Page 3: Important Safety Notice
Consequently, Chevrolet has not undertaken any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Chevrolet must first satisfy himself thoroughly that neither his safety nor vehicle safety will be...
Page 7 AIR CONDITIONING 1B-1 SECTION IB A/C COMPRESSORS CONTENTS Axial Six Cylinder C o m p resso r........IB-1 Radial Four Cylinder C om pressor....... IB-22 Leak Testing..............IB-33 AXIAL SIX-CYLINDER COMPRESSOR Compressor REM OVAL A N D be discarded and new 525 viscosity refrigerant oil added to IN STA LLA TIO N , refer to the ON CA R SERVICE the compressor.
Page 8 Shaft Seal Assembly Seal S eat S eal S eat Retainer Ring A bsorbent Sleeve Pressure Relief V a lv e Seal R etainer Clutch Coil Retainer Ring Compressor Shell Clutch Coil and Housing Assembly Suction Screen Drain Plug Pulley Bearing Bearing R etainer O il Pump G e a r...
Page 9 AIR CONDITIONING 1B-3 FRONT DISCHARGE VALVE PLATE SUCTION REED SHAFT SEAL ASM. ^ - ^ T E F L O N PISTON RING BALL SHELL PULLEY SHAFT \ AXIAL PLATE PULLEY BEARING PISTON SHOE DISC CLUTCH PLATE REAR HEAD HUB ASSEMBLY SEAL SEAT OIL PUMP .y/.y4±;...
Page 10 OVERHAUL MANUAL 1B-4 Remove Pulley and Bearing Assembly using Pulley Puller J-8433 (Fig. 11). Inspection Check the appearance of the pulley and bearing assembly. See Fig. 6. The frictional surfaces of the pulley and bearing assembly should be cleaned with a suitable solvent before reinstallation.
Page 11 AIR CONDITIONING 1B-5 KEYWAY IN SHAFT HOLDING FIXTURE J-9396 Fig. 7 - A l i g n i n g Drive Plate Key Fig. 9 --Checkin g A ir Gap 3. Install pulley and bearing assembly as described in PULLEY BEARING "Compressor Pulley and Bearing Asm."...
Page 12 1B-6 OVERHAUL MANUAL BEARING RETAINER PULLEY A N D B E A R IN G A S S E M B L Y Fig. 1 3 -R e m o v in g Pulle y and B e a rin g Retainer Ring replaced is of great importance, as is the use of the proper, clean service tools.
Page 13 AIR CONDITIONING 1B-7 THIS RIDGE OF TOOL MUST BE UP WHEN ELECTRICAL INSTALLING TERMINALS BEARING PULLEY A N D B EAR IN G INSTALLER SUPPORT BLOCK J - 2 1 Fig. 1 7 — 1 nsta lling Coil H ousin g Fig.
Page 14 1B-8 OVERHAUL MANUAL O-RING INSTALLER J-21508 SEAL INSTALLER J -9 3 9 2 ^ SEAL PROTECTOR J-22974 Fig. 2 0 --Repla cin g Seal and O-Ring Replace 1. Coat new seal seat O-ring with clean 525 viscosity making refrigerant oil and install in compressor neck, certain it is installed in bottom groove (Fig.
Page 15 AIR CONDITIONING 1B-9 L E A K TEST DISCHARGE SYSTEM BEFORE O IL F IT T IN G ADAPTER REMOVING HIGH PRESSURE J-9625 RELIEF VALVE HI. PRESS. Fig. 22--Leak T estin g A-6 C o m pressor RELIEF VALVE 4. Coat the seal face of the new seal seat with clean 525 viscosity refrigerant oil.
Page 16 IB-10 OVERHAUL MANUAL REAR D IS C H A R G E REED R ETAINERS REAR HEAD HOLDING FIXTURE SHELL Fig. 2 6 - R e m o v in g Rear Dis c h a rge Valve Plate on identical position. 8.
Page 17 ■ | AIR CONDITIONING IB-11 OIL PICK-UP TUBE REMOVER J-5139 Piston Front Cylinder Half SUPPORT OIL PICK-UP TUBE Fig. 28--Removing Oil Pick-U p Tube Fig. 3 0 - N u m b e r i n g Piston and C y lin d e r Bores head.
Page 18 IB-12 OVERHAUL MANUAL TEFLON RING GROOVE Thrust Races (PISTON FRONT END) SUPPORT Fig. 32 --N o tch I d e n tify in g Fro n t End o f A-6 Piston BLOCK J-21352 replace the piston rings as required if either condition exists. Fig.
Page 19 AIR CONDITIONING 1B-13 Thrust Bearing Holding Fixture J-9 9 396 B ALL Compressing Fixture J-9397 Fig. 3 7 — 1 nsta lling FRONT Shoe Disc Fig. 3 6 — In sta llin g Rear T h r u s t Races and Bearin gs clean wood and ham m er (Fig.
Page 20 OVERHAUL MANUAL IB-14 8 ounces is obtained. Record clearance between ball and axial plate that results in the 4 to 8-ounce pull on Spring Scale. 16. Now rotate shaft 120° and repeat Step 15 between same ball and axial plate. Record this measurement. If shaft is hard to rotate, install shaft nut onto shaft and turn shaft with wrench.
Page 21 AIR CONDITIONING 1B-15 THRUST BEARING RACE SHOE DISC MIN.FEELER PART NO. IDENTIFICATION DIAL INDICATOR PART NO. IDENTIFICATION STAMP ENDING IN STAMP READING ENDING IN GAGE READING .0000 .0000 .0050 17-1/2 .0175 .0180 5-1/2 .0055 .0060 .0185 18-1/2 .0190 6-1/2 .0065 .0070 19-1/2 .0195...
Page 22 IB-16 OVERHAUL MANUAL J -2 4 6 0 8 -5 R IN G INSTALLER Fig. 4 4 - C h e c k in g Piston and S h a ft End Play TEFLON R IN G Installer Segment Retainer O-Ring J-24608-3 will be stretched and possibly weakened during Fig.
Page 23 AIR CONDITIONING 1B-17 "SELECTED" REAR SHOE DISC "SELECTED" REAR THRUST RACE THRUST BEARING "Z E R O "T H R U S T RACES. LI FT SHAFT UPWARD " Z E R O "F R O N T SHOE DISC AND HOLD THE THRUST RACES AND BEARING...
Page 24 IB-18 OVERHAUL MANUAL PISTONS IN " S T A I R S T EP " POS ITION REAR T H R U S T RACES A N D B E A R IN G cross-over tube with the hole in the rear half of the cylinder. 8.
Page 25 AIR CONDITIONING 1B-19 Front Discharge Valve Dowel Pins Plate Assembly BUSHING SUPPORT BLOCK RING J-21352__________ ! Fig. 5 8--I nsta lling Fro nt Dis c h a rge Valve Plate Remove Support Block. Fig. 5 6 — In sta llin g O-Ring On Dis ch a rge Cross-over Tub e 12.
Page 26 1B-20 OVERHAUL MANUAL Fig. 6 0 — I nsta llin g Fro nt Head Casting Fig. 6 2 — 1 nsta lling A-6 C o m p r e s s o r Shell with 525 viscosity refrigerant oil around outer edge where pins.
Page 27 AIR CONDITIONING 1B-21 IN N E R G E A R F R O N T H E A D C A V IT Y B E T W E E N G E A R TEETH (3 O 'C L O C K ) O IL S U M P (6 O 'C L O C K ) O IL D R A IN PLU G...
Page 28 OVERHAUL MANUAL 1B-22 REAR HEAD SLIGHTLY ROTATE FRONT HEAD IF NECESSARY TO LINE UP LOCATOR PINS AND HOLES I Fig. 6 6 — In sta llin g Rear Head R4 -C0 MPRESSOR OVERHAUL Among them are replacement of the clutch drive plate and GENERAL hub assembly, clutch rotor and bearing assembly and clutch When servicing a compressor, it is essential that steps...
Page 29: Air Conditioning
AIR CONDITIONING 1B-23 15. Pressure Relief Valve 1. Screw 24. Belleville W asher 16. O-Ring 2. Locking W asher 25. O-Ring 17. Screw 3. Pulley Rim 26. Shell Assy. 18. Shipping Plate 4. Coil and Housing Assy. 27. Ring Seal 19.
Page 30 OVERHAUL MANUAL 1B-24 DISCHARGE SUCTION PORT PORT J9401 CLUTCH PLATE AND HUB ASSEMBLY HIGH PRESSURE RELIEF VALVE Fig. 6 8 — I nsta lling H o ld in g Fixture 9401 into hub. Hold body of tool with a wrench and turn center screw into J-9401 remover to remove clutch plate and hub assembly (Fig.
Page 31 AIR CONDITIONING 1B-25 J -9 4 8 0 -1 J - 9 4 8 0 - 2 J-23128 A IR G A P ( .0 2 0 " — . 0 4 0 " ) CERAMIC SEAL SEAT J-22974 Fig. 7 2 — 1 nstallin g Clu tch Plate and Hub A s s e m b ly Install a new shaft nut with the small diameter boss Fig.
Page 32 OVERHAUL MANUAL 1B-26 CLUTCH ROTOR BEARING RETAINING RING Fig. 7 5--I nstaI ling Seal Seat " 0 " Ring Fig. 7 6 - R e m o v in g Be a rin g R etain in g Ring rotor until the puller arms engage the recessed edge of rotor hub.
Page 33 AIR CONDITIONING 1B-27 J -25031-2 BEARING STAKE LOCATIONS Fig. 7 8--Installing Rotor and Bearin g Puller Fig. 80-- B e a rin g Stake Lo c a tion s CLUTCH ROTOR BEARING REPLACEMENT Removal 1. Perform "Compressor Clutch R otor and Bearing Assembly Removal"...
Page 34 OVERHAUL MANUAL 1B-28 SP AC E R -U S E PIECE OF F L A T STOCK ROTOR A N D BE ARING ASM. IN S T A L L E R J 25008-1 HO LDING F IX T U R E Fig.
Page 35 AIR CONDITIONING 1B-29 Fig. 85--Remove Fro nt Head A s s e m b ly seal ring (Fig. 86) or the Belleville and thrust washers may be replaced. Installation 1. Check front head and compressor cylinder area for any dirt or lint and install a new thrust washer kit if Fig.
Page 36 OVERHAUL MANUAL 1B-30 Fig. 8 7 - R e p la c in g T h r u s t and Bellevil le W a s h e rs Fig. 8 8 - R e m o v in g M a in Bearin g into front head (Fig.
Page 37 AIR CONDITIONING 1B-31 SHELL RETAINING STRAP Fig. 90--Releasing R etain in g Strap Fig. 9 2 --Rem oving Valve Plate 1. Pry shell retaining strap away from cylinder and If one screw appears to require more force to turn than position the strap high enough to clear cylinder as shell is the other, immediately turn the other screw to bring the removed (Fig.
Page 38 1B-32 OVERHAUL MANUAL P IS T O N A N D REED A SSE M BLY Fig. 9 4 — I nsta11ing Shell A s s e m b ly Fig. 9 3 -- ln s p e c tin g Piston and Reed A s s e m b ly rings and back against shell stop flange at the rear of Oil Charge-Compressor Replacement compressor cylinder.
Page 39 AIR CONDITIONING 1B-33 COMPRESSOR LEAK TESTING - EXTERNAL AND INTERNAL A-6 and R-4 Compressors type valve. Bench-Check Procedure NOTE: Oil will drain out of the compressor suction 1. Install Test Plate J-9625 on rear head of compressor. port adapter if the compressor is positioned with the 2.
Page 40 1B-34 OVERHAUL MANUAL 1. J -83 9 3 C h a rg in g Station 11. J -5 4 2 1 -0 2 Pocket Thermometers (2) 22. J-93 9 8 Pulley B earing Remover 2. J -2 4 0 9 5 O il Inducer 23.
Page 41 AIR CONDITIONING 1B-35 1. J - 2 5 0 3 0 C lu tc h H u b H o ld in g T o o l J - 2 5 0 2 9 R otor B e a r in g R e m o v e r a n d R otor Assy.
Page 43 STEERING 3B-1 SECTION 3B STEERING CONTENTS OF THIS SECTION M anual Steering G ears................3B-1 Power Steering P u m p ................3B-7 Integral Power Steering G e a r..............3B-12 C ontrol Valve - Corvette................3B-24 Power C ylinder-C orvette.................3B-29 Special T ools....................3B-30 MANUAL STEERING GEARS INDEX Overhaul O perations............
Page 44 3B-2 OVERHAUL MANUAL PITMAN SHAFT BALL NUT WORM BEARING SECTOR (LOWER) WORMSHAFT WORM BEARING (UPPER) ADJUSTER PLUG SEAL BEARING S E C TO R W O R M S H A F T LOCK NUT BEARING CLAMP EXPANSION GUIDE BEARINGS PLUG Fig.
Page 45 STEERING 3B-3 Fig. 3 B -7 ~ R e m o v in g Lower Be a rin g R e ta in e r- E x c e p t Corvette Fig. 3B-8--Rem ovin g Pitman S h a ft B u s h in g - T y p ic a l Repairs expansion plug out of the lower end of the housing.
Page 46 3B-4 OVERHAUL MANUAL W O R M BEARING RACE Fig. 3 B - 10— I nsta I li ng W o r m s h a f t Be a rin g Race-Typica l Fig. 3B-1 2--F i llin g Ball C ir c u its -C o r v e tte 3.
Page 47 STEERING 3B-5 Upper Worm Bearing Race Worm Bearing Adjuster Lash Adjuster Pitman Shaft Seal Lash Adjuster Shim Locknut Worm Bearing Adjuster Housing Housing Side Cover and Lower Worm Bearing Race Wormshaft Seal Bushing Assembly Side Cover Gasket Lower Ball Bearing Lash Adjuster Locknut Pitman Shaft Bushing Side Cover Bolts...
Page 48 3B-6 OVERHAUL MANUAL Side Cover Screws E xpansion Plug W orm Bearing Race—U pper S teering Gear Housing Lash A d ju s te r L o c k n u t A d ju s te r Plug Side Cover and B ushing P itm an S h a ft Seal W o rm s h a ft Seal Lash A d ju s te r S him...
Page 49: Power Steering Pump
STEERING 3B-7 center tooth space of the ball nut. turn stop and then turn back about one-half turn. 9. Pack the remaining portion of lubricant into the 3. Tighten the adjuster plug until the proper thrust housing. bearing preload is obtained; (See the Specifications at the rear 10.
Page 50 OVERHAUL MANUAL 3B-8 L-6 AND SMALL V-8 MARK V-8 Spring M ounting Stud Square Ring Seals Union Union " 0 ” Ring Seal Pressure Plate Flow C ontrol Valve M ounting Studs 12.. Pump Ring Flow C ontrol Valve Spring Reservoir Mark Engine &...
Page 51 STEERING 3B-9 Fig. 3 B - 2 0 --lm p e lle r U n it Removal Fig. 3 B -2 2 -- ln s ta llin g Seal Using Tool J - 2 2 6 7 0 2. Install both dowel pins in the pump housing and install a new pressure plate "O"...
Page 52 3B-10 OVERHAUL MANUAL ARROW Fig. 3 B -2 4 --ln s ta llin g S h a ft S nap Ring Fig. 3 B - 2 6 - l n s t a l l i n g Pu m p Ring rotor as shown in Figures 3B-27 and 3B-28.
Page 53 STEERING 3B-11 D O W EL CRO SS-O VER HOLE PUMP R IN G HOLE PUMP ROTOR Fig. 3 B -3 0 -- ln s ta llin g End Plate Retaining Ring PUMP V A N E S Fig. 3 B - 2 8 ~ C o r r e c t V a n e A s s e m b ly Fig.
Page 54 3B-12 OVERHAUL MANUAL INTEGRAL POWER STEERING GEAR INDEX Overhaul O perations............3B-12 R ack-P iston............... 3B-18 Disassem bly..............3B-12 Hose Connector Inverted F la re s ......3B-19 Overhauling Individual U n its........3B-15 Pitm an Shaft Needle Bearing and Seals..... 3B-19 Pitman Shaft Seal Removal Adjuster Plug A ssem bly..........3B-15 Valve and Stub Shaft A ssem bly......3B-16...
Page 55 STEERING 3B-13 2. Turn the stub shaft counter-clockwise until the rack- piston just forces end cover out of housing. Remove cover and discard "O" ring. CAUTION: DO N O T turn the stub shaft any further than absolutely necessary to remove the end plug, or balls from rack-piston and worm circuit may escape and lay loose inside the rack-piston chamber.
Page 56 3B-14 OVERHAUL MANUAL Locknut Valve Body Balls Retaining Ring Stub Shaft Rack-Piston Dust Seal " 0 " Ring Teflon Oil Seal Oil Seal Wormshaft " 0 " Ring Bearing Thrust Washer Plug Adjuster Plug Thrust Bearing " 0 ” Ring "...
Page 57 STEERING 3B-15 RACK PISTON 1. R eta in in g Ring 5 . A d ju s te r Plug 8 . Thrust Bearing 2 . Dust S eal " O " Ring 9 . Thrust W asher (S m a ll) 3 .
Page 58 OVERHAUL MANUAL 3B-16 Fig. 3 B-4 1--Removing Bearin g and Seal Fig. 3 B - 4 3 — In s ta llin g A d ju s t e r Plug Seal bottomed on the stub shaft assembly. V a |v e g n d s h a f t A s s e m b |y Disassembly 3.
Page 59 STEERING 3B-17 "O ” RING SPOOL VALVE TEFLON RINGS (3) "O ” RINGS (3) INSTALLED UNDER TEFLON RINGS VALVE BODY DISENGAGE STUB SHAFT STUB SHAFT PIN FROM HOLE IN SPOOL VALVE "O" RING Fig. 3 B -4 5--Rem ovin g Stu b S h a ft A s s e m b ly Fig.
Page 60 OVERHAUL MANUAL 3B-18 NOTCH IN END CAP MUST FULLY ENG AG E PIN PROJECTING INTO VALVE BODY BACK-UP O-RING MUST BE INSTALLED RACK-PISTON UNDER PISTON RING Fig. 3 B -4 9 — In s ta llin g Ring on Rack-Piston Fig.
Page 61 STEERING 3B-19 CONNECTOR SPRING POPPET 4 . Steel Washer 6. Steel Washer 1. Housing Fig 3B -5 1 --In sta llin g N ew C o n n e c to r in H o u sin g 2. Bearing 5.
Page 62 3B-20 OVERHAUL MANUAL NOTE: Only one layer of tape should be used; an RETAINING RING excessive am ount of tape will not allow the seals to pass BACK UP WASHER over it, due to the close tolerance between the seals and the pitm an shaft.
Page 63 STEERING 3B-21 STUB VALVE SHAFT BODY B E A R IN G W ASHERS Fig. 3 B -5 6 --W o rm and V a lve B o d y -E x p lo d e d V ie w Fig.
Page 64 OVERHAUL MANUAL 3B-22 A D J U S T E R P L U G Fig. 3 B -6 0 — I nsta 1 1 i ng A d ju s te r Plug 8. Install a new housing end cover "O" ring and lubricate it with Power Steering Fluid.
Page 65 STEERING 3B-23 Fig. 3 B -6 5 -M e a s u re B ack and R em ark H ousing Fig. 3 B -6 7 --T ig h te n Lock N ut...
Page 66 3B-24 OVERHAUL MANUAL Fig. 3 B-6 8 — I nsta llin g Rack Piston Fig. 3 B -7 0 -T o rq u in g O ver-C enter L o c kn u t Fig. 3 B -6 9 ~ A d ju s tin g Over C e n te r P reload CONTROL VALVE-CORVETTE INDEX Overhaul O perations..................
Page 67 STEERING 3B-25 OVERHAUL OPERATIONS Hold the bolt from rotating while turning the nut off the bolt. Disassembly This will force the washer against the port boss face and will 1. Place the valve in a vise as shown and remove dust back out the bolt thus drawing the connector seat from the cover (fig.
Page 68 3B-26 OVERHAUL MANUAL Fig. 3 B -7 3 ~ R e m o vin g S p o o l fro m H o u sin g Fig. 3 B -7 5 ~ R e m o vin g Plug-to-S leeve Key NOTE: If the rod extends upon starting the pump, move the Always use a new nut.
Page 69 STEERING 3B-27 Fig. 3 B -7 7 --T u rn in g A d ju s te r Plug o u t o f Sleeve Fig. 3 B -7 9 --ln s ta llin g C o n n e c to r Seat Fig.
Page 70 3B-28 OVERHAUL MANUAL D ust Cover V a lve S h a ft 1 1. S p rin g T h ru s t W a sh e r A d ju s tin g Nut Ball Seat S p rin g V alve S p ring Ball Seat Vee B lo ck Seal...
Page 71 STEERING 3B-29 POWER CYLINDER-CORVETTE OVERHAUL OPERATIONS out using Tool J-8937. Disassembly (Fig. 3B-84) 1. To remove the piston rod seal, remove the snap ring; Assembly then pull out on rod, being careful not to spray oil. 1. Reassemble the piston rod seal components by 2.
Page 72: Special Tools
3B-30 OVERHAUL MANUAL SPECIAL TOOLS Pitman A rm Puller J-7539 Ball Retainer 1. J-6632 J-7624 Spanner Wrench Pitman A rm Puller J-5504 S h ift Tube Installer J-4245 No. 23 Internal Pliers J-23073 S h ift Tube Remover J-22670 Pump S haft Seal Installer J-23072 Oil Pressure Gauge J-6222...
Page 73: General Information
Truck - D ana 10-1/2" and 9-3/4" Ring G e a r... 4B-54 T ruck 8-7/8 Ring G e a r........... .. 4B-15 Truck - Chevrolet 12-1/4" Ring G e a r ......4B-68 C orv ette................4B-27 Eaton Positive Locking D ifferentials......
Page 74 4B-2 OVERHAUL MANUAL Fig. 4 B -3 A ~ P in io n G a u g in g T o o ls - 8 1 /2 " Ring G ear Fig. 4 B -4 A -P in io n G a u g in g T o o ls - C orvette 4.
Page 75 REAR AXLE DIFFERENTIAL 4B-3 11-(N O T ON B O TYPE AXLES) 1. Companion Flange 13. Cover 19. Thrust Washer 7. Differential Case 2. Deflector 14. Pinion Shaft 20. Differential Pinion 8. Shim 3. Pinion Oil Seal 15. Ring Gear 21.
Page 76 4B-4 OVERHAUL MANUAL Fig. 4 B -2 --D iffe re n tia l Case Rem oval gear, or J-25299 for 7-1/2" ring gear, as shown in figure Inspection 4 B 4 . 1. Clean all parts in cleaning solvent; inspect all bearing Before bearing installation on opposite hub, support cups, races and rollers for scoring, chipping or evidence of differential case on proper adapter plug.
Page 77 REAR AXLE DIFFERENTIAL 4B-5 Now measure the above dimensions as shown in Figure 4B-8, for 8-1/2" and 8-3/4" ring gear, figure 4B-7 for the 7-1/2" ring gear. 5. For the 8-1/2" and 8-3/4" ring gear: Using a m icrometer as in Figure 4B-9, measure the thickness of J- 22779 in a m inim um of three places and average these readings.
Page 78 4B-6 OVERHAUL MANUAL A-SERVICE SPACER B - SERVICE SHIM C - FEELER GAUGE BEARING BEARING CARRIER CARRIER RING GEAR EXAMPLE RING GEAR SIDE OPPOSITE SIDE Com bined to ta l o f: Combined to ta l Service Spacer ( A ) Service Spacer (A ) Service Shim...
Page 79 4B-7 REAR AXLE DIFFERENTIAL EXAMPLE OPPOSITE SIDE RING GEAR SIDE Thickness o f Tool J-22779 Combined to ta l o f: required force ring Service Spacer (A ) .265” .250” gear in to contact w ith Service Shim (B ) pinion Feeler Gauge (C )
Page 80 4B-8 OVERHAUL MANUAL Fig. 4B-1 1--C hecking Ring G ear B acklash Fig. 4 B -9 --M e a s u rin g G auge T h ic kn e ss Bearing Removal and Cup Replacement Remove flange by turning J-8614-3 while holding J-8614-11 1.
Page 81 REAR AXLE DIFFERENTIAL 4B-9 DRIFT Fig. 4 B - 1 5--R em oving D rive Pinion Fig. 4B -1 3 --D rive P in io n N u t Rem oval from the design or "nominal" setting due to allowable 5.
Page 82 4B-10 OVERHAUL MANUAL Fig. 4 B -1 7 — In s ta llin g P inion Rear B e a rin g Cup Fig. 4 B -1 9 --G a ug e Plate In sta lle d 3. Position gauge plate J-2 1777-29 on preload stud J- of the arbor with the contact button resting on the top surface 21777-43 (8-1/2"...
Page 83 REAR AXLE DIFFERENTIAL 4B-11 "ZE R O " THE INDIC A TO R , WITH THE PROBE ON THE HIGH POINT OF THE GAUGING SURFACE. Fig. 4 B -2 1 --D e p th G auge In s ta lle d in P ositio n T y p ic a l to move.
Page 84 4B-12 OVERHAUL MANUAL PROTECTIVE TUBE OR PIPE REAR PINION BEARING INSTALLER Fig. 4 B -2 3 --D rive P in io n Rear B e a rin g In s ta lla tio n Fig. 4 B -2 5 --D rive P in io n F lan g e In s ta lla tio n when Holder J-8614-11 will no longer pivot freely as am ount of tightening.
Page 85 REAR AXLE DIFFERENTIAL 4B-13 2. Use gear marking com pound and apply this mixture sparingly to all ring-gear teeth using a medium stiff brush. W hen properly used, the area of pinion tooth contact will be visible when hand load is applied. 3.
Page 86 4B-14 OVERHAUL MANUAL Fig. 4 B -2 8 --G e ar T eeth C o n ta ct Pattern C heck...
Page 87 REAR AXLE DIFFERENTIAL 4B-15 SERIES 10 TRUCK DIFFERENTIAL 8 — 7 / 8 RING GEAR INDEX Checks and Adjustments Differential Case Drive Pinion Pinion Bearing Preload....4B-25 Removal and Disassembly ..4B-16 Removal........
Page 88 4B-16 OVERHAUL MANUAL DIFFERENTIAL CASE Inspection Removal and Disassembly Clean all p arts in cleaning solvent; inspect all bearing cups, races and rollers for scoring, chipping N O T E: Before pro ceed ing w ith following or evidence o f excessive w ear. steps, it is advisable to check the existing ring gear to p inion backlash as described u n der Inspect axle sh aft and side gear splines for evidence...
Page 89 REAR AXLE DIFFERENTIAL 4B-17 Position p inions and thru st w ashers thro u gh loading hole in case 180° a p a rt so they engage side gears. Rotate gears until the differen tial p in io n bores and the case sh a ft holes are aligned.
Page 90 4B-18 OVERHAUL MANUAL EXAMPLE RING GEAR SIDE OPPOSITE SIDE Thickness o f T ool J-22779 Combined to ta l o f: required force ring Service Spacer (A ) .250” .265” gear in to contact w ith Service Shim (B ) pinion Feeler Gauge (C )
Page 91 REAR AXLE DIFFERENTIAL 4B-19 places and average these readings. R ecord the result. A dd together the dim ensions o f the Service Shim , Service Spacer an d F eeler G auge. R ecord the result. sam ple proced u re F igure determ in e the p roper thickness fo r each shim pack.
Page 92 OVERHAUL MANUAL 4B-20 Fig. 12B—Drive Pinion N u t Removal Fig. 1 I B —Checking Ring Gear R unout N O TE: C are m ust be tak en not to dam ag e backlash exceeds .008", increase shim p inion bearings w hile rem o v in g p in io n from thickness on the ring g ear side, w hile decreasing the an equal shim...
Page 93 REAR AXLE DIFFERENTIAL 4B-21 Fig. 16B—In sta llin g Pinion Rear B earing Cup Fig. 14B—Removing Drive Pinion Install the fro n t cup, w ith the large end against the Rem ove rea r pinion b e a rin g from pinion sh aft bore shoulder, using Installer J-7137 as shown in using Press Plate J-22912, as shown in figure 15B.
Page 94 OVERHAUL MANUAL 4B-22 " n o m in a l" settin g allo w ab le v a ria tio n m achining the parts. W hen a p in io n is fo u n d h aving a plus or m inus reading recorded in th o u san d th s on the re a r face o f the pinion, this indicates th a t the pinion d urin g testing was found to have best tooth contact at a...
Page 95 REAR AXLE DIFFERENTIAL 4B-23 indicator read in g. F o r exam ple, if indicator read in g is .019, and p in io n is m arked ( + 2), the correct dep th shim fo r in stallatio n will be .019 + .002 = .021 inch.
Page 96 OVERHAUL MANUAL 4B-24 Fig. 2 6B —Insta llin g Pinion Oil Seal—Truck Fig. 24B —In sta llin g Rear B e a rin g -T ru c k pinion nut and tighten sufficiently to draw pinion c a rrie r shoulder and seal flange. T u rn gauge plate through the fro n t b earin g fa r enough to leave 180°;...
Page 97 REAR AXLE DIFFERENTIAL 4B-25 or 10-15 inch pounds on reused b earings. Use an C ontact P attern Check is necessary to v erify the correct inch-pound torque w rench such as J-5853, as shown relationship betw een rin g gear an d drive pinion . G ear in figure 28B, to m easure the ro tatin g torque.
Page 98 OVERHAUL MANUAL 4B-26 Adjustments Affecting Tooth Contact tolerances. Increasing shim thickness will move the Two adjustm ents can be m ade w hich will affect tooth contact pattern . These are backlash and position o f drive p inio n closer to centerline o f the rin g gear. D ecreasing p inion in carrier.
Page 99 REAR AXLE DIFFERENTIAL 4B-27 CORVETTE DIFFERENTIAL INDEX Differential Case Drive Pinion Checks and Adjustments Removal and Disassembly... 4B-28 Removal.........4B-31 Pinion Bearing Preload....4B-35 Side Bearing Repl......4B-28 Inspection ........4B-32 Side Bearing Preload.....4B-35 Ring Gear or Case Repl....4B-28 Bearing Repl........4B-32 Pinion Depth and Backlash..
Page 100 OVERHAUL MANUAL 4B-28 DIFFERENTIAL CASE J 22 8 8 8 Removal and Disassembly C lam p carrier in H olding F ixture J-3289. Rem ove snap rings securing side gear yokes and pull yokes out o f carrier. See F igure 1C. M ark differential b earin g caps for reassem bly in sam e relative location and rem ove caps.
Page 101 REAR AXLE DIFFERENTIAL 4B-29 J-9774 Fig. 5C—Ring Gear Guide Pins Installed Install every other ring g e a r bolt and draw ring Fig. 7C—In sta llin g Side Gear Yoke Seal g ear up evenly until g ear is seated against flange. Installation and Adjustment Rem ove guide pins and install re m a in in g ring gear bolts.
Page 102 OVERHAUL MANUAL 4B-30 Shim Id e n tifica tio n Shim Notches Thickness I.D. O.D. .040 .042 .044 .046 .048 .050 .052 .054 .056 .058 .060 .062 .064 .066 .068 .070 Fig. 9C—M easuring D iffe re n tia l Shim Requirem ent .072 .074 .076...
Page 103 REAR AXLE DIFFERENTIAL 4B-31 Fig. 11C—Insta llin g D iffe re n tia l Shim Fig. 13C—Checking Ring Gear Runout EXAM PLE: .008" preferred . Check re ad in g at fo u r equally spaced positions around the ring gear. V ariatio n in G auge thickness (h ig h er r e a d in g ) ....
Page 104 OVERHAUL MANUAL 4B-32 Inspection Clean all gears and b earin gs in cleaning solvent and blow dry. N O TE: D o not spin b earin g s d u rin g drying process. The extrem ely fast sp in n in g and lack o f lubrication m ay quickly result in the failure o f an otherw ise reusab le bearing.
Page 105 REAR AXLE DIFFERENTIAL 4B-33 o rd er com pensate fo r allow able m achining variables, a procedu re o f gaging the ca rrie r and shim m ing the pin ion has been developed. A fter gaging carrier, assem bler m ust install...
Page 106 4B-34 OVERHAUL MANUAL Check the re a r face o f the p inion being installed for a pinion code num ber. T his n um ber indicates Preload the dial in d icato r one h a lf revolution, and necessary alteratio n p inion...
Page 107 REAR AXLE DIFFERENTIAL 4B-35 PROTECTIVE TUBE OR PIPE J—8 6 0 9 Fig. 25C—M easuring R o tating Torque ... - ..: Fig. 23C—Insta llin g Pinion Rear Bearing are a) Pinion Bearing P reload, b) Side B earing Preload, c) Pinion D ep th and d) R ing gear-to -P in io n Backlash.
Page 108 OVERHAUL MANUAL 4B-36 Adjustments Affecting Tooth Contact Two adjustm ents can be m ade w hich will affect tooth contact p attern . These are backlash and position o f drive pinion in carrier. The effects o f b earin g prelo ads are not readily ap p aren t on hand loaded teeth p a tte rn tests: however, these adjustm ents should be w ithin specifica...
Page 109 REAR AXLE DIFFERENTIAL 4B-37 Fig. 27C—Gear Tooth Contact Pattern LIMITED SLIP DIFFERENTIAL UNITS INDEX G en eral D escrip tio n ................. 4B-38 E a to n P o s itr a c tio n ................4B-39 D is a s s e m b ly ..................4B-39 I n s p e c t i o n .........
Page 110: General Description
4B-38 OVERHAUL MANUAL GENERAL DESCRIPTION Vehicles w ith 8 1 /2 " ring g ear o r 8 7 /8 " rin g gear axles use three optional lim ited slip differentials, nam ely C hevrolet, E aton and Borg W a rn e r. C orvette uses only the E aton unit.
Page 111 4B-39 REAR AXLE DIFFERENTIAL EATON POSITRACTION—FIGURE 2D Disassembly Rem ove ring gear and side bearin g s follow ing the procedures established fo r the conventional differ ential unit. For all models except Corvette, rem ove the preload spring re ta in e r and springs by tap p in g on the spring retain er through the o b serv atio n hole in the case.
Page 112 4B-40 OVERHAUL MANUAL Fig. 7D —Removing Preload Springs from Pack Fig. 9D —Removing Side Gear For Truck Models S eparate clutch pack assem bly from side gear. roll out the differential pinions R etain clutch pack assem bly w ith origin al side gear. and thrust w ashers.
Page 113 REAR AXLE DIFFERENTIAL 4B-41 Fig. 10D—Assem bling Clutch Pack Position pin io n gears an d th ru st w ashers on side gears. Install pinion sh a ft th ro u g h case and gears. Install dial indicator in case so th at contact button rests against pinion g ear as shown in F igure 1 ID .
Page 114 4B-42 OVERHAUL MANUAL CHEVROLET POSITRACTION-FIGURE 16D A C hevrolet produced P ositraction differential un it is used optionally in 8 1/2 inch rin g gear axles. Individual com ponents o f this positraction un it are not in terch a n g e...
Page 115 SHIM BOLT (PINION SHAFT) SPLINED DISC (3) PINION FIXED SHAFT DISC (4) THRUST WASHER BOLT SIDE PINION (RING G E A R )^ GEAR GEAR ^-PRELOAD SIDE SPRING BEARING Fig. 16D—Chevrolet Positraction—Exploded...
Page 116 4B-44 OVERHAUL MANUAL POWER-LOK DIFFERENTIAL Rem ove five plates and discs from side g e ar ring. The Power-Lok differential show n in F igure 17D is a N O TE: A series o f clutch plates and dished unit w hich is installed as o p tio nal eq u ipm en t in place o f (Belleville) friction plates on each side o f the stan d ard differential.
Page 117 REAR AXLE DIFFERENTIAL 4B-45 Inspect clutch discs and plates for w ear, cracked, or Before tightening bolts, use axle shafts and align splines o f the side gear and side g ear ring, on each disto rted co n d itio n . R e fe r "S p ec ific a tio n s"...
Page 118 7. Collapsible Spacer 17. Side Bearing A djusting Nut 8. Pinion Rear Bearing 18. Adjusting N u t Retainer 9. Drive Pinion Fig. IE -C ro s s Section of Chevrolet Truck Differential with 10 1 /2 " Ring Gear...
Page 119 REAR AXLE DIFFERENTIAL 4B-47 DIFFERENTIAL CASE Removal M ount axle assem bly in a bench vise or holding fixture. Rem ove cover bolts and cover, as seen in figure 2E, and allow lubricant to d ra in into pan. Rem ove axle shafts as o u tlined in Truck Service M anual.
Page 120 OVERHAUL MANUAL 4B-48 Loosen the right side ad ju stin g nut and tighten the left side nut, using J-24429 as shown in figure 3E, until the ring gear contacts the drive pinion. Do not force the gears into contact so as to bind them . At this point, zero lash is ob tain ed .
Page 121 REAR AXLE DIFFERENTIAL 4B-49 DRIVE PINION ASSEMBLY Removal Rem ove differential as previously outlined. Check pinion b earing p relo ad as described u n der "D riv e Pinion - R eassem bly". R ecord the result. If there is no preload read in g , check for looseness o f pin io n assem bly by shaking the com panion flange.
Page 122 4B-50 OVERHAUL MANUAL Fig. 10E—Pressing Drive Pinion from Bearing Fig. 11E—Removing Pinion Rear Bearing Retainer Inspect the bearing re ta in e r for cracks, im p erfec tions, corrosion, pits and grooves. Replace p arts as required. Reassembly Lubricate all parts w ith hypoid lubricant. Press pin io n rear b earin g onto drive pinion as shown in figure 13E, using J-24433.
Page 123 REAR AXLE DIFFERENTIAL 4B-51 the drive pinion. Install a new collapsible spacer CODE NUMBER ON O R IG IN A L PINIO N into position. Press fro n t bearin g onto drive pinion. L ubricate the oil seal lips w ith a lithium -base A D D .001 A D D .002 A D D .003 AD D .004 extrem e pressure lu bricant, an d install the seal in the retain er bore.
Page 124 4B-52 OVERHAUL MANUAL teeth. W hen p ro p erly applied, the a re a o f tooth contact will be clearly visible a fte r load is applied. T ighten b earing cap bolts to specifications. A pply load to gears by ex p an d in g brake shoes or by w rap pin g a heavy rag aro u n d the co m p an ion flange to resist rotation.
Page 125 REAR AXLE DIFFERENTIAL 4B-53 Fig. 18E—Gear Teeth Contact Pattern Check...
Page 126 4B-54 OVERHAUL MANUAL DANA DIFFERENTIALS 10 -1 /2 " RING GEAR INDEX D ifferential C ase— R em oval and D isassem bly ....4B-55 D rive Pinion— R em oval and D is a s s e m b ly ......4B-56 D ifferential C ase—...
Page 127 REAR AXLE DIFFERENTIAL 4B-55 DIFFERENTIAL CASE the ring gear w ith a so ft-faced h am m er to free it from the case. Removal Scribe both case halves fo r reassem bly in sam e Place vehicle on hoist w ith re a r axle h an gin g free. position.
Page 128 OVERHAUL MANUAL 4B-56 DRIVE PINION Removal and Disassembly Rem ove differential as previously outlined. Check pinion bearing p relo ad as described u nder "D riv e Pinion - Installation and A d justm ent." If there is no preload readin g , check for looseness o f pinion assem bly by shaking the co m panion flange.
Page 129 REAR AXLE DIFFERENTIAL 4B-57 tools J-8092 and b earin g in staller J-24383 as shown in figure 7F. Install bearing opposite side sam e m anner. Be sure to su p p o rt differential case on pilot plug J-8107-3. SHIM REQUIREMENTS—GAUGING PROCEDURES Side Bearing Shims...
Page 130 4B-58 OVERHAUL MANUAL New Pinion M arking Old Pinion M arking + 0.008 + 0.007 + 0 .006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 + 0.007 + 0 .006 + 0 .005 + 0.004 + 0.003 + 0.002 + 0.001 - 0.001...
Page 131 REAR AXLE DIFFERENTIAL 4B-59 B earing S him s". F rom th a t figure, su b tract the size o f the shim installed in step 9 above; then add .006 inch for preload and backlash. For exam ple, if the read in g in step 18 was .329 inch, and the shim ju st installed on the ring g ear side o f the case was .172 inch, the correct shim dim ension would be .329 —.172 = .157 + .006 = .163 inch.
Page 132 4B-60 OVERHAUL MANUAL GEAR TOOTH CONTACT PATTERN CHECK P rior to final assem bly o f the differential, a G e a r Tooth C ontact P attern Check is necessary to v erify the correct relationship between ring g e a r and drive pin io n . G e a r sets w hich are not positioned p ro perly m ay be noisy, or have short life, or both.
Page 133 REAR AXLE DIFFERENTIAL 4B-61 Adjustments Affecting Tooth Contact Use gear m arking com pound (yellow lead chrom ate or equivalent) and apply this m ixture sparingly to Two adjustm ents can be m ade w hich will affect tooth all ring gear teeth using a m edium stiff brush. contact p attern .
Page 134 OVERHAUL MANUAL 4B-62 B o lt (D iffe re n tia l Cover and Plug Shims (Inn e r Pinion N u t Bearing Cap) Lock Pin (Pinion Bearing) Washer B o lt (Ring Gear) Cup (In n e r Pinion Shaft) C om panion Flange Pinion S haft...
Page 135 REAR AXLE DIFFERENTIAL 4B-63 Fig. 17F—Removing Pinion Flange Install Tool J-8 6 14-2, and 3 into holding b a r as shown in figure 17F and rem ove flange from drive pinion. Rem ove drive pin ion from carrier. W ith a long d rift, tap on inn er race o f ou ter p in io n Fig.
Page 136 OVERHAUL MANUAL 4B-64 Place differential case in carrier and install bearing caps. C are should be taken to install caps in original position. Use m ark placed on caps and ca rrier at rem oval. T ighten caps ju st enough to keep bearin g caps in place.
Page 137 REAR AXLE DIFFERENTIAL 4B-65 New P inion M arking O ld P inion M arking + 0 .0 0 8 + 0 .0 0 7 + 0 .0 0 6 + 0 .0 0 5 + 0 .0 0 4 + 0 .0 0 3 + 0 .002 + 0.001...
Page 138 OVERHAUL MANUAL 4B-66 Install flange, w asher and nut. Torque n u t to specifications. DIFFERENTIAL CASE Preload and Adjustment Place differential assem bly (with pinion assem bled) into housing. Install bearin g caps in their p ro p er position and tighten screws ju st enough to hold the b earin g cups in place.
Page 139 REAR AXLE DIFFERENTIAL 4B-67 Install dial in dicator and check ring gear backlash U sing a new gasket, install housing cover and at four equally spaced points around the ring gear. torque bolts to specifications. Backlash m ust be held to .004" to .009" and m ust R einstall the re a r universal joint, and torque "...
Page 140 OVERHAUL MANUAL 4B-68 CHEVROLET TRUCK DIFFERENTIAL 1 2 - 1 / 4 RING GEAR INDEX C ase and D rive P in io n ...........4B-69 Ring G ear R e p la c e m e n t..........4B-70 R e m o v a l ................. 4B-69 D ifferential B earing R e p la c e m e n t......
Page 141 4B-69 REAR AXLE DIFFERENTIAL CASE AND DRIVE PINION bearin g from p in io n , using Tool J - 1453, as shown in figure 2G . Removal Position drive p in io n in an a rb o r press so th at the D rain lubricant from differential, rem ove axle shaft bearing is su pported by two pieces o f flat steel stock as outlined in Truck Service M anual.
Page 142 4B-70 OVERHAUL MANUAL Pinion Reassembly exercise care to prevent damage to ground surface o f pilot. Pack the cavity betw een the p in io n oil seal lips w ith a lithium -base EP lu b ricant to provide initial Slide oil seal retain e r on p in io n sh aft, then tap lub rication and to aid in in sertin g p in io n flange.
Page 143 REAR AXLE DIFFERENTIAL 4B-71 Inspect ring gear pilot case flange and back o f ring and has pilot to assure p ro p e r installation and seating o f bearin g. g ear for dirt or burrs. Install two guide pins (m ad e from cap screws w ith Differential Reassembly heads cut off and ends...
Page 144 OVERHAUL MANUAL 4B-72 Ring Gear Thrust Pad Adjustment Inspect bronze tip o f thrust pad and if w orn install a new one. Install thrust pad and tig h ten screw until bronze tip engages back face o f ring g ea r while ro tatin g gear. Back off screw one-tw elfth (1 /1 2 ) turn and tighten locknut to specifications.
Page 145 R eassem bly................4B-77 GENERAL DESCRIPTION engage a latching bracket whenever the wheel-to-wheel speed Chevrolet Trucks equipped with locking differentials use one of the Eaton locking units in Figure 4B-1H, 2H. These varies by approximately 100 rpm or more. This action retards...
Page 146 4B-74 OVERHAUL MANUAL SCREW (3) SHIM GUIDE CLIP (6) DISC PACK S/A THRUST WASHER (3) CASE HALF-R.H GUIDE CLIP (6) PINION GEAR (3) GOVERNOR ASS'Y CASE HALF-L.H SIDE GEAR SHIM EARED DISC (3) PINION YOKE SPLINED DISC (2) THRUST BLOCK (2) LATCHING BRK'T ASS'Y Fig.
Page 147: Possible Cause
4B-75 REAR AXLE DIFFERENTIAL DIFFERENTIAL DIAGNOSIS Complaint Possible Cause Correction Does n o t lo c k : L ittle or no spring Replace g o ve rn o r assem bly p re lo a d on th e la tch in g and la tch in g b ra cke t.
Page 148 4B-76 OVERHAUL MANUAL Disassembly 1. Note position of governor and latching bracket assembly, Figure 4B-4H. Remove ring gear and side bearings following procedures established for the standard differential. 2. Using bushing puller tool No. J-26252, remove governor assembly and latching bracket by pulling the retaining bushings as shown in Figure 4B-5H.
Page 149 4B-77 REAR AXLE DIFFERENTIAL position. Install the opposite end side gear and original shim. NOTE: O R IG IN A L SHIM MUST BE USED TO M A IN T A IN PR O PE R CL EA R A N C E D IM ENSION S.
Page 150 4B-78 OVERHAUL MANUAL Inspection 1. Clean all parts with solvent. Inspect all bearings for chipping or evidence of excessive wear. Replace parts as needed. 2. Inspect all differential components for excessive wear and breakage. Replace parts as needed. THE FOLLOWING A R E S E R V IC E A B L E COM PO N EN TS...
Page 151 4B-79 REAR AXLE DIFFERENTIAL THRUST RING GUIDE CLIP (6) PRESS TO SHOULDER WAVE SPRING CAM PLATE SPLINED DISC (3) CAM FORM SIDE GEAR EARED DISC (6) SPLINED DISC (LARGE SPLINE) F ig. 4 B -9 H --C a m P la te a n d C lu tc h D isc NOTE: RESULT IN DIFFERENTIAL FAILURE.
Page 152 4B 80 OVERHAUL MANUAL NOTE: O R IG IN A L SHIM M UST USED. 13. Turn entire unit over and install three (3) seres. ATTEMPS TO INSTALL OTHER THAN ORIGINAL 14. Lock an axle shaft in a vise in a vertical position. SHIM WILL DISTURB CRITICAL CLEARNCES AND INstall differential assembly on axle shaft engaging the spline MAY RESULT IN DIFFERENTIAL FAILURE.
Page 153 REAR AXLE DIFFERENTIAL 4B-81 f r o vbhmI & iu > ..X J ~ ^ c s a Pinion Setting Gauge Differential Bearing Remover 1. J-6266 9. J-22888 J 6266 28 Barrel Adapter 10. J-7079-2 Driver Handle (Insert Type) J-6266 25 Plug Driver Handle (Threaded Type) 11.
Page 154 4B-82 OVERHAUL MANUAL P inion S etting Gauge J-6266 J-22 1 7 5 D iffe re n tia l Bearing In sta lle r J-6266-28 Barrel Gauge J-22888 D iffe re n tia l Bearing Rem over (Used w ith J-6266-31 Sleeves J-8 107-4)
Page 155 REAR AXLE DIFFERENTIAL 4B-83 —o :r ff •/ & J2>M Z J-22912 Press Plate J-8001 Dial In d ic a to r Set J-1453 P inion Bearing Press Plate J-0972 D iffe re n tia l N u t W rench D iffe re n tia l Bearing Puller Set J -8 107 J-24381...
Page 157: Table Of Contents
4C-1 FRONT WHEEL DRIVE SECTION 4C FRONT AXLE DIFFERENTIAL (4-WHEEL DRIVE) CONTENTS Drive P inion................4C-5 Front Axle D ifferential............4C-1 Installation and A djustm ent........... 4C-5 Differential C a s e ..............4C-1 Differential C a se ..............4C-6 Rem oval................4C-1 Oil Seal R eplacem ent.............
Page 158 4C-2 OVERHAUL MANUAL 1. Nut 11. Differential Bearing Cone 20. Differential Case 29. Thrust Washer 2. Washer 12. Differential Bearing Cup 21. Differential Bearing Adjusting 30. Ring Gear Bolt 3. Pinion Flange 13. Bearing Cap Shims 31. Oil Slinger 4. Outer Bearing Shims 14.
Page 159: Differential C A S
Bolt (Differential 11. Shims (Inner Pinion 17. Cover and Plug 1. Nut Bearing Cap) Lock Pin (Pinion Bearing) 2. Washer Bolt (Ring Gear) Shaft) 12. Cup (Inner Pinion 3. Companion Flange Pinion Shaft Differential Case Bearing) Pinion Oil Seal 27. Thrust Washer 20.
Page 160: Inspectio
4C-4 OVERHAUL MANUAL J 2 2 8 8 8 Fig. 4C -6--R em oving In n er P in io n B e a rin g Cone and R oller Fig. 4 C -4 -R e m o v in g Side B e a rin g not indicate a defective bearing.
Page 161: Drive Pinion
4C-5 FRONT WHEEL DRIVE New Pinion M arking Old Pinion M arking + 0.002 + 0.001 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.008 + 0.004 + 0.003 + 0.002 + 0.001 - 0.001 + 0.006 + 0.005 + 0.007 - 0.002...
Page 162: Differential C A
4C-6 OVERHAUL MANUAL Fig. 4 C -9 — In s ta llin g In n er P inion Core and R oller 6. Install drive pinion and inner bearing cone and roller assembly in differential carrier. 7. Install shims and outer pinion cone and roller on Fig.
Page 163: Gear Tooth Contact Pattern Check
FRONT WHEEL DRIVE 4C-7 Test 1. Wipe oil out of carrier and carefully clean each tooth of ring gear. 2. Use gear m arking com pound and apply this mixture sparingly to all ring gear teeth using a medium stiff brush. When properly used, the area of pinion tooth contact will be visible when hand load is applied.
Page 164 4C-8 OVERHAUL MANUAL Fig. 4C -12--G ear T o o th Pattern C o n ta c t P attern...
Page 165 FRONT WHEEL DRIVE 4C-9 SPECIAL TOOLS J 5231 01 Spreader - A xle Carrier J-86 14-01 Holder and Remover - J-22888 Puller - Side Bearing Companion Flange J-22175 Installer - Side Bearing J-23476 Installer - Companion Flange J-5590 Installer - Pinion inner and J-5341 Gauge - Pinion Depth Consists outer bearing cone...
Page 167 BRAKES SECTION 5 BRAKES The following caution applies to one or more steps in the assembly procedure of components in this portion of the m anual as indicated at appropriate locations by the terminology "See Caution on page 1 of this section".
Page 168 OVERHAUL MANUAL PRIMARY RETAINER REACTION AIR VALV E PRIMARY DIAPHRAGM SILENCERi RING BUMPER SPRING SUPPORT PLATE O' RING SEAL PRIMARY POWER FLOATING PISTON CONTROL VALVE REACTION SECONDARY PISTON POWER PISTON FLOATING CONTROL REACTION V A L V E RETAINER DISC ILTER PISTON SECONDARY...
Page 169 BRAKES M A C H I N E S L O T IN B O T H T A N G S ON Fig. 5 -5 A -L o c k in g o r U n lo c k in g P rim a ry and S e c o n d a ry P ow er P istons round shanked screwdriver.
Page 170 OVERHAUL MANUAL Fig. 5-7 A --R e m oving R e action P iston and R eaction Disc From Fig. 5 -9 A ~ L o c k in g o r U n lo c k in g P rim a ry S u p p o rt Plate From S e c o n d a ry P o w e r Piston P rim a ry P o w e r P iston contamination or any evidence o f corrosion,...
Page 171 BRAKES Inspecting Metal Parts BADLY D A M A G E D ITEM S, O R TH O SE W H ICH W O U LD T A K E EX TEN SIV E W O RK O R T IM E TO R E PA IR , SH O U LD BE R EPLA C ED .
Page 172: Final Assembly
OVERHAUL MANUAL vise. Position the primary power piston so that the two radial slots in the piston fit over the ears (tangs) of the tool (fig. 5-8A). 15. Fold the primary diaphragm away from the O.D. of the primary support plate. 16.
Page 173 BRAKES in the front housing. 3. Assemble the power piston group to the rear housing by pressing the tube of the prim ary piston through the rear housing bearing. Press down until the housing divider seats in the rear housing and the prim ary power piston bottoms against the housing.
Page 174 OVERHAUL MANUAL BENDIX TANDEM POWER BRAKE UNIT UNIT REPAIR an arbor press with rear housing up and secure to plate of Disassembly press by a suitable means of holding Tool J-22805 (fig. 5-4B). 1. Scribe a line across the front and rear housings to By using a 1-1/2"...
Page 175 BRAKES plunger and valve return spring as the parts are separated (fig. 5-5B). NORMAL LANCE 25. Remove the square ring seal from the shoulder of the front diaphragm plate hub. DEEP 26. Remove the reaction disc from inside the front LANCE diaphragm plate hub.
Page 176 5-10 OVERHAUL MANUAL SQUARE SECTIONED O-RING VALVE RETURN SPRING VALVE PLUNGER REAR DIAPHRAGM PLATE, REAR DIAPHRAGM, REAR DIAPHRAGM RETAINER REAR SHELL VALVE POPPET POPPET RETAINER VALVE ROD SPRING SILENCER SILENCER RETAINER FRONT SHELL SPRING REACTION DISC FRONT DIAPHRAGM PLATE RONT DIAPHRAGM CENTER PLATE Fig.
Page 177 BRAKES 5-11 Fig. 5-6B --R em oving Rear Seal Fig. 5 -8 B — In s ta llin g Rear B e a rin g and V a cu u m Seal alcohol and guide air valve rod into valve plunger. Tap end 4.
Page 178 5-12 OVERHAUL MANUAL REAR PLATE AIR V AL V E D I I I M r ' C D REAR DIAPHRAGM FRONT DIAPHRAGi R E T A I N E R H H ■ C E N T E R PLATE Fig.
Page 179 5-13 BRAKES Fig. 5-1C-- T y p ic a l P o w e r Brake U n it - E xploded V ie w d. Press down on Spanner W rench J-9504 and rotate the Power Piston Assembly Group (Fig. 5-5C) rear housing counterclockwise to unlocked position.
Page 180 5-14 OVERHAUL MANUAL LOCK RING Fig. 5 -4 C ~ S e p a ra tin g T ilt B ra cke t T ype H o u sin g s power piston (fig. 5-6C). Remove reaction retainer, piston, reaction plate, three (3) reaction levers and air valve spring.
Page 181 5-15 BRAKES REACTION RETAINER REACTION LEVERS POWER PISTO REACTION PLATE Fig. 5 -9 C -P o s itio n in g P o w e r P iston on S u p p o rt Plate R em over 8. Remove diaphragm from support plate and lay both Fig.
Page 182: Cleaning Of Parts
5-16 OVERHAUL MANUAL CAUTION: there suspicion contamination or any evidence o f corrosion completely flush hydraulic brake system. Failure to clean hydraulic brake system can result in early repetition o f trouble. Use o f gasoline, kerosene, anti-freeze alcohol or any other cleaner with even a trace o f mineral oil will damage rubber parts.
Page 183 5-17 BRAKES INSPECTION CHA R T Corrective Action Inspect For Part 1. Clean up or replace. 1. Cracks, distortion, Power Piston and Support chipping, damaged lever Plate and Reaction seats, pitted or rough Retainer holes. 2. Replace 2. Worn seal surfaces (tubes).
Page 184 5-18 OVERHAUL MANUAL IN S T A L L E R J - 2 1 6 0 1 P O W E R P I S T O N Fig. 5-1 4 C --H ousing L o ck in g Tabs narrow ends will rest on top of air valve return spring.
Page 185 5-19 BRAKES Tilt Mounting Bracket (Except Chevelle) - Position Tool J-22893 inside tilted m ounting bracket. Place Spanner W rench J-9504 on top of J-22893 and tighten nuts and washers to bolts provided, securing Spanner W rench. d. Press down on spanner wrench and twist rear housing clockwise in relation to front housing until fully locked.
Page 186 5-20 OVERHAUL MANUAL the other lances (fig. 5-3D). The metal that forms the four 8. Place Spanner W rench J-9504 over studs on rear deep lances must be partially straightened so that the lances housing and attach with nuts and washers. Draw nuts down will clear the cutouts in the front housing.
Page 187 BRAKES 5-21 diaphragm plate tension. 11. Lift the rear housing assembly from the unit. Rear Housing Group 1. Remove the air filter element from location within the diaphragm plate extension. CAUTION: To prevent chipping o f the plastic diaphragm plate, exercise extreme caution when removing the air filter retainer.
Page 188 5-22 OVERHAUL MANUAL Inspecting Rubber Parts Wipe fluid from the rubber parts and carefully inspect each rubber part for cuts, nicks or other damage. These parts are the key to the control of fluid or air flow, if the unit is in for overhaul, or if there is any question as to the serviceability of rubber parts, R EPLA C E them.
Page 189 BRAKES 5-23 2. Remove the front housing seal to assure that no vacuum is in the power head while gaging. 3. Insert the master cylinder piston rod, flat end first, into the piston rod retainer. 4. Press down on the master cylinder piston rod (with approximately a 40-50 pound load) to be sure it is properly seated.
Page 190 5-24 OVERHAUL MANUAL Pedal Push Rod Plunger Seat O u tp u t Push Rod Pedal Rod Retainer " 0 ” Ring Seal Push Rod R etainer Plunger Spool Spring B o o t Plug " 0 " Ring Bracket N u t Spacer Spool Plug Linkage Bracket...
Page 191 5-25 BRAKES INPUT ROD AND PISTON Fig. 5-4 E— I nsta 1 1 i ng In p u t Rod Seals 7. Assemble the N E W "O" ring onto the N E W accum ulator check valve, and dip the assembly in clean power steering fluid.
Page 192 5-26 OVERHAUL MANUAL Fig. 5-6 E— I nsta llin g M o u n tin g B ra cke t N ut of the spool bore. Press in on plug and assemble the plug snap ring in the groove in the bore. Fig.
Page 193 BRAKES 5-27 SPECIAL TOOLS Front Plate Holding Fixture 1. J-4880 Snap Ring Pliers 11. J-22839 Booster Separating Adapter 12. J-22893 2. J-25085 Special Socket 13. J-23101 Power Piston Holding Tool 3. J-21183 Height Gauge Control Valve Installer 14. J-23175 4. J-21524 Power Piston Remover and Installer Secondary Bearing Protector Power Brake Retainer and Installer...
Page 195 CARBURETOR 6C-1 SECTION 6C CARBURETOR A L L N EW 1977 CHEVROLETS A R E C E R T IF IE D BY T H E U N IT E D STATES D E PA R T M E N T O F H E A L T H E D U C A T IO N A N D W E L FA R E AS C O N FO R M IN G TO T H E R E Q U IR E M E N T S T H E REG U L A T IO N S...
Page 196 6C-2 OVERHAUL MANUAL E L E C T R IC A U T O M A T I C C H O K E S O L E N O ID C A M C A M Fig. 6 C -3 -V a c u u m B reak D ia p h ra g m F O L L O W E R Float Bowl Disassembly Fig.
Page 197 CARBURETOR 6C-3 ACTUATOR LINK Fig. 6C -7--Pum p and P o w e r P iston A c tu a to r Lever at the same time by inverting the bowl. Fig. 6 C -5--A ir H orn Rem oval 13.
Page 198 6C-4 OVERHAUL MANUAL Fig. 6C-1 1--Fuel F ilte r and C heck V alve Throttle Body (Fig. 6C-12) 1. Invert carburetor bowl on bench and remove two Fig. 6 C -9 ~ M e te rin g Rod and A c c e le ra to r Pum p throttle body to bowl attaching screws.
Page 199 6C-5 CARBURETOR C L E A N IN G A N D IN S P E C T IO N The carburetor should be cleaned in a cold immersion type cleaner. 1. Thoroughly clean carburetor castings and metal parts in an approved carburetor cleaner such as Carbon X (X-55) or equivalent.
Page 200 6C-6 OVERHAUL MANUAL Fig. 6C-1 4 -F lo a t Level A d ju s tm e n t Metering Rod Adjustment (Fig. 6C-15) 1. Open throttle valve, slide metering rod out of holder and remove from main metering jet. Fig.
Page 201: Adjustments
CARBURETOR 6C-7 lever link into notched hole in choke coil lever on choke for locating choke housing. housing. Then carefully twist and lower air horn onto float 5. Install fast idle cam, and fast idle cam link to upper bowl. Install three long and one short air horn to float bowl choke lever assembly.
Page 202 6C-8 OVERHAUL MANUAL Fig. 6 C -20 ~ R e m o ving Pum p Rod S p rin g C lip Fig. 6C -22 --R e m o vin g V a cu u m Break Lever rod out of hole in fast idle cam. The upper end of the choke screwdriver.
Page 203: Throttle Body
6C-9 CARBURETOR M A IN METERING VALVE JETS Fig. 6 C -2 4 -R e m o v in g Fast Id le Cam Fig. 6 C -2 6 --F lo a t B o w l overhaul. The service pum p assembly uses a grooved pump may be necessary to file off staked ends on choke valve screws plunger stem and retaining clip.
Page 204 6C-10 OVERHAUL MANUAL "T " RETAINER P U M P RETURN S P R IN G Fig. 6 C -2 7 ~ R e m o vin g Pum p R eturn S p rin g Fig. 6 C -29--P um p D isch a rg e "T " R etainer The idle mixture needles have been adjusted and set idle mixture needles had to be removed, install the idle at the factory and capped, to prevent excessive adjustment...
Page 205 6C-11 CARBURETOR 3. Clean all idle fuel passages. 4. Check throttle lever and valves for binds, nicks and other damage. A S S E M B L Y Throttle Body 1. Install idle speed screw and spring assembly in throttle body if removed.
Page 206 6C-12 OVERHAUL MANUAL VENTURI CLUSTER METERING VALVE JETS Fig. 6 C -3 2 ~ F lo a t B o w l A sse m b ly Fig. 6 C -3 3 --A ir Horn T ig h te n in g Sequence choke valve screws and stake lightly in place.
Page 207 6C-13 CARBURETOR MODEL M 4 M C /M 4 M E CARBURETOR protruding from the air horn. These tubes are DISASSEMBLY permanently pressed into the air horn casting. DO Place carburetor on a holding fixture to prevent damage N O T REMOVE. to throttle plates (Figs.
Page 208 6C-14 OVERHAUL MANUAL Fig. 6 C -3 6 ~ R e m o vin g U p p e r C hoke Lever Fig. 6 C -3 8 -R e m o v in g Pum p Lever 8. Remove aneroid cavity insert from float bowl. (Fig. 6C-46).
Page 209 6C-15 CARBURETOR Fig. 6 C -4 2 ~ R e m o vin g A ir Horn G asket and Pum p P lu n g e r Fig. 6 C -4 0 -R e m o v in g A ir Horn Choke Remove vacuum break rod by holding down on fast idle cam (hot idle position);...
Page 210 6C-16 OVERHAUL MANUAL Fig. 6 C -4 4 -P o w e r P iston and M e te rin g Rods Fig. 6 C -46 --R em oving A n e ro id C a vity In se rt 4.
Page 211 6C-17 CARBURETOR REAR V A C U U M SEAL BREAK LEVER FAST IDLE LO CKOUT C A M SEC O N DA R Y FAST IDLE INTERMEDIATE LOCK O U T C A M FOLLOWER CH O K E SHAFT LEVER Fig.
Page 212 6C-18 OVERHAUL MANUAL Check pum p linkage for excessive wear, repair or replace as necessary. c. H ard Starting - Poor Cold Operation 1. Check choke valve and linkage for excessive wear, binds or distortion. 2. Inspect choke vacuum diaphragm for leaks. 3.
Page 213 6C-19 CARBURETOR Fig. 6 C -55 --P u ll C lip L o ca tion 7. Install aneroid cavity insert into float bowl. Fig. 6 C -5 4 --ln s ta llin g C hoke Rod Lever 8. Install new needle seat assembly, with gasket. 9.
Page 214 6C-20 OVERHAUL MANUAL G A U G E FR O M TOP OF C A S T IN G TO TOP OF F L O A T — G A U G IN G P O IN T 3 / 1 6 " BACK F R O M END OF FLOAT A T TOE (SEE IN SET) (IN S E T ) G A U G IN G P O IN T...
Page 215 6C-21 CARBURETOR Fig. 6 C -59 --C h oke Lever and H o using 6. Connect check rod into lower choke lever inside bowl cavity; they install choke rod into slot in upper choke lever and retain the choke lever to the end of the choke shaft with attaching screw.
Page 216 6C-22 OVERHAUL MANUAL MODEL 4 M V CARBURETOR CHOKE VALVE ACCELERATOR PUMP ROD AIR VALVE VACUUM BREAK PART NUMBER SECONDARY THROTTLE LEVER FUEL INLET PRIMARY THROTTLE LEVER IDLE MIXTURE SCREW CURB IDLE SCREW Fig. 6 C -62 --R em oving Pum p Lever Fig.
Page 217 CARBURETOR 6C-23 Fig. 6 C -6 5 ~ R e m o vin g P o w e r P iston and M e te rin g Rods depressing piston stem and allowing it to snap free (Fig. 6C- 65). The power piston can be easily removed by pressing the Fig.
Page 218 6C-24 OVERHAUL MANUAL Fig. 6C -68--Fuel F ilte r 6C-69). NOTE: Be careful when inverting bowl assembly as smallest venturi protrudes beyond the gasket surface. 5. Remove throttle body to bowl insulator gasket. Throttle Body Disassembly 1. Remove pump rod from throttle lever by rotating rod out of lever.
Page 219 CARBURETOR 6C-25 bushing in bowl will w ithstand normal cleaning. Rinse (Fig. 6C-69). thoroughly after cleaning. 3. Place carburetor on proper holding fixture J-8328. 1. Thoroughly clean all metal parts and blow dry with 4. Install fuel inlet filter spring, filter, new gasket and compressed air.
Page 220 6C-26 OVERHAUL MANUAL properly positioned in metering jets. Press down firmly on plastic power piston retainer to make sure the retainer is seated in recess in bowl and the top is flush with the top of the bowl casting. If necessary, using a drift punch and small hammer, top retainer lightly in place.
Page 221 6C-27 CARBURETOR 6. Connect upper end of pum p rod to pump lever by Air Horn to Bowl Assembly placing rod in specified hole in lever. Align hole in pump lever 1. Install vacuum break rod into vacuum break with hole in air horn casting using J-25322. Using small diaphragm plunger.
Page 222: Special T O O
OVERHAUL MANUAL 6C-28 SPECIAL TOOLS J 9 7 8 9 -1 18 CARBURETOR H O L D IN G STAND J 9 7 89 -0 2 UNIVERSAL CARBURETOR G A U G E SET J26701 CHOKE VALVE ANGLE G A U G E J 2 3 41 7 CHOKE LEVER INSTALLING TOOL Fig.
Page 223: Engine Electrical
ENGINE ELECTRICAL 6D-1 SECTION 6D ENGINE ELECTRICAL CONTENTS Starting M o to r..............6D-1 Installation................6D-6 Disassembly ............... 6D-1 10 SI Series G enerator............6D-7 Cleaning and Inspection..........6D-2 Disassembly ............6D-7 Testing and R epairs............6D-3 Cleaning and Inspection..........
Page 224 6D-2 OVERHAUL MANUAL 1. Drive Housing 7. Solenoid Case 15. Overrunning Clutch As 22. Grounded Brush Holders 2. Shift Lever Bolt, 8. Screw and Lock Washer sembly 23. Brushes Nut and Lock 9. Grommet 16. Armature 24. Screws Washer 10. Field Frame 17.
Page 225 ENGINE ELECTRICAL 6D-3 _____...JS u , Fig. 6 D -4 S --A rm a tu re S h o rt C irc u it T est CYLINDER RETAINER Some starter motor models use a CAUTION: molded armature commutator design and no attempt to undercut the insulation should be made or serious damage may result to the commutator.
Page 226 6D-4 OVERHAUL MANUAL SlhUOd Fig. 6 D -5 S --A rm a tu re G round T est Fig. 6D -7S --F ield C o il G rou n d Test Field Coil Replacement Field coils may be removed from the field frame using Turning The Commutator a pole shoe screwdriver and a pole shoe spreader.
Page 227 ENGINE ELECTRICAL 6D-5 wire to insulated brush. d. Repeat for other set of brushes. Assemble overrunning clutch assembly to arm ature shaft. a. Lubricate drive end of arm ature shaft with silicone Fig. 6 D - 10 S --F o rcin g Snap Ring In to R etainer lubricant.
Page 228: Installation
6D-6 OVERHAUL MANUAL — RETAINER PINIO N Fig. 6D-1 2 S --C he ckin g P in io n C le a ran ce Fig. 6D-1 1S— C irc u it fo r C h e ckin g P inion C le a ran ce STARTING SOLENOID Replacement of Contacts (fig.
Page 229 ENGINE ELECTRICAL 6D-7 GENERATOR 10-SI SERIES "BAT" terminal screw, and disconnect the capacitor lead. DISASSEMBLY (fig. 6D-1C) Remove rectifier bridge from the end frame. 1. Hold generator in a vise, clamping the mounting 7. Remove two attaching screws, and remove brush flange lengthwise.
Page 230: Cleaning And Inspection
6D-8 OVERHAUL MANUAL Fig. 6 D -2C -R em oving P ulley OHMMETER (CHECK FOR SHORTS AND OPENS) CLEANING AND INSPECTION W ith generator completely disassembled components should be cleaned and inspected. Be sure testing Fig. 6 D -3 C -C h e c k in g R otor equipment is in good working order before attem pting to check the generator.
Page 231 ENGINE ELECTRICAL 6D-9 BRUSH RESISTOR HOLDER REGULATOR INSULATED HEAT SINK INSULATING WASHER GR OU N DE D Fig. 6 D -5C --D iode T rio C hecks HEAT SINK OHMMETER Open Circuit If lamp fails to light or if ohm m eter reads high when successively connected between each pair of stator leads, the windings are open.
Page 232 6D-10 OVERHAUL MANUAL OHMMETER INSULATING WASHERS RESISTOR Fig. 6 D -8 C -D riv e End B e a rin g Cross S e ctio n CAPACITORi DIODE RECTIFIER ATTACHING TRIO Slip rings which are rough or out of round should be BRIDGE NUTS trued in a lathe to .002 inch maximum indicator reading.
Page 233 6D-11 ENGINE ELECTRICAL shaped hole at end of shaft and torque the shaft nut to 40-50 ft. lbs. (fig. 6D-9C). 3. Install capacitor and retaining screw in slip ring end frame. 4. Position brush holder and regulator assemblies in end 1 5 /1 6 "...
Page 234 AMPS FOR 25 AMP. RESERVE MODEL NO. APPLICATION @ 0°F (-18°C) LOAD TEST CAPACITY (MINUTES) Y87P 250 L-6 (L22) 275 Amps (Except Chevrolet) 85-4* 250 L-6 (L22) 275 Amps (Chevrolet) R87P 305 V-8 (LG3) 350 Amps 350 V-8 (LM1) (Except Chevrolet)
Page 235 ENGINE ELECTRICAL 6D-13 TRUCK GENERATOR FIELD CURRENT COLD OUTPUT* RATED HOT DELCO REMY MODEL NO. APPLICATION AMPS 27°C (80°F) AMPS @ OUTPUT** AMPS SPEC. NO. @ 12 VOLTS 5000 RMP 1102394 All L-6 (Base) 4519 4-4.5 1102491 (Except G-20, 30 & 1102889 P-Truck) All C-K-G Truck Base V-8...
Page 236: Starting Motor
6D-14 OVERHAUL MANUAL TRUCK STARTING MOTOR FREE SPEED MODEL NO. APPLICATION SPEC. NO. VOLTS AMPERES 1108778 250 L-6 (LD4) 3573 50-80* 5500-10500 (C & K-10) 1108779 250 L-6 (LD4) (G-Van) 3573 50-80* 5500-10500 1108780 292 L-6 (L25) 2438 50-80* 3500-6000 1109056 305 V-8 (LG9) (C &...
Page 237: Automatic Transmission
(200J7A-1 AUTOMATIC TRANSMISSION SECTION 7 A AUTOMATIC TRANSMISSION THM 200 TRANSMISSION INDEX D isassem bly............... 7 A-1 Rear Gear P a r ts ............7A-13 Removal of C o n v e rte r..........7A-1 Low and Reverse C lutch ..........7A-17 Teflon S e a ls ..............
Page 238 OVERHAUL MANUAL (200)7A-2 O IL SCREEN M A N U A L D E T E N T RO LLER & SPRING ASSEMBLY Fig. 7 A-3 A ~ R e m ov ing Oil Screen Fig. 7 A-5 A ~ R e m o v in g M a n u a l Detent Roller and Sp rin g A s s e m b ly Snap Rings CAUTION:...
Page 239 AUTOMATIC TRANSMISSION (200)7A-3 1 -2 ACCUMULATOR* SPRING Fig. 7A-1 O A - R e m o v in g G o ve rn o r Cover Fig. 7 A -7 A ~ R e m o v in g 1-2 A c c u m u la t o r Sp rin g IN T E R M E D IA T E S E R V O R E T A IN IN G R IN G 5th CHECK BALL...
Page 240 (200)7A-4 OVERHAUL MANUAL APPLY A IR PRESSURE HERE TO REM O VE IN T E R M E D IA T E SERVO INTERM EDIATE SERVO COVER Fig. 7 A - 1 3 A - R e m o v in g In te rm e diate Servo Fig.
Page 241 (200)7A-5 AUTOMATIC TRANSMISSION FRONT UN IT END PLAY CHART THICKNESS ID EN TIFIC A TIO N J-25013-5 Number and/or Color 1.66-1.77mm (0.065' -0.070") 1.79-1.90mm (0.070' -0.075") (0.076' -0.080") 3 - Black 1.92-2.03mm 2.05-2.16mm (0.081' -0.085") 4 - Light Green 2.18-2.29mm (0.086' -0.090") 5 - Scarlet 6 - Purple...
Page 242 OVERHAUL MANUAL (200)7A-6 Fig. 7 A - 2 2 A - R e m o v in g Pump A s se m b ly Fig. 7 A - 2 5 A - R e m o v in g I n t e rm e d ia te Band A n c h o r Pin Fig.
Page 243 AUTOMATIC TRANSMISSION (200)7A-7 J-7057. Position extension against end of output shaft and set dial indicator to zero (Fig. 7A-27A). d. Move output shaft upward by turning adjusting screw on J-25013-5 until the white or scribed line on sleeve F R O N T C A R R I E R J-25013 begins to disappear;...
Page 244 (200)7A-8 OVERHAUL MANUAL INPUT DRUM L O & REVERSE CLUTCH HO USING Fig. 7 A - 3 2 A - R e m o v in g In p u t Drum and Rear Sun Gear Fig. 7 A -3 5 A --R e m o vin g Lo w and Reverse Clu tch H o u s in g c.
Page 245 (200)7A-9 AUTOMATIC TRANSMISSION Fig. 7 A - 3 7 A - R e m o v in g Rear U n it Parts Fig. 7 A - 4 0 A - R e m o v in g Rear Oil Seal 7.
Page 246 (200)7A-10 OVERHAUL MANUAL Fig. 7 A-4 1 A - M a n u a l S h a ft and Parking S h a ft Parts 12. If vent was removed, apply Loctite Prim er "T", or 5. Inspect reverse clutch seal and interm ediate band equivalent, to the outside diam eter of the vent that locates anchor pin bores for damage.
Page 247 (200J7A-11 AUTOMATIC TRANSMISSION Fig. 7 A -4 4 A--R e m o vin g M a n u a l S h a ft Seal From Case Fig. 7 A - 4 7 A - R e m o v in g P arkin g Pawl S h a ft Cup Plug from Case 6.
Page 248 (200)7A-12 OVERHAUL MANUAL Fig. 7 A -4 9 A ~ O il Passages - Bo tto m o f Case 7. Install parking pawl shaft retaining pin. 8. While holding the parking pawl toward center of transm ission/install parking bracket. Torque bolts to 20.0- 27.0 N -m (15-20 ft.
Page 249 AUTOMATIC TRANSMISSION (200)7A-13 Fig. 7 A - 5 2 A ~ M a n u a l S h a ft and Parking S h a ft Parts 10. Install parking actuator rod and inside detent lever 12. Aligning inside detent lever with flats on manual with detent lever pin toward center of transmission and shaft, install inside detent lever on shaft.
Page 250 (200)7A-14 OVERHAUL MANUAL SPEEDOMETER DRIVE GEAR CLIP SPEEDOMETER OUTPUT SHAFT DRIVE GEAR CUP PLUG Fig. 7 A - 5 8 A - O u t p u t Sh a ft Fig. 7 A - 5 5 A - l n s t a l l i n g Parking Pawl Cup Plug 3.
Page 251 (200)7A-15 AUTOMATIC TRANSMISSION THRUST BEARING ASSY. REAR IN TE R N A L (INSIDE D IA M ETER RACE GEAR AG AINST GEAR) OUTPUT SHAFT OUTPUT SHAFT Fig. 7 A - 6 1 A - l n s t a l l i n g T h r u s t Be a rin g A s s e m b ly Fig.
Page 252 OVERHAUL MANUAL (200)7A-16 Reassembly 1. Install roller clutch to rear carrier thrust washer REAR CARRIER (Fig. 7A-64A). 2. Install rollers that may have come out of roller clutch cage, by compressing the energizing spring with forefinger and inserting roller from outer edge (Fig. 7A-65A). 3.
Page 253 (200)7A-17 AUTOMATIC TRANSMISSION THRUST WASHER OUTPUT SHAFT PARKING PAWL LUGS REAR CARRIER ASSEMBLY Fig. 7 A - 6 8 A - -ln s ta llin g T h r u s t W a s h e r LOW AND REVERSE CLUTCH I n s p e c t i o n I f low and reverse clutch housing has C A U T IO N :...
Page 254 OVERHAUL MANUAL (200)7A-18 LO & REVERSE LO & REVERSE LO & REVERSE CLUTCH LO & REVERSE CLUTCH LO & REVER SE CLU TC H HO USING LO & REVERSE C LU TC H APPLY SPRING STEEL C LU TC H S E L E C T IV E ASSEMBLY PISTON SEALS...
Page 255 AUTOMATIC TRANSMISSION (200)7A-19 J-25023 1 LO & REVERSE CLUTCH PISTON CLUTCH OUTER SEAL (LIP UP) CLUTCH HOUSING Fig. 7 A - 7 8 A - C h e c k i n g f o r C o rre c t L o w and Reverse Selective Fig.
Page 256 OVERHAUL MANUAL (200)7A-20 LO& REVERSE CLUTCH HOUSING TO CASE SPACER L O & REVERSE CLUTCH HOUSING Fig. 7 A - 8 3 A - -ln s t a llin g Lo w and Reverse Clu tch Hou sin g Fig. 7A-8 1 A - P r o p e r L o ca ti on o f Lo w and Reverse Ho using to Case Spacer NOTE: It may be necessary to loosen adjusting screw...
Page 257 AUTOMATIC TRANSMISSION (200J7A-21 INPUT DRUM Fig. 7 A - 8 7 A - F r o n t Sun Gear I d e n tif ic a tio n Fig. 7 A - 8 4 A - l n s t a l l i n g In p u t Drum and Rear Sun Gear Reassembly INPUT D R U M REA R SUN G EAR...
Page 258 OVERHAUL MANUAL (200)7A-22 jSNAP RING FRONT SUN GEAR REAR SELECTIVE WASHER & IDENTIFICATION THRUST WASHER FRONT INTERNAL THRUST BEARING & GEAR RACE ASSEMBLY (NEEDLE BEARINGS AGAINST GEAR) Fig. 7 A - 9 2 A - l n s t a l l i n g O u tp u t S h a ft to Selective W a s h e r Snap Ring Fig.
Page 259 (200)7A-23 AUTOMATIC TRANSMISSION REAR UNIT END PLAY CHART THICKNESS IDENTIFICATIO N Number and/or Color 2.90- 3.01mm (0.114' -0.119") 1 Orange 3.19mm 3.08- (0.121' -0.126” ) 2 White 3.26- 3.37mm (0.128' -0.133” ) 3 Yellow 3.44- 3.55mm (0.135' -0.140” ) 4 Blue 3.62- 3.73mm (0.143' -0.147") 5 Red...
Page 260 (20017A-24 OVERHAUL MANUAL D IR E C T D IR E C T D IR E C T F L A T D IR E C T C LU TC H C LU TC H C LU T C H S TE E L C LU T C H PISTON...
Page 261 (200)7A-25 AUTOMATIC TRANSMISSION D IR E C T C L U T C H IN N E R S E A L C L U T C H CLUTCH CLUTCH OUTER SEAL P ISTO N (L IP UP) PISTON (LIP UP) Fig.
Page 262 OVERHAUL MANUAL (200)7A-26 DIRECT CLUTCH H O I-------- O M ITTE D J-25010 DIRECT CLUTCH PISTON GUIDE DIREC T CLUTCH PISTON Fig. 7 A - 10 6 A - -ln s t a llin g Dir e ct Clutch Piston Fig.
Page 263 (200)7A-27 AUTOMATIC TRANSMISSION Fig. 7A-1 1 0 A - F o r w a r d Clu tch A ss e m b ly - Explo ded V ie w 6. Remove the clutch plates from the forward clutch 8. Inspect backing plate for scratches or damage. housing and keep them separated from the direct clutch 9.
Page 264 (200)7A-28 OVERHAUL MANUAL Inspect cup plug for damage. If cup plug is damaged or missing, proceed as follows: FORWARD CLUTCH PISTON a. Use 4mm (No. 3) easy out (grind to fit) and remove cup plug. b. Install new cup plug to 1 .Omm (.039") below surface. Reassembly 1.
Page 265 AUTOMATIC TRANSMISSION (200)7A-29 If removed, install new turbine shaft seal rings, FLAT STEEL PLATES making sure cut ends are assembled in the same relationship as cut and rings are seated in their groove. Retain with petrolatum. (See Fig. 7A-120A for correct way to position cut ends.) Intermediate Band Assembly COMPOSITION-FACED...
Page 266: Pressure Regulator
OVERHAUL MANUAL (200)7A-30 FORWARD CLUTCH HOUSING 19.05 mm (3/4") DIRECT CLUTCH HOUSING INTERMEDIATE BAND Fig. 7A-1 2 2 A - F o r w a r d C lu tch P ro p e rly Seated in Direct Fig. 7A-1 2 5 A - -ln s ta llin g In te rm e d ia te Ba nd A s se m b ly Clu tch Pump Assembly (Fig.
Page 267 (200)7A-31 AUTOMATIC TRANSMISSION PUMP BODY THRUST WASHER PUMP ASSEMBY PUMP DRIVEN GEAR PUMP DRIVE GEAR (ID E N TIFIC A TIO N MARKS ON TANGS UP) Fig. 7 A - 1 2 9 A - R e m o v in g Pump Drive Gear Fig.
Page 268 OVERHAUL MANUAL (200)7A-32 J-25016 PUMP BODY SEAL Fig. 7 A-1 3 4 A --C h e c k in g Pum p B o dy-to-G ear End Clearance Fig. 7 A - 1 3 1 A - l n s t a l l i n g Seal Into Pump Bo d y B L E E D PUMP DRIVEN GEAR (IDENTIFICATION...
Page 269 (200)7A-33 AUTOMATIC TRANSMISSION 7A-120A). Also, make sure rings are seated in the grooves to prevent damage to the rings during reassembly of mating PUMP part over rings Retain with petrolatum. ASSY. 9. Install pum p to case seal ring, chamfered side out, making sure the ring is not twisted.
Page 270 (200)7A-34 OVERHAUL MANUAL o v e r n o r c o v e r FRONT UN IT END PLAY CHART THICKNESS ID EN TIFIC A TIO N Number and/or Color 1.66-1.77mm (0.065' -0.070” ) 1.79-1.90mm (0.070' -0.075") 1.92-2.03mm (0.076' -0.080” ) 3 Black 2.05-2.16mm (0.081' -0.085")
Page 271 AUTOMATIC TRANSMISSION (200)7A-35 IN TER M ED IA TE SNAP IN TER M ED IA TE SER VO CO VER RING SER VO PISTON WASHER J-25014-2 Fig. 7A-1 4 4 A --ln te r m e d ia te Servo-Exploded J-25014-1 DIAL INDICATOR NOTE:...
Page 272 (200)7A-36 OVERHAUL MANUAL INTERMEDIATE BAND APPLY PIN CHART DIAL INDICATOR TRAVEL APPLY PIN IDENTIFICATION APPLY PIN IDENTIFICATION + .72mm (.0 029") 1 Ring ,72mm 1.44mm (.029"- 057") 2 Rings 1.44mm 3 Rings 2.16mm (.057"- 086") 2.16mm 2.88mm (.086" - 114") Wide Band J-22269-01 Fig.
Page 273: Control Valve Assembly
AUTOMATIC TRANSMISSION (200)7A-37 INTERMEDIATE SERVO COVER CUP PLUG INTERMEDIATE SERVO PISTON ASSY. SEAL ”0 " RING SEAL 7A-1 5 0 A ~ ln s t a llin g I n t e rm e d ia te Servo Piston and Cover Fig.
Page 274 (200)7A-38 OVERHAUL MANUAL 45 46 1. M A N U A L V A L V E 17. R E T A I N I N G C O IL E D PIN 33. T H R O T T L E V A L V E 2.
Page 275 AUTOMATIC TRANSMISSION (200)7A-39 PIN SLOT IDENTIFICATION Fig. 7 A - 1 5 6 A — I nsta 1 1 1-2 T h r o ttle Valve Bu shin g Fig. 7A-1 53 A--R e m o vin g S h if t T. V. Plug bore.
Page 276 (200)7A-40 OVERHAUL MANUAL £ 4. Install 5th check ball in case as shown (Fig. 7A- 160A). 5. Install 2 guide pins as shown in Fig. 7A-161A. 6. Install 4 check balls into ball seat pockets in control valve assembly and retain with petrolatum. (See Fig. 7A- 162A for check ball location.) 7.
Page 277: Oil Pan
(200)7A-41 AUTOMATIC TRANSMISSION INTERMEDIATE LINE RNDI BOOST REV ERSE BOOST PUMP INTAKE PART THRO TTLE LINE BOOST 4 CHECK B A LLS (NOTE: 5TH CHECK B A LL IN CASE) D IRECT D IRECT CLUTCH TV EXHAUST CLUTCH ACCUMULATOR Fig. 7 A - 16 2 A --L o c a tio n of Four Ch eck Balls Oil Screen Speedometer Driven Gear (Fig.
Page 278 (20017A-42 OVERHAUL MANUAL T.V. EXHAUST V A LV E LIFTER PU MP C O V E R THROTTLE LEVER & BRACKET ASSEMBLY THROTTLE LEVER CABLE LIN K Fig. 7A-1 6 5 A — I nsta 1 1 i n g T h r o ttle Valve and B ra c k e t A s s e m b ly Fig.
Page 279 (200)7A-43 AUTOMATIC TRANSMISSION J-8092 J-25019-12 PUM P B O D Y PUMP CO VER Fig. 7 A-1 7 3 A - l n s t a l l i n g Pump B o d y Bu sh in g Fig.
Page 280 OVERHAUL MANUAL (20017A-44 J-8092 J-8092 J-25019-4 J-25019-9 D IR E C T C LUT CH HO USIN G FRONT IN T E R N A L GEAR Fig. 7A-1 7 6 A - R e m o v in g Dir ect Clu tch Ho using B ushin g - Fig.
Page 281 AUTOMATIC TRANSMISSION (200)7A-45 Using tool J-25019-9 with Driver Handle J-8092, drive or press new bushing into place until tool bottoms (Fig. 7A-179A). REAR SUN GEAR 1. Using tool J-25019-14 with Slide Hamm er J-7004-1, J-7004-1 remove bushing (Fig. 7A-180A). 2. Place rear sun gear with gear side down on block of J-25019-16 wood to prevent damaging the gear.
Page 282 OVERHAUL MANUAL (200)7A-46 Fig. 7A-1 8 5 A — I nsta lling Rear Ca rrie r B ushin g Fig. 7 A - 1 8 6 A - R e m o v in g or I n s ta llin g Case B ushin g Fig.
Page 283 (200)7A-47 AUTOMATIC TRANSMISSION SPECIFICATIONS TURBO-HYDRAMATIC "200" Pump Cover Bolts ......................... 24 N m (18 ft. lbs.) Pump to Case Attaching B olts....................24 N m (18 ft. lbs.) Parking Pawl Bracket B o lts ....................24 N- m (18 ft.
Page 285 AUTOMATIC TRANSMISSION (350)7A-1 SECTION 7 A AUTOMATIC TRANSMISSION CBC 350 TRANSMISSION INDEX Transmission Disassembly and R eassem bly....7A-3 Low and Reverse Roller Clutch S u p p o rt....7A-29 Disassembly (T ransm ission)..........7A-3 Disassembly..............7A-29 Inspection............... 7A-29 Converter Inspection............7A-3 Converter End Clearance C heck........7A-4 Assembly.................
Page 286 CONVERTER INTERMEDIATE INTERMEDIATE FORWARD ASSEMBLY CLUTCH OVERRUN BAND CLUTCH LOW AND REVERSE OUTPUT CLUTCH GEAR SHAFT REACTION CARRIER GOVERNOR A ND REVERSE OVERRUN ROLLER INPUT SHAFT PARKING PAWL OUTPUT CARRIER STATOR INTERMEDIATE MANUAL SHAFT OVERRUN SHAFT ROLLER CLUTCH Fig. 7 A-1 B--C B C 3 5 0 S e c tio n e d V i e w...
Page 287 (350)7A-3 AUTOMATIC TRANSMISSION TRANSMISSION DISASSEMBLY AND REASSEMBLY DISASSEMBLY Install Holding Fixture J-8763-02 on transmission and place into Holding Tool base J-3289-20 with converter facing up (fig. 7A-2B). NOTE: Cleanliness is an im portant factor in the overhaul of the transmission. Before attem pting any disassembly operation, the exterior of the case should be thoroughly cleaned to prevent the possibility of dirt entering the transmission internal mechanism.
Page 288 (350)7A-4 OVERHAUL MANUAL EXTENSION HO U SIN G LIP SEAL Fig. 7 A - 5 B ~ ln s t a llin g J - 2 1 5 7 1 -8 Fig. 7 A - 7 B - R e m o v in g Extension Ho using Lip Seal Converter End Clearance Check (Figs.
Page 289 (350)7A-5 AUTOMATIC TRANSMISSION Fig. 7A-9B--R em ovin g G o ve rn o r Cover 5. Install speedometer drive gear remover tool J-21427- 01 and J-9539 bolts with J-8 105 or suitable puller on output shaft and remove speedometer drive gear. Remove retaining Fig.
Page 290 (350)7A-6 OVERHAUL MANUAL R A N G E SELECTOR IN N ER LEVER DETENT C O N T R O L VALVE WIRE Fig. 7 A-1 3B --R em oving Oil Pump S uctio n Screen (Strainer) Fig. 7 A-1 5 B - R e m o v in g M a n u a l C o n tro l Valve Link, Valve Bo d y fr o m Valve Bo d y and De tent A c t u a t in g Lever REMOVAL OF VALVE BODY AND LINKAGE...
Page 291 (350)7A-7 AUTOMATIC TRANSMISSION V A L V E B O D Y SPACER PLATE OIL PUMP PRESSURE SCREEN V A L V E B O D Y SPACER PLATE PRESSURE HOLE? TO CA S E G A S K E T Fig.
Page 292 (350)7A-8 OVERHAUL MANUAL RANGE SELECTOR MA NU AL SHAFT TO INNER LEVER CASE RETAINER M A N U A L SHAFT PARKING PAWL AC T UATIN G ROD Fig. 7A-2 1 B - R e m o v in g M an u a l S h a ft to Case Re tainer Fig.
Page 293 (350)7A-9 AUTOMATIC TRANSMISSION PARK PAWL A C T U A T I N G R O D SHAFT PARKING PAWL SHAFT R E TAIN ING PLUG PARK LOCK LOCK BRACKET Fig. 7 A-2 5 B--R e m o vin g Park Lock, Lock B ra cke t Fig.
Page 294 (350)7A-10 OVERHAUL MANUAL PUMP A S S E M B L Y INTERMEDIATE CLUTCH TO CA S E A T T A C H I N G * C U S H I O N S P R I N G ^ * BOLTS (8) Fig.
Page 295 (350)7A-11 AUTOMATIC TRANSMISSION IN T E R M E D I A T E CLUTCH F O R W A R D A N D DIRECTX PRESSURE PLATE CLUTCH ASSEMBLIES Fig. 7 A - 3 3 B - R e m o v in g I n t e rm e d ia te Clu tch Pressure Plate Fig.
Page 296: Output Shaft
(350)7A-12 OVERHAUL MANUAL o u t p u c a r r i e r INPUT RING GEAR THRUST W A S H E R ^ OUTPUT CARRIER OUTPUT SHAFT SNAP RING Fig. 7 A - 3 7 B ~ R e m o v in g In p u t Ring Gear to O u tp u t S h a ft Snap Fig.
Page 297 (350)7A-13 AUTOMATIC TRANSMISSION S U N G E A R DRIVE SHELL ASSEMBLY LOW AND REVERSE CLUTCH PACK Fig. 7 A - 4 3 B ~ R e m o v in g L o w and Reverse Clu tch Pack Fig.
Page 298 (350)7A-14 OVERHAUL MANUAL OUTPUT RING GEAR OUTPUT RING GEAR TO CASE OUTPUT RING GEAR W ii NEEDLE BEARING A N D OUTPUT SHAFT ASSEMBLY Fig. 7 A - 4 5 B - R e m o v in g O u t p u t Ring Gear and S h a ft A s s e m b ly Fig.
Page 299 (350)7A-15 AUTOMATIC TRANSMISSION L O W A N D REVERSE CLUTCH PIS TO N RETURN SPRINGS OUTER SEAL REVERSE L O W A N D REVERSE LUTCH PISTON CLUTCH PISTON Fig. 7A-5 1 B - R e m o v in g L o w and Reverse Clutch Piston Outer Fig.
Page 300: Reassembly
(350)7A-16 OVERHAUL MANUAL VALVE BODY DISASSEMBLY, INSPECTION, AND REASSEMBLY (FIG. 7A-56B) Disassembly J-2 30 69 1. Position valve body assembly with cored face up and direct clutch accum ulator piston pocket positioned as shwon in Figure 7A-56B. 2. Remove manual valve from lower left hand bore. 3.
Page 301 (350)7A-17 AUTOMATIC TRANSMISSION © p nrrcnrn IS' 'tt*= ffflfflT R I 9 $ I b© 21 22 8335s £ S S S * or n f r n nnnnnnr i ® » g o a g | © E M U *— ' 27 M A N U A L V A L V E 1-2 S H I F T V A L V E...
Page 302 (350)7A-18 OVERHAUL MANUAL INTERMEDIATE CLUTCH I N T E R M E D I A T E PISTON OUTERSEAL C L U T C H S P R I N G S E A T R E T A I N E R PUMP B O D Y B O L T S (5) Fig.
Page 303 AUTOMATIC TRANSMISSION (350)7A-19 NOTE: Forw ard clutch oil seal rings are teflon on JA and JH models. Remove pump cover to direct clutch drum housing selective thrust washer (fig. 7A-61B). NOTE: A needle bearing is used on C series Truck instead of a thrust washer.
Page 304 (350)7A-20 OVERHAUL MANUAL IN T E R M E D IA T E C L U T C H J-21 3 5 9 C O O L E R O U T ( FR O M R A D IA T O R C O O L E R IN PUMP TO R E V E R S E...
Page 305 AUTOMATIC TRANSMISSION (350)7A-21 D IR E C T C L U T C H D R U M STEE L SE PARATOR D IR E C T CL U T C H F A C E D PLA TE P I S T O N A S S E M B L Y ' R E T A I N I N G R I N G —...
Page 306 (350)7A-22 OVERHAUL MANUAL DIRECT CLUTCH DRUM TO FORWARD CLUTCH HOUSING NEEDLE ROLLER BEARING Fig. 7 A -7 2 B --D ir e c t Clu tch Drum to F orward Clutch Ho usin g Fig. 7 A - 7 3 B - R e m o v in g Dir e ct C lu tch Pressure Plate Ne edle Roller Bearing 4.
Page 307 (350)7A-23 AUTOMATIC TRANSMISSION .020" PIANO WIRE CRIMPED INTO COPPER TUBING DIRECT CLUTCH H O U S IN G Fig. 7 A - 7 8 B - -ln s t a llin g Direct Clu tch Piston Fig. 7 A - 7 6 B ~ R e m o v in g Dir e ct Clu tch Outer and Inner Seals 3.
Page 308 (350)7A-24 OVERHAUL MANUAL F O R W A R D CLUTCH P IS T O N CLUTCH ASSEMBLIES FOR THM 350 DRIVE DRIVEN CUSHION CLUTCH PLATE PLATES SPRING FORWARD 250 L-6, 262-305 T A X I A N D T R U C K IN TER M ED IATE 250 L-6, 262 305-350...
Page 309 (350)7A-25 AUTOMATIC TRANSMISSION R E T A IN IN G \ l | F O R W A R D CLUTCH R IN G A S S | MBLY PRESSURE PLATE Fig. 7 A - 8 3 B --R e m o v in g F orw a rd Clutch, Clutch Pack Fig.
Page 310 (350)7A-26 OVERHAUL MANUAL WHEN DIM. C IS (OR EQUIVALENT) F O R W A R D C LU TC H 6261072 .0160— .0520 BALL C H E C K . 0 5 2 0 — .0830 6261349 EXH AU ST .0830—...
Page 311 (350)7A-27 AUTOMATIC TRANSMISSION Fig. 7 A - 8 9 B - P la n e t a r y Gear Train - Explo ded V ie w 2. Remove sun gear to drive shell flat rear steel thrust washer (fig. 7A-91B). S U N G E A R 3.
Page 312 (350)7A-28 OVERHAUL MANUAL SU N G E A R DRIVE SHELL SUN G E A R i f f f f l ' FLAT THRUST W A S H E R Fig. 7A-9 1 B - R e m o v in g Sun Gear to Drive Shell Rear Steel _____________________________________________________________ T h ru s t W a s h e r Fig.
Page 313 {350)7A-29 AUTOMATIC TRANSMISSION LOW & REVERSE ROLLER CLUTCH RETAINING RING L O W A N D REVERSE O V E R R U N C LU TC H RACE Fig. 7 A -9 5 B --R e m o vin g O verrun Roller Clu tch Retaining Ring Fig.
Page 314 (350)7A-30 OVERHAUL MANUAL governor weight retaining pins and one governor gear retainer split pin. Replacement of gear must be performed with care in the following manner: 1. Drive out governor gear retaining split pin using small punch. 2. Support governor on 3/16 inch plates installed in exhaust slots of governor sleeve, place in arbor press, and with a long punch, press gear out of sleeve.
Page 315 (350)7A-31 AUTOMATIC TRANSMISSION J-8092 OUTPUT RING GEAR DRIVE HANDLE J-21424-7 OUTPUT SHAFT J-9534 PUMP COVER PUMP AND STATOR BODY SHAFT ASSEMBLY ADAPTER SLIDE HAMMER Fig. 7 A -9 9 B --R e m o v in g O u t p u t S h a ft Bush ing BUSHING REPLACEMENT Extension Housing Bushing Fig.
Page 316 (350)7A-32 OVERHAUL MANUAL Stator Shaft Rear Bushing W ith stator shaft properly supported, remove front bushing (fig. 7A-102B). Place tool J-2 1424-7 and drive handle J-8092 with extension J-2 1465-13 through front of stator shaft and drive out two (2) rear bushings. Using tool J-23062- S U N 2 and extension J-2 1465-13, install inner bushing to G E A R...
Page 317 (350)7A-33 AUTOMATIC TRANSMISSION and face plates, starting with a steel plate and alternating with face plates. Install low and reverse clutch support retainer (anti-clunk) spring. NOTE: N otch in steel separator plates should be placed toward bottom of case. 9. Install low and reverse clutch support assembly with position of notch with low and reverse clutch support retainer (anti-clunk) spring as shown on Figure 7A-107B.
Page 318 (350)7 A-34 OVERHAUL MANUAL NOTE: N otch in steel reaction plates is installed toward selector lever inner bracket. 23. Install intermediate clutch cushion spring. Pump to Direct Clutch Thrust Washer Selection Procedure 24. To check for proper thickness of selective fit thrust washer between the oil pump cover and direct clutch J-5154 assembly, proceed as follows:...
Page 319 AUTOMATIC TRANSMISSION (350)7A-35 2. Install parking pawl, tooth toward the inside of case, 8. Install spacer support plate, torque bolts to 130 in. lbs. into case. 9. Connect detent control valve wire to detent valve actuating lever, then attach lever to valve body. 3.
Page 321 AUTOMATIC TRANSMISSIONS (400)7A-1 SECTION 7 A AUTOMATIC TRANSMISSION TURBO HYDRA-MATIC 40 0 TRANSMISSION INDEX O utput Shaft, Rear Internal Gear, Transmission Disassembly and Reassem bly....7A- 1 Sun Gear and Shaft.............7A -40 Disassembly of M ajor U n its........... 7A- 1 Sun G ear Shaft B ushing-Front........7A -40 Governor, Speedometer Driven Gear, Pan, Filter Sun G ear Shaft B ushing-R ear........
Page 322 (400)7A-2 OVERHAUL MANUAL Fig. 7A-1C--Side Cross Section-Typical...
Page 323 (400)7A-3 AUTOMATIC TRANSMISSIONS M O D U L A T O R VALVE V A C U U M M O D U L A T O R Fig. 7 A -2 C ~ T ra n sm is s io n in H o ld in g Fixture Fig.
Page 324 (400)7A-4 OVERHAUL MANUAL STRAINER ASSEMBLY INTAKE] PIPE LOCATOR TABS____ | Fig. 7 A - 8 C -R e m o v in g Filter A s s e m b ly and Ring " 0 " 7A -11C). Clean governor screen in clean solvent and air dry. Fig.
Page 325 (400)7A-5 AUTOMATIC TRANSMISSIONS CONTROL VALVE GOVERNOR PIPES SERVO COVER A TTA C H IN G BOLTS Fig. 7 A - 10C--R emoving C o n tro l Valve A s s e m b ly and G o ve rn o r Pipes fr o m Case Fig.
Page 326 (400J7A-6 OVERHAUL MANUAL TORQUE WRENCH TORQUE J-21370-6 WRENCH J-21370-6 J - 2 1370-9 Fig. 7 A - 1 5C--C heckin g Rear Band A p p ly Pin, Except M od e ls Fig. 7A-1 C - C h e c k in g Rear Band A p p ly Pin, M odels CB and CL CB and CL c.
Page 327 (400)7A-7 AUTOMATIC TRANSMISSIONS G A S K E T Fig. 7 A - 2 0 C - R e m o v in g Fro nt Servo Piston, Retainer Ring, and Fig. 7A-1 C--Removing De te n t S o le n o id and Gasket Before removing gauging tool make note of the proper Remove front servo piston, retainer ring, washer, pin, band apply pin to be used during assembly of the transmission...
Page 328 OVERHAUL MANUAL (400)7A-8 RETAINING SPRING SHAFT M ANUAL Fig. 7 A - 2 5 C - R e m o v in g Parkin g S h a ft Re ta in in g Sp rin g SHAFT DETENT LEVER NOTE: The following steps are to be completed only if Fig.
Page 329 (400)7A-9 AUTOMATIC TRANSMISSIONS DIAL IN D IC A T O R Fig. 7 A -2 7C--Rem ovin g Rear Oil Seal from Case Extension J -8 0 0 1 Fig. 7 A-2 9 C --C h e c k in g Fro nt U n it End Play Removal of Rear Oil Seal and Case Extension 1.
Page 330 (400)7A-10 OVERHAUL MANUAL Fig. 7 A - 3 3 C - R e m o v in g Forw a rd C lu tc h A s s e m b ly and T u rb in e S h a ft 9539 with weights J-6585-01, into bolt holes in pump body Fig.
Page 331 (400)7A-11 AUTOMATIC TRANSMISSIONS D I AL I N D I C A T O R J - 9 5 3 9 Fig. 7 A-3 7 C --C h e c k in g Rear U n it End Play Fig. 7 A - 3 5 C - R e m o v in g Fro nt Band REAR END WASHER THICKNESS 9.
Page 332 (400)7A-12 OVERHAUL MANUAL BACKING PLATE COMPOSITION PLATES STEEL PLATES Fig. 7 A -4 0C--Rem ovin g I n te rm e d ia te Ba c kin g Plate and Clutch Plates shown in Fig. 7A-38C. 10. Remove center support to case bolt (Fig. 7A-39C), using a 3/8"...
Page 333 (400)7A-13 AUTOMATIC TRANSMISSIONS Fig. 7 A -4 4 C ~ R e m o v in g C e nter S u p p o r t to Case Spacer Fig. 7 A -4 6 C --R e m ov in g Center S u p p o rt A s s e m b ly 19.
Page 334 (400)7A-14 OVERHAUL MANUAL ROLLER CLUTCH SNAP RING ASSEMBLY REACTION CARRIER GEAR PLASTIC GEAR RING OUTPUT CARRIER Fig. 7 A - 5 0 C - R e m o v in g O u tp u t S h a ft to C a rrie r Sn ap Ring REMOVE A N D IN STALL REACTION CARRIER 10.
Page 335 AUTOMATIC TRANSMISSIONS (400)7A-15 SPEEDOMETER DRIVE GEAR CLIP INTERNAL GEAR Fig. 7 A - 5 4 C - l n s t a l l i n g S p e e d o m e te r Drive Gear Clip SNAP RING MAIN SHAFT speedometer drive gear with clip and install gear.
Page 336 (400)7A-16 OVERHAUL MANUAL Fig. 7 A - 5 6 C --ln s ta llin g Steel S p e e d o m e te r Drive Gear Fig. 7 A -5 8 C --C h e ck in g Valve O p e n in g W it h W e ig h t s O u tw a rd Install new steel speedometer drive gear and drive to due to foreign material causing im proper operation.
Page 337 (400)7A-17 AUTOMATIC TRANSMISSIONS Fig. 7 A - 6 0 C - R e m o v in g G o ve rn o r Gear R etain in g Pin Fig. 7 A -5 9 C--Checkin g Valve O p e n in g W it h W e ig h t I n w a rd 1.
Page 338 (400)7A-18 OVERHAUL MANUAL Carefully remove any chips that may have shaved off gear hub and press gear in until it bottoms on shoulder. 5. A new pin hole must be drilled through sleeve and gear. Locate hole position 90 degrees from existing hole, center punch and then, while supporting governor in press, drill new hole through sleeve and gear using a standard (1/8 inch) drill.
Page 339 (400)7A-19 AUTOMATIC TRANSMISSIONS RETAINING “ E” RING SERVO PISTON SERVO PIN Fig. 7 A - 6 4 C - R e a r Servo and A c c u m u la t o r A s s e m b ly -E x p lo d e d V ie w CONTROL VALVE, DISASSEMBLY, INSPECTION 4.
Page 340 (400)7A-20 OVERHAUL MANUAL a. (Models CG, CJ and CP) Remove retaining pin, 1-2 plug, 1-2 accum ulator valve and spring. m odulator bushing, 1-2 valve spring, 1-2 m odulator valve, b. (Models CB, CG, CJ, CL and CS) Remove the and 1-2 shift valve.
Page 341 (400)7A-21 AUTOMATIC TRANSMISSIONS Fig. 7 A - 6 8 C --ln s ta llin g Detent R e g u la to r Valve and Detent Valve Fig. 7 A -7 0 C --R e m ovin g Pressure Re g u la tor Valve Inspect accum ulator piston and oil seal ring for damage.
Page 342 (400)7A-22 OVERHAUL MANUAL retaining pin. 10. In next bore up, install the 2-3 shift valve, open end out, into the bore and install 3-2 intermediate spring. 11. Install 2-3 m odulator valve into bushing and install both parts into valve body bore. 12.
Page 343 AUTOMATIC TRANSMISSIONS (400)7A-23 VENT CONVERTER DRIVE MODULATOR OR INTERMEDIATE COOLER RETURN COOLER COOLER INTAKE COOLER RETURN BREATHER HOLE REVERSE LUBE DRIVE PRESSURE REGULATOR COVER-PUMP VENT FEED HOLE MODULATOR OR INTERMEDIATE Fig. 7 A -75C--Pum p B o d y Oil Passages Fig.
Page 344 (400)7A-24 OVERHAUL MANUAL RETAINING PIN BORE PLUG PRESSURE REGULATOR VALVE PRESSURE REGULATOR SPACER-, SPRING RETAINER WASHERn PRESSURE REGULATOR SPRING PUMP COVER THRUST WASHER- PRESSURE BOOST VALVE PUMP OIL SEAL RING PRESSURE BOOST BUSHING (CAST IRON) SNAP RING TEFLON OIL SEAL RING Fig.
Page 345: Automatic Transmissions
(400)7A-25 AUTOMATIC TRANSMISSIONS PUMP COVER PUMP BODY Fig. 7A-8 0 C --R e m ovin g F o rw a rd Clutch Ho using to Direct C lu tch Hub Sn ap Ring Fig. 7 A - 7 8 C ~ A lig n in g Pump, Cove r to Pump Body FORWARD CLUTCH HUB THRUST...
Page 346 OVERHAUL MANUAL (400)7A-26 BOLT FORWARD CLUTCH PISTON CLUTCH OUTER SEAL TURBINE SHAFT Fig. 7 A-84C--Rem oving F o rw a rd C lu tch Piston O uter Seal 8. Remove forward clutch piston. 9. Remove inner and outer clutch piston seals (Fig. 7A- Fig.
Page 347 AUTOMATIC TRANSMISSIONS (400)7A-27 F O R W A R D CLUTCH ASSEMBLY S N A P FLAT STEEL DIRECT F O R W A R D R IN G CLUTCH HUB PLATES (4) CLUTCH HUB W A V E D STEEL PLATE C O M P O S I T I O N...
Page 348 (400)7A-28 OVERHAUL MANUAL COM POSITION FORWARD CLUTCH ASSEMBLY PLATES STEEL PLATES FORWARD CLUTCH H O USING PUMP ASSEMBLY Fig. 7 A - 8 8 C --ln s ta llin g F orw a rd Clutch C o m po sit io n and Steel Fig.
Page 349 AUTOMATIC TRANSMISSIONS (400)7A-29 SNAP RING INTERMEDIATE CLUTCH RETAINER IN T E R M E D IA T E C L U T C H O U T E R R AC E I N T E R M E D IA T E R O L L E R C L U T C H DIRECT CLUTCH H O U SING...
Page 350 (400)7A-30 OVERHAUL MANUAL J -4 6 7 0 1 Fig. 7 A-94C--Rem oving or In s ta llin g Direct Clutch Sn ap Ring Fig. 7 A - 9 6 C --ln s ta llin g Dir e ct C lu tc h In ner Seal Assembly 5.
Page 351 AUTOMATIC TRANSMISSIONS (400)7A-31 CHECK BALL DIRECT CLUTCH HOUSING CLUTCH CENTER SEAL Fig. 7 A - 9 8 C --ln s ta llin g Dir e ct Clu tch Center Seal Fig. 7 A - 1 0 0 C - D i r e c t C lu tch H ousin g w it h Ch e ck Ball The direct clutch housing for models CAUTION: CB, CL and CS use the 6 plate tlutch assembly.
Page 352 (400)7A-32 OVERHAUL MANUAL DIRECT CLUTCH B A C K IN G P L A lc DIRECT CLUTCH HOUSING (1) WAVED STEEL PLATE (5) COMPOSITION PLATES (4) FLAT STEEL PLATES DIRECT CLUTCH BACKING PLATE SNAP RING DIRECT CLUTCH H O U S IN G Fig.
Page 353 AUTOMATIC TRANSMISSIONS (400)7A-33 Fig. 7 A - 1 0 7 C - ln s t a llin g I n te rm e d ia te Clutch Outer Race to D ir e ct Clutch Fig. 7 A - 1 0 9 C - l n s t a l l i n g I n te rm e d ia te C lu tch Re tainer 12.
Page 354 (400)7A-34 OVERHAUL MANUAL Fig. 7 A-1 1 1 C— A ir C h e ck in g Direct Clutch A s se m b ly Fig. 7A-1 1 3 C -R e m o v in g In te rm e d ia te C lu tch Piston Sn ap Ring DISASSEMBLY, INSPECTION AND RE...
Page 355 AUTOMATIC TRANSMISSIONS (400)7A-35 INTERMEDIATE CLUTCH RELEASE SPRING (3) & RACE ASSEMBLY Fig. 7A-1 1 5C --R em oving C lu tch Release S p rin g s Fig. 7A-1 1 7 C ~ R em oving In te rm e d ia te C lu tc h Piston retaining roller clutch inner race to center support.
Page 356 (400)7A-36 OVERHAUL MANUAL ROLLER ASSEMBLY CENTER SUPPORT ASSEMBLY INTERMEDIATE CLUTCH INNER SEAL INTERMEDIATE CLUTCH RELEASE SPRINGS THRUST WASHER SUPPORT TO CASE SPACER TEFLON OIL SEAL RING S INTERMEDIATE CLUTCH OUTER SEAL INTERMEDIATE CLUTCH PISTON INTERMEDIATE CLUTCH INTERMEDIATE CLUTCH SPRING RETAINER SPRING G UIDE Fig.
Page 357 (400)7A-37 AUTOMATIC TRANSMISSIONS INTERMEDIATE CLUTCH RELEASE SPRING (3) CLUTCH J—2 1 3 6 3 PISTON CENTER Fig. 7 A - 1 2 1 C --ln sta llin g In te rm e d ia te C lu tch Piston Fig. 7A-1 2 3 C --ln s ta llin g In te rm e d ia te C lu tch Release S p rin g s INTERMEDIATE CLUTCH SPRING GUIDE Fig.
Page 358 (400)7A-38 OVERHAUL MANUAL REACTION SPACER CARRIER RING Fig. 7A-1 2 5 C --T eflo n Rings Fig. 7A-1 2 7 C -ln s p e c tin g S p a c e r Ring of mating parts over rings. Retain with petrolatum. spacer ring is used optionally and interchangeably with the reaction carrier which does not have an undercut and Air check operation of intermediate clutch piston...
Page 359 AUTOMATIC TRANSMISSIONS (400)7A-39 F P INION PIN BRONZE WASHER STEEL WASHER HEADED END PLANET PINION NEEDLE BEARINGS STEEL WASHER BRONZE WASHER Fig. 7 A - 13 1 C -P la n e t P inion A s s e m b ly -E x p lo d e d V ie w Fig.
Page 360 (400)7A-40 OVERHAUL MANUAL OUTPUT SHAFT, REAR INTERNAL GEAR, SUN a. (All except CA and CB Models) Using tool J-2 1465- GEAR AND SHAFT 17, with Driver Handle J-8092, drive or press replacement bushing into place, flush to .010 below oil seal counter bore Output Shaft area.
Page 361 (400)7A-41 AUTOMATIC TRANSMISSIONS INSPECTION OF MODULATOR AND VALVE 1. Inspect m odulator assembly for any signs of bending or distortion (Fig. 7A-134C). 2. Inspect "O" ring seal seat for damage. 3. Apply suction to vacuum tube and check for diaphragm leaks. MODULATOR VALVE 4.
Page 362 (400)7A-42 OVERHAUL MANUAL LINE DRIVE MODULATOR OR INTERMEDIATE TO COOLER PUMP INTAKE COOLER RETURN P i INTERMEDIATE C L U T C H i i ^ ^ v E N T ^ M CUP PLUG Fig. 7A-1 36C --C ase--F ront V ie w Passage Id e n tific a tio n Fig.
Page 363 (400)7A-43 AUