECT PAGE General Engine Mechanical............................6A- 1 2.5 Liter L 4 ..................................6A1- 1 2.8 Liter V 6 ..................................6A2- 1 4.3 Liter V 6 ..................................6A3- 1 4.8 Liter L 6 ..................................6A4- 1 V8 E ngine..................................6A5- 1 6.2 Liter D ie s e l................................
Page 354: Use Of Rtv Sealer And Anaerobic Gasket Eliminator
6A-2 GENERAL ENGINE MECHANICAL GENERAL INFORMATION USING RTV SEALER STATEMENT ON 1. Do not use RTV when extreme temperatures are CLEANLINESS AND CARE expected, such as exhaust manifold, head gasket or where gasket eliminator is specified. • An engine is a combination of many machined, 2.
Page 355: Measuring Cylinder Bore Taper And Out-Of-Round (All M Odels)
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 Cylinder 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 356: Cylinder Bore Reconditioning (2.8 L Engines)
6A-4 GENERAL ENGINE MECHANICAL . 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 357: Honing
GENERAL ENGINE MECHANICAL 6A-5 boring bar may be tilted which would result in the . 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 358 GENERAL ENGINE MECHANICAL J-24086-8 Figure 6—Removing the Piston Pin . 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.
Page 359 GENERAL ENGINE MECHANICAL 6A-7 B-04981 Figure 8—Measuring Piston Pin Diameter CLEANING AND INSPECTION Pjyi Clean — Piston. — Remove all varnish and carbon deposits. DO Measure (Figures 8 and 10) NOT USE A WIRE BRUSH. — Remove the carbon from the ring grooves. Use 1.
Page 360: Piston Selection (2.5 L And 2.8 L Engines)
GENERAL ENGINE MECHANICAL • Refer to “ S pecification s” in the proper A. 65mm (2V -inches) section. Determine if the piston clearance is in B. C ylinder Bore the acceptable range. 2. If the used piston is not acceptable, determine if a new piston can fit the cylinder bore.
Page 361 GENERAL ENGINE MECHANICAL 6A-9 • The piston must be installed with the piston crown indent on the same side as the connecting rod bearing tang slots (figure 14). 2. Piston pin. Apply engine oil to the pin and push into place.
Page 362 6A-10 GENERAL ENGINE MECHANICAL Inspect (Figures 17) Ring fit as follows: 1. Fit each compression ring to the piston on which it is going to be used. . Slip the outer surface of the top and second compression ring into the respective piston ring groove (figure 17), to make sure that the ring is free.
Page 363 GENERAL ENGINE MECHANICAL 6A-11 The top compression ring is a keystone type. The oil ring is a two-piece type, consisting of an expander and a scraper ring. Measure (Figures 7 and 16) Ring end gap as follows: 1. Select rings comparable in size to the piston being used.
Page 364: Camshaft Bearings
6A-12 GENERAL ENGINE MECHANICAL CAMSHAFT BEARINGS Figure 19—Removing or Installing the Inner Figure 20—Removing or Installing the Outer Camshaft Bearings Camshaft Bearings • Assemble the bearing tool and driver handle. CAMSHAFT BEARING • Drive the outer camshaft bearings out of the REPLACEMENT (2.5 L AND block.
Page 365: Hydraulic Lifters
GENERAL ENGINE MECHANICAL 6A-13 1. Outer camshaft bearings. Drive the bearings into Holding the puller screw with a wrench, turn place using J 6098-01 (figure 20). the nut with a second wrench to pull the camshaft bearing into place. Important Remove the puller screw, pilot, and bearing tool.
Page 366 6A-14 GENERAL ENGINE MECHANICAL 230 221 223 225 l i e . Lifter Body 226. Plunger . Plunger Spring 227. M etering Valve 223. Check Ball Retainer 228. Pushrod Seat 224. Check Ball Spring 229. Retainer 225. Check Ball 230. Roller B-09402 Figure 24—Roller Type Hydraulic Lifter Components Important...
Page 367: Valve Lifter Leak-Down Rate Test (Flat Type Lifters O N
GENERAL ENGINE MECHANICAL 6A-15 A. Screwdriver Figure 26— -Removing the Check Ball Retainer (Typical) clean, lint-free shop rags. Work with clean hands, on a clean work surface. 1. Check ball (225) to the small hole in the bottom of the plunger (226). A.
Page 368: Cylinder Head
6A-16 GENERAL ENGINE MECHANICAL Adjust the ram (with the weight arm clear of the ram) so that the point is positioned on the set line (marked “ S” ). Tighten the jam nut to maintain the setting. Operate the lifter through full travel of the plunger by pumping the weight arm to fill the lifter with test fluid and force out air.
Page 369 GENERAL ENGINE MECHANICAL 6A-17 Figure 32—Measuring Stem to Bore Clearance Figure 30—Cleaning the Combustion Chambers (Typical) (Typical) • Move the stem of the valve from side to side REPAIR using light pressure to obtain a clearance reading. If clearance exceeds specifications, it will be necessary to ream valve guide bores VALVE GRINDING for oversize valves as outlined later in this...
Page 370: Assembly
6A-18 GENERAL ENGINE MECHANICAL Regardless of what type of equipment 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 “’Specifications” in the proper section for valve seat angle specifications.
Page 371: Measuring Main Bearing Clearance
GENERAL ENGINE MECHANICAL 6A-19 B-00546 Figure 36—Reaming the Valve Guides (Typical) MEASURING MAIN BEARING CLEARANCE Main bearings are of the precision insert type and do not use shims for adjustment. If clearances are found to be excessive, new upper and lower inserts will be re quired.
Page 372: Measuring Connecting Rod Bearing C Le A Ra N C
6A-20 GENERAL ENGINE MECHANICAL On the edge of the gaging plastic envelope there is a graduated scale. Without removing the gaging plastic, measure its compressed width (at the widest point) with the graduations on the gaging plastic en velope (figure 38). If the flattened gaging plastic tapers toward the mid...
Page 373 GENERAL ENGINE MECHANICAL 6A-21 A. Measure W idest Point o f Gaging Plastic w ith Graduated Scale B-04997 Figure 39—Placing the Gaging Plastic on the Figure 40—Measuring the Gaging Plastic Connecting Rod Journal Measure (Figure 40) sively out-of-round, interference between the Gaging plastic at its widest point, using the scale at bearing and the crankpin will result in rapid the gaging plastic envelope (figure 40).
Page 374 GENERAL ENGINE MECHANICAL - 2 2 SPECIAL TOOLS J 8087 J 5790 J 25220 J 8089 J 24086 J 8101 J 29134-A J 8001 ■ J 6098 01 J 8056 © © J 29664 1. C ylinder Bore Gage 2. Ring Expander 3.
Page 375 6A1-1 SECTION 6A1 2.5 LITER L4 ENGINE CONTENTS SUBJECT PAGE Description..................................6A1- 2 Engine Lubrication..............................6A1- 2 Disassembly of the Engine............................6A1- 4 Tools and Shop Equipment............................. 6A1- 4 Accessory Removal..............................6A1- 4 Cleaning..................................6A1- 4 Parts Identification..............................6A1- 4 Draining the Engine..............................6A1- 4 Intake Manifold Removal............................
Page 376: Subject Page
6A1-2 2.5 LITER L4 ENGINE CONTENTS (CONT.) SUBJECT PAGE Assembly of Engine Cont. Oil Pan Installation..............................6A1-27 Oil Pump Driveshaft Installation..........................6A1-27 Cylinder Head Installation............................6A1-27 Valve Train Component Installation........................6A1-29 Water Pump Installation............................6A1-29 Thermostat Housing Installation...........................6A1-30 Intake Manifold Installation.............................6A1-30 Exhaust Manifold Installation..........................6A1-30 Flywheel Installation...............................
Page 377 2.5 LITER L4 ENGINE 6A1-3 A. Oil Pump Drive Gear O iling B. Oil Pressure Sending Unit B-07950 Figure 1—Engine Lubrication Diagram...
Page 378: Disassembly Of The Engine
6A1-4 2.5 LITER L4 ENGINE DISASSEMBLY OF THE ENGINE 34. Valve Stem Oil Shield 1. Outer Engine Heat Stove 17. Cylinder Head Gasket 2. Bolt 18. Intake Valve 35. Valve Spring 3. Stud 19. Exhaust Valve 36. Intake Valve Stem Seal 37.
Page 379 2.5 LITER L4 ENGINE 6A1-5 Figure 3—Cylinder Head, Manifolds, and Components...
Page 380: Intake Manifold Removal
6A1-6 2.5 LITER L4 ENGINE 102. Front Cover 50. Push Rod Cover 77. Oil Pump 103. Screw 51. Piston and Pin 78. Nut 104. Cam shaft Gear 52. Piston Rings 79. Pin 105. Cam shaft Thrust Bearing 53. C onnecting Rod 80.
Page 381 2.5 LITER L4 ENGINE 6A1-7 Figure 5—Block and Components...
Page 382 6A1-8 2.5 LITER L4 ENGINE 37. Washer 38. Bolt 42. Stud 43. Intake M anifold 44. Gasket F-01984 Figure 6—Intake Manifold Components 2. Bolt 3. Stud 5. Exhaust M anifold 7. Gasket F-01985 Figure 7—Exhaust Manifold Components...
Page 383: Valve Train Component Removal
2.5 LITER L4 ENGINE 6A1-9 A. 22 mm (7/s") B. 55 mm (21 /s") C. 40 mm (11 /2") 110. B oll D. 10 mm {3/s") 111. C oolant Pump 25 mm (1") Deep 112. Gasket Holes for Pushrods F-01987 E.
Page 384: Cylinder Head Removal
6A1-10 2.5 LITER L4 ENGINE 31. Bolt 32. Rocker Arm Ball 17. Head Gasket 33. Rocker Arm 24. C ylinder Head 45. Push Rod Guide 25. Head Bolt (Stud) 47. Push Rod 27. Head Bolt F-01989 F-01991 Figure 11—Valve Train Components Figure 13—Cylinder Head Components CYLINDER HEAD REMOVAL Remove or Disconnect (Figure 13)
Page 385: Oil Pan Removal
2.5 LITER L4 ENGINE 6A1-11 89. Key 94. Bolt 95. Crankshaft Pulley 96. Bolt 97. Crankshaft and Power Steering Pulley 98. Bolt 99. Washer 100. Crankshaft Pulley Hub F-01992 Figure 14—Timing Gear Cover and Components OIL PAN REMOVAL PISTON AND CONNECTING ROD REMOVAL Remove or Disconnect (Figure 5) Remove or Disconnect (Figures 5, 16 and 17)
Page 386: Flywheel Removal
6A1-12 2.5 LITER L4 ENGINE markings, to insure proper reassembly. Use a silver pencil to mark the parts if necessary. • To avoid mismatching the connecting rods apd connecting rod caps, remove only one connecting rod cap at a time. Place the piston at the bottom of its stroke.
Page 387: Crankshaft Rear Oil Seal Removal (Without Removing Crankshaft)
2.5 LITER L4 ENGINE 6A1-13 CRANKSHAFT REAR OIL SEAL REMOVAL (WITHOUT REMOVING CRANKSHAFT) Remove or Disconnect (Figure 5) NOTICE: Care must be taken not to damage the crankshaft outside diameter surface with the pry tool. 1. Rear crankshaft oil seal. •...
Page 388: Cleaning, Inspection, And Repair
6A1-14 2.5 LITER L4 ENGINE A. Tim ing Marks 87. Crankshaft Gear 103. Thrust Plate Bolts 104. Camshaft Gear 105. Thrust Plate 108. Camshaft F-05719 Figure 21—Camshaft and Timing Gears CLEANING, INSPECTION, AND REPAIR A solvent tank, large enough to hold the larger engine Inspect parts, will be needed along with various bristle brushes All expansion plugs for looseness or leakage.
Page 389: Cylinder Bores
2.5 LITER L4 ENGINE 6A1-15 21/4 •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. A. Bore Gaging Point CYLINDER BORES B.
Page 390: Intake And Exhaust Manifold
6A1-16 2.5 LITER L4 ENGINE 108. Camshaft F-01998 Figure 25—Measuring Camshaft Journal Runout Figure 27—Measuring Camshaft Thrust Plate Clearance (Camshaft End Play) INTAKE AND EXHAUST journals. If runout exceeds 0.020-inch, the camshaft MANIFOLDS is excessively bent and should be replaced, along with the camshaft bearings.
Page 391: Camshaft Bearings
2.5 LITER L4 ENGINE 6A1-17 Arbor Press Press Tool 104. Camshaft Gear 105. Thrust Plate 108. Camshaft F-02027 Figure 29—Installing the Camshaft Gear A. Bearing Tool B. Driver Handle NOTICE: The thrust plate must be positioned B-05233 so that the woodruff key (107) does not damage it during the removal operation.
Page 392: Water Pump
6A1-18 2.5 LITER L4 ENGINE Pump Body Spring Retaining Spring Cover Screws Cover Cover Gasket Pressure Relief Valve Idler Gear 127> Drive Gear and Shaft P1 Pick-Up Screen and Pipe — Press the seal into place. The open end of the seal faces inside the front cover.
Page 393: Valve Train Components
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 permit oil PUSHRODS, PUSHROD GUIDES, to leak past the ends of the gears. ROCKER ARMS AND BALLS The pump gears and body are not serviced separately.
Page 394 6A1-20 2.5 LITER L4 ENGINE 18. Intake Valve 19. Exhaust Valve 28. Valve Spring Cap 29. Valve Stem Oil Seal 30. Valve Keepers 34. Valve Stem Oil Shield 35. Valve Spring (with damper) 36. Valve Stem Seal F-04484 Figure 35—Compressing the Valve Springs Figure 34—Valves and Components •...
Page 395: Thermostat And Housing
2.5 LITER L4 ENGINE 6A1-21 Make sure that the keepers seat properly in the groove. Repeat the preceding steps on the remaining valves. Check each valve seal using J 22330. Wet the suction cup portion of the tool lightly with engine oil.
Page 396: Assembly Of Engine
6A1-22 2.5 LITER L4 ENGINE • Mount 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. B-02792 Figure 38—Checking Crankshaft Runout ASSEMBLY OF ENGINE...
Page 397 2.5 LITER L4 ENGINE 6A1-23 A. A lignm ent Hole in Crankshaft B. Dust Lip C. Dowel Pin D. Collar E. Mandrel F. Screws 71. Crankshaft Rear Oil Seal F-02029 r - ^ W 71. Crankshaft Rear Oil Seal Figure 4 1 — Installing the Rear Crankshaft Oil Seal 72.
Page 398: Main Bearing Installation (Without Removing The Crankshaft)
6A1-24 2.5 LITER L4 ENGINE Tim ing Marks MAIN BEARING INSTALLATION Crankshaft Gear (WITHOUT REMOVING THE Thrust Plate Bolts CRANKSHAFT) Camshaft Gear Thrust Plate Camshaft Install or Connect (Figures 5 and 42) F-05719 Tool Required: J 8080 Main Bearing Remover/Installer Figure 43—Camshaft and Timing Gears 1.
Page 399: Crankshaft Pulley Hub Installation
2.5 LITER L4 ENGINE 6A1-25 CRANKSHAFT PULLEY HUB INSTALLATION -► <- Install or Connect (Figures 5 and 47) 1. Crankshaft pulley and hub. Slide the hub on the crankshaft until it bottoms against the crankshaft gear. 2. Bolt (98) and washer (99). Tighten •...
Page 400: Oil Pump Installation
6A1-26 2.5 LITER L4 ENGINE 89. Key 94. Bolt 95. Crankshaft 96. Bolt 97. Crankshaft 98. Bolt 99. Washer 100. Crankshaft F-01992 Figure 47—Timing Gear Cover and Components FINAL ASSEMBLY OIL PUMP INSTALLATION -► + Install or Connect (Figure 5) I+ + I Install or Connect (Figure 5) Apply engine oil to the connecting rod bearing inserts (55) and crankshaft journal.
Page 401: Oil Pan Installation
2.5 LITER L4 ENGINE 6A1-27 Tighten • Oil pan bolts to 10.0 N m (90 in. lbs.). OIL PUMP DRIVESHAFT INSTALLATION Install or Connect (Figures 5 and 52) 1. Shaft and gear assembly (115 and 114). Turn the shaft until it indexes the oil pump shaft pilot properly in the oil pump body.
Page 402 6A1-28 2.5 LITER L4 ENGINE Cylinder head bolts should be washed in solvent and dry at the time of installation. All residual oil should be wiped from the cylinder head mating surfaces. Coat the threads of bolt 9 with sealing com pound (Part Num ber...
Page 403: Valve Train Component Installation
2.5 LITER L4 ENGINE 6A1-29 LSfJsdETSJ A. Apply A C ontinuous (5 mm 3/ie-lnch) Diameter Bead Of RTV As Shown B-07963 Figure 56—Applying RTV to the Pushrod Cover VALVE TRAIN COMPONENT INSTALLATION + + Install or Connect (Figures 3, 5, 54, 55 and 56) •...
Page 404: Thermostat Housing Installation
6A1-30 2.5 LITER L4 ENGINE INTAKE MANIFOLD INSTALLATION Install or Connect (Figure 59) 1. Gasket. • Apply sealant to the bolts indicated in figure 59. 2. Intake manifold. 3. Intake manifold bolts and washers. Tighten • Intake manifold bolts to 34 N m (25 ft. lbs.). 4.
Page 405 2.5 LITER L4 ENGINE 6A1-31 “A” Group Bolts: 50 N m (36 Ft. Lbs.) “B” Group Bolts: 43 N-m (32 Ft. Lbs.) B-07994 Figure 60—Exhaust Manifold Installation...
Page 406 6A1-32 2.5 LITER L4 ENGINE 2. Fill the crankcase with the proper quantity and 5. Listen for improperly adjusted valves or sticking grade of oil. Refer to the proper Truck Service lifters, or other unusual noises. Manual or Owner’s and Driver’s Manual for this 6.
Page 407: Specifications
2.5 LITER L4 ENGINE 6A1-33 SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherwise noted. GENERAL DATA: Type 2.5L Displacement 4.00 Bore 3.00 Stroke 8.3:1 Compression Ratio 1-3-4-2 Firing Order 36-41 psi @ 2000 RPM Oil Pressure CYLINDER BORE: Diameter 4.000 0.001 (Maximum)
Page 408 6A1-34 2.5 LITER L4 ENGINE SPECIFICATIONS (CONT.) ENGINE SPECIFICATIONS (CONT.) All specifications are in INCHES unless otherwise noted. CRANKSHAFT: Diameter 2.300 Main Taper 0.0005 Out of Round Journal 0.0005 Main Bearing Clearance 0.0005-0.0022 Crankshaft End Play 0.0035-0.0085 Diameter 2.000 Crankpin Taper 0.0005 Out of Round...
Page 409 2.5 LITER L4 ENGINE 6A1-35 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Item N-m Ft. Lbs. In. Lbs. Main Bearing Cap B o lts ..................... — Connecting Rod N u ts ......................— Oil Pan Bolts (AN)........................ 10.0 — Oil Pump to Block B o lts ..................... —...
Page 410: Special Tools
6A1-36 2.5 LITER L4 ENGINE SPECIAL TOOLS J-21882 J-8037 J-34995 J-34144-A J-8080 J-34924-A J-8062 J-22330 J-33049 £ S5&1 J-3049 1. Piston Ring Compressor 2. Front Crankshaft Seal Installer 3. Main Bearing Replacer 4. Valve Spring Com pressor 5. Cam Bearing Replacer J-7872 6.
Page 411 2 - 1 SECTION 6A2 2.8 LITER V-6 CONTENTS SUBJECT PAGE Description..................................6A2- 2 Engine Lubrication..............................6A2- 2 Disassembly.................................. 6A2- 6 Tools and Shop Equipment............................. 6A2- 6 Accessory Removal..............................6A2- 6 Cleaning..................................6A2- 7 Draining the Engine..............................6A2- 7 Air Injection Tube R em oval........................... 6A2- 7 EGR Valve Removal..............................6A2- 7 Exhaust Manifold Removal.............................
Page 412: Subject Page
2.8 LITER V 2 - 2 CONTENTS (CONTINUED) SUBJECT PAGE Assembly of Engine (Continued) Torsional Damper Installation..........................6A2-21 Piston and Connecting Rod Installation......................6A2-22 Oil Pump Installation............................... 6A2-23 Oil Pan Installation..............................6A2-23 Cylinder Head Installation............................6A2-23 Valve Train Component Installation........................6A2-24 Valve Adjustment..............................6A2-25 Intake Manifold Installation.............................6A2-25 Rocker Arm Cover Installation..........................6A2-25 Exhaust Manifold Installation..........................6A2-26...
Page 413 2.8 LITER V 6A2-3 Figure 1—Engine Lubrication Diagram...
Page 414 6A2-4 2.8 LITER V Figure 2—Engine Lubrication Diagram...
Page 415 2.8 LITER V 6A2-5 A. Lubrication Begins B. 189° Duration Of Lubrication C End Of Lubrication D. Lubrication Ends 154° BTDC E. Cylinders 2, 4 And 6 F. 190° Duration Of Lubrication G. Lubrication Ends 134° BTDC H. For Cylinders 1, 3 And 5 J.
Page 416: Disassembly
6A2-6 2.8 LITER V Figure 4—Engine Lubrication Diagram DISASSEMBLY TOOLS AND SHOP EQUIPMENT ACCESSORY REMOVAL A clean, well lit work area should be available. Other This manual assumes that the engine accessories have necessary equipment includes: A suitable parts cleaning been removed.
Page 417: Cleaning
2.8 LITER V 6A2-7 Figure 6—EGR Valve Figure 5—Air Injection Tube EGR VALVE REMOVAL CLEANING Remove the engine accessories before cleaning, to + + Remove or Disconnect (Figure 6) provide better access to engine exterior surfaces. After removing the TBI unit, distributor, etc., cover the openings 1.
Page 418: Valve Train Component Removal
6A2-8 2.8 LITER V Figure 7—Exhaust Manifold Installation VALVE TRAIN COMPONENT 1. Nuts (6), balls (8), rocker arms (7), and pushrods (9). • Every effort should be made to insure that REMOVAL these mating parts are installed in their original locations during assembly. A simple Remove or Disconnect (Figure 9) valve train organizer can be made from a piece of wood.
Page 419: 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 Remove or Disconnect 1. Water pump. 2. Front cover bolts. 3. Front cover. 4. Gasket. the same place for future reference. Number one cylinder reference is the first clockwise mark from the keyway OIL PAN REMOVAL when viewing the engine from the front.
Page 420: Camshaft Removal
6A2-10 2.8 LITER V A. Front 40. Bolt 41. Oil Pump 42. Shaft F-6523 Figure 12—Oil Pump Installation Figure 13—Replacing the Camshaft (Typical) CAMSHAFT REMOVAL 3. Connecting rod and piston (figure 15). • Install guide hose over the threads of the rod +•+ Remove or Disconnect (Figure 13) studs to prevent damage to the bearing journal and rod studs.
Page 421: Flywheel Removal
2.8 LITER V 6A2-11 A. Thread Protector B-09433 Figure 15—Replacing the Piston and Connecting Rod (Typical) A. Front FLYWHEEL REMOVAL 85. Bolt 86. Main Bearing Cap 87. Bearing Insert |*"»| Remove or Disconnect 88. Oil Seal 1. Bolts. B-09405 2. Retainer (automatic transmisison only). Figure 16—Crankshaft Installation 3.
Page 422: Cleaning, Inspection, And Repair
6A2-12 2.8 LITER V Figure 17—Removing or Installing the Main Bearing Insert CLEANING, INSPECTION, AND REPAIR A solvent tank, large enough to hold the larger engine — The area where the main bearing inserts parts, will be needed along with various bristle brushes contact the main bearing bore should be and a gasket scraper.
Page 423: Piston And Connecting Rod Assemblies
2.8 LITER V 6A2-13 PISTON AND CONNECTING ROD ASSEMBLIES Refer to GENERAL ENGINE MECHANICAL (SEC. 6A) and perform the following: <+»| Disassemble Components as required. Clean Components as outlined. Inspect Components as outlined. Measure Piston pin diameter and clearance. Piston to bore clearance, and fit the pistons. 1.
Page 424: Camshaft
6A2-14 2.8 LITER V Figure 19—Checking the Camshaft Journals CAMSHAFT Important • Whenever the camshaft needs to be replaced, a new set of lifters must also be installed. Inspect Camshaft lobes and journals for scratches, pitting, scoring, and wear. Measure Camshaft journal diameter (figure 19).
Page 425: Water Pump
2.8 LITER V 6A2-15 + 4- Install or Connect 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 426: Valve Train Components
6A2-16 2.8 LITER V B-09438 Figure 22—Installing the Oil Pump Screen Tighten • Pushrods for bending. Roll the pushrod on a flat surface to determine if it is bent. Replace if • Screws to 9.0 N m (80 in. lbs.). necessary.
Page 427 2.8 LITER V 6A2-17 20. Intake Valve 21. Exhaust Valve 22. Valve Keepers 23. Valve Cap 24. Oil Shedder 90. Rocker Arm Stud 25. Seal 91. Pushrod Guide 26. O-Ring B-09551 B-09444 Figure 23—Valves and Components Figure 25—Rocker Arm Studs •...
Page 428: Thermostat And Water Outlet
6A2-18 2.8 LITER V H| i ,j , i l , Tr|TT|l l , l jH ' l , i i | rr, l , i || | i ' l , i ,Jr r|l | i |j l *, l |i || |i ,Trr 1 ________________ J _________________4 ________________ A.
Page 429: Assembly Of Engine
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 misaligned more than 0.025 mm, the crankshaft is bent and must be replaced, along with the main bearing. B-00549 Figure 28—Measuring the Crankshaft Journals ASSEMBLY OF ENGINE...
Page 430: Rear Crankshaft Oil Seal Installation
6A2-20 2.8 LITER V A. Alignment Hole In Crankshaft 7. Main bearing caps with arrows pointing toward the B. Dust Lip front of the engine. C. Dowel Pin D. Collar 8. Main bearing cap bolts. E. Mandrel F. Screws 85 Crankshaft Rear Oil Seal B-07973 •...
Page 431: Camshaft, Timing Chain And Sprocket Installation
2.8 LITER V 6A2-21 be replaced to insure durability of the camshaft lobes and lifter feet. 1. Camshaft. Important • All camshaft bearing journals are the same diameter and care must be exercised in installing the camshaft to avoid bearing damage.
Page 432: Piston And Connecting Rod Installation
6A2-22 2.8 LITER V The torsional damper has three timing notches on the inertia ring. The number one cylinder timing reference ENGINE LEFT ENGINE FRONT ENGINE RIGHT mark will be identified by a dab of white paint. If a new damper assembly is installed, mark the new assembly in the same place for future reference.
Page 433: Oil Pump 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 transposed from one block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder number.
Page 434: Valve Train Component Installation
6A2-24 2.8 LITER V Figure 40—Rocker Arms and Pushrods VALVE TRAIN COMPONENT INSTALLATION 35. Bolts 36. Bolts If lifter replacement is necessary, use new lifters with a 37. Reinforcem ents narrow flat along the lower 3U of the body length. This 38.
Page 435: Valve Adjustment
2.8 LITER V-6 6A2-25 INTAKE MANIFOLD INSTALLATION Install or Connect (Figure 42) RTV to the front and rear sealing surfaces on the block. Apply a mm (3 /ie-inch) bead of RTV (part 1052917 number or equivalent) to the front and rear of the block as shown.
Page 436: Exhaust Manifold Installation
6A2-26 2.8 LITER V-6 A. Apply Sealer H e re \ 1. Nuts 2. Reinforcem ents 4. Gasket 3. Rocker Arm Cover 5. Studs B-09303 Figure 43—Rocker Arm Cover Installation EXHAUST MANIFOLD INSTALLATION I j j l Clean Mating surfaces of the manifold and cylinder head. Install or Connect (Figure 44) 1.
Page 437: Air Injection Tube Installation
2.8 LITER V-6 6A2-27 Figure 44— Exhaust Manifold Installation Important AIR INJECTION TUBE INSTALLATION • If a new camshaft or hydraulic lifters were installed, add Engine Oil Supplement (GM Part No. 1051396) or equivalent to the engine Install or Connect (Figure 5) oil.
Page 438: Specifications
6A2-28 2.8 LITER V-6 SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in MILLIMETERS unless otherwise noted. GENERAL DATA: 60° V-6 Type 2.8L Displacement 89.0 Bore 76.0 Stroke 8.9:1 Compression Ratio 1-2-3-4-5-6 Firing Order 69 kPa Q 500 RPM; 205-380 kPa (a 2000 RPM Oil Pressure (10 psi (ft 500 RPM;...
Page 439 2.8 LITER V-6 6A2-29 SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) All specifications are in MILLIMETERS unless otherwise noted. CRANKSHAFT Diameter - 3 Dots 67.241-67.249 Diameter - 2 Dots 67.249-67.257 Main Diameter - 1 Dot 67.257-67.265 Journal Taper 0.005 (Maximum) Out of Round 0.005 (Maximum) Main Bearing Clearance 0.041-0.081...
Page 440 6A2-30 2.8 LITER V-6 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Item Ft. Lbs. Rocker Arm Cover Bolts......................Intake Manifold Bolts........................Exhaust Manifold Bolts......................Cylinder Head B o lts ........................Torsional Damper Bolt........................ Timing Chain Damper........................ Front Cover B o lt........................Oil Pan Bolts (Rear Two)..............
Page 441: Special Tools
2.8 LITER V-6 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-35466 J-21882 1. Hydraulic Lifter Remover (Plier Type) 2. Crankshaft Sprocket Installer 3. Crankshaft Sprocket Puller 4. Valve Spring Com pressor 5. Ring Com pressor 6.
Page 443 6A3-1 SECTION 6A3 4.3 LITER V-6 CONTENTS SUBJECT PAGE Description..................................6A3- 2 Engine Lubrication..............................6A3- 2 Disassembly.................................. 6A3- 5 Tools and Shop Equipment............................. 6A3- 5 Accessory Removal..............................6A3- 5 Cleaning..................................6A3- 5 Draining The Engine..............................6A3- 5 EGR Valve Removal..............................6A3- 5 Exhaust Manifold Removal............................. 6A3- 5 Rocker Arm Cover Removal...........................
Page 444: Subject Page
6A3-2 4.3 LITER V-6 CONTENTS SUBJECT PAGE Assembly of Engine (Continued) Front Cover Installation............................6A3-18 Torsional Damper Installation..........................6A3-18 Piston and Connecting Rod Installation......................6A3-20 Oil Pump Installation............................... 6A3-21 Oil Pan Installation..............................6A3-21 Cylinder Head Installation............................6A3-21 Valve Train Component Installation........................6A3-23 Valve Adjustment..............................
Page 445 4.3 LITER V-6 6A3-3...
Page 446 6A3-4 4.3 LITER V-6 Front View Rear View Showing Path Of Oil To Tim ing Chain. Showing Main Gallery, Oil Filter And C rankshaft Oil Feed. F-05526 Figure 2—Engine Lubrication Diagram...
Page 447: Disassembly
4.3 LITER V-6 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 information. Diagrams of emission and vacuum hose routings, wiring harness routing, accessory drive belt layout, etc., should be made before removing accessories.
Page 448: Rocker Arm Cover Removal
6A3-6 4.3 LITER V-6 40. Bolt 41. Retainer 42. Nuts 43. Balls 44. Rocker Arms 45. Pushrods 46. R estrictor 47. H ydraulic Lifter B-07611 Figure 4—Valve Train Components ROCKER ARM COVER REMOVAL VALVE TRAIN COMPONENT REMOVAL |<~+| Remove or Disconnect (Figure 3) Remove or Disconnect (Figure 4) 1.
Page 449: Cylinder Head Removal
4.3 LITER V-6 6A3-7 B-07877 Figure 5—Removing the Torsional Damper CYLINDER HEAD REMOVAL Remove or Disconnect 1. Spark plugs. 2. Cylinder head bolts. 3. Cylinder heads. 4. Head gaskets. TORSIONAL DAMPER REMOVAL Remove or Disconnect (Figure 5) Tool Required: 70. Gasket J 23523-E, Torsional Damper Puller and 71.
Page 450: Piston And Connecting Rod Removal
6A3-8 4.3 LITER V-6 Figure 7—Camshaft and Components PISTON AND CONNECTING ROD • Place a cloth on top of the piston. • Perform the cutting operation with a ridge REMOVAL reamer (figure 9). • Turn the crankshaft until the piston is at TDC. |+“»| Remove or Disconnect (Figures 9 and 10) •...
Page 451: Flywheel Removal
4.3 LITER V-6 6A3-9 CRANKSHAFT REMOVAL Remove or Disconnect • Check the main bearing clearance before removing the crankshaft. Refer to “ Crankshaft and Main A. Guide Rod Bearing Installation” later in this section. B. Thread Protector B-05269 • The main bearings and rear oil seal can be replaced Figure 10—Replacing the Piston and Connecting without removing the crankshaft as outlined later in Rod (Typical)
Page 452: Main Bearing Removal (Without Removing Crankshaft)
6A3-10 4.3 LITER V-6 MAIN BEARING REMOVAL (WITHOUT REMOVING CRANKSHAFT) R e m o ve o r D is c o n n e c t Tool Required: J 8080, Main Bearing Remover/Installer 1. Main bearing caps. • Check the main bearing caps for location markings.
Page 453: Intake And Exhaust Manifolds
4.3 LITER V-6 6A3-11 Alignment of manifold flanges. Use a straight edge M e a su re and feeler gage. If the flanges do not align, the Piston pin diameter and clearance. manifold is warped and should be replaced. Piston to bore clearance, and fit pistons as outlined. CAMSHAFT A s s e m b le Components as outlined.
Page 454: Front Cover
6A3-12 4.3 LITER V-6 Install or Connect 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. — Support the cover at the seal area. Lubricate the seal with engine oil before installing the torsional damper.
Page 455: Valve Train Components
4.3 LITER V-6 6A3-13 NOTICE: Be careful of twisting, shearing or collapsing the pipe while installing the pump. 7. Pickup screen and pipe (if removed) (figure 18). • If the pickup screen and pipe assembly was removed, it should be replaced with a new part.
Page 456 6A3-14 4.3 LITER V-6 CLEANING AND INSPECTION OF COMPONENTS 20. Valve Keeper Refer to GENERAL ENGINE MECHANICAL (SEC. 6A) 21. Cap jjjl and perform the following. 22. Shield Clean 23. O-Ring Seal 24. Seal Components as outlined. 25. Damper Inspect Components as outlined.
Page 457 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 458: Thermostat And Water Outlet
6A3-16 4.3 LITER V-6 • Compress the valve spring using J 8062 (figure 20). Compress the spring enough so the lower valve stem groove can be seen clearly. • Push a new O-ring seal (23) onto the valve stem. The seal is to be installed on the stem’s lower groove.
Page 459: Assembly Of Engine
4.3 LITER V-6 6A3-17 ASSEMBLY OF ENGINE PRIOR TO ASSEMBLY The importance of cleanliness during the assembly procedure cannot be overstressed. Dirt will cause premature wear of the rebuilt engine. Lubricate all moving parts lightly with engine oil or engine assembly lubricant (unless specified otherwise) during assembly.
Page 460: Rear Crankshaft Oil Seal Installation
6A3-18 4.3 LITER V-6 • Tighten screws securely with screwdriver. This will ensure that the seal is A. Rear o f Block installed squarely over the crankshaft. 80. Screw • Turn the handle until it bottoms. 81. Nut • Remove J 35621. 82.
Page 461 4.3 LITER V-6 6A3-19 Figure 29—Camshaft and Components NOTICE: The inertia weight section of the torsional damper is assembled to the hub with rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertia weight section of the hub will destroy the tuning of the torsional damper.
Page 462: Piston And Connecting Rod Installation
6A3-20 4.3 LITER V-6 ENGINE LEFT ENGINE FRONT ENGINE RIGHT A. Oil Ring Rail Gaps B. 2nd Compression Ring Gap Notch In Piston D. Oil Ring Spacer Gap (Tang In Hole Or Slot With Arc) E. Top Compression Ring Gap B-07895 Figure 33—Piston Ring End Gap Locations 3.
Page 463: 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. Without disturbing the ring end gap location, install J 8037 over the piston (figure 34). The piston must be installed so that the notch in the piston faces the front of the engine (figure 33).
Page 464 6A3-22 4.3 LITER V-6 Figure 37—Oil Pan Installation...
Page 465: Valve Train Component Installation
4.3 LITER V-6 6A3-23 (Even numbered cylinders are in the right bank; odd numbered 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 466: Egr Valve Installation
6A3-24 4.3 LITER V-6 40. Bolt 41. Retainer 42. Nuts 43. Balls 44. Rocker Arms 45. Pushrods 46. Restrictor 47. Hydraulic Lifter B-07611 Figure 39—Valve Train Components • Bolts on front and rear exhaust tubes to 28 FLYWHEEL INSTALLATION N m (20 ft. lbs.). -►+ Install or Connect •...
Page 467: Engine Set-Up And Testing
4.3 LITER V-6 6A3-25 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. 2.
Page 468 6A3-26 4.3 LITER V-6 installed, add Engine Oil Supplement (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. Listen for any unusual noises or evidence that any parts are binding.
Page 469: Specifications
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 Compression Ratio 9.3:1 Firing Order - 5 - 4 - 3 - 2 1000 psi @ RPM;...
Page 470 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 Main Production 0.0002 (Maximum) Taper Journal Service Limit 0.001 (Maximum) Out Of Production 0.0002 (Maximum) Round Service Limit 0.001 (Maximum)
Page 471 4.3 LITER V-6 6A3-29 SPECIFICATIONS (CONTINUED) TORQUE SPECIFICATIONS ITEM FT. LBS. IN. LBS. Rocker Arm Cover B o lts ....................10.2 — Intake Manifold Bolts.....................48 Exhaust Manifold Bolts Center Two Bolts....................36 All O th e rs .......................28 Cylinder Head Bolts.......................90 Torsional Damper B o lt....................95 Front Cover Bolts......................13.6 —...
Page 472: Special Tools
6A3-30 4.3 LITER V-6 SPECIAL TOOLS Qn»-— rt) J-8080 1. Torsional Damper Remover and Installer . Stud Remover 2. Valve Spring Compressor 9. Reamer (0.003-inch oversize) 3. Crankshaft Seal Installer 10. Reamer (0.013-inch oversize) 4. Main Bearing Replacer 11. Stud Installer 5.
Page 473 6A4-1 SECTION 6A4 4.8 LITER L6 CONTENTS SUBJECT PAGE Description..................................6A4- 2 Disassembly..................................6A4- 4 Tools and Shop Equipment............................. 6A4- 4 Accessory Removal..............................6A4- 4 Cleaning..................................6A4- 4 Parts Identification..............................6A4- 4 Draining the Engine..............................6A4- 8 Air Manifold and Injection Tube Removal......................6A4- 8 Manifold R em oval..............................6A4- 8 Thermostat Housing R em oval..........................6A4- 9 Water Pump Rem oval.............................
Page 474 6A4-2 4.8 LITER L6 CONTENTS (CONTINUED) SUBJECT PAGE Assembly of Engine (Cont.) Oil Pan Installation..............................6A4-28 Cylinder Head Installation............................6A4-29 Valve Train Component Installation........................6A4-29 Valve Adjustment..............................6A4-29 Checking Valve Tim ing............................6A4-30 Rocker Arm Cover and Tappet Cover Installation....................6A4-30 Water Pump Installation............................6A4-30 Thermostat Housing Installation...........................6A4-30 Intake and Exhaust Manifold Installation......................
Page 475 4.8 LITER L6 6A4-3 A. Oil Pressure Sending Unit B. Distributor Shaft Oiling C. Splash Oiling D. Filter Bypass System E. Full Flow Oil Filter B-09222 Figure 2—Lubrication Diagram (Front View)
Page 476 6A4-4 4.8 LITER L6 DISASSEMBLY 41. Stud . Oil Cap . Pushrod 42. Intake Valve . Clip . Bolt 3. Screw 23. Bolt 43. Exhaust Valve 4. Reinforcement 44. Switch 24. Washer 5. PCV Valve 45. Plug 25. Bracket . Seal 26.
Page 477 4.8 LITER L6 6A4-5 Figure 4—Cylinder Head, Manifolds, and Components...
Page 478 6A4-6 4.8 LITER L6 ( »-108 «^109 1 4 9 B-05056 Figure 5—Block and Components...
Page 479 4.8 LITER L6 6A4-7 145. Bolt 93. Screw 146. Oil Pan 94. Camshaft Gear 147. Front Oil Pan Seal 95. Thrust Plate 148. Bolt 96. Key 149. Nut 97. Spacer 150. Bolt 98. Outer Cam shaft Bearing 151. Oil Pump 99.
Page 480 6A4-8 4.8 LITER L6 182. A ir M a n ifo ld 183. A ir In jectio n Tube 184. Valve B-05058 Figure 7—AIR System Components Figure 8—AIR Manifold Installation DRAINING THE ENGINE Remove or Disconnect (Figure 5) — Oil pan drain plug (144). Allow the oil to drain. —...
Page 481 4.8 LITER L6 6A4-9 mm (7/®” ) B. 55 mm ( -1/8” ) C. 40 mm ( ") mm ( /s” )drill 25 mm ( ” )deep H oles for Pushrods E. 22 mm ( /s” ) d rill 25 mm (1” )deep Holes for Valve Lifters F.

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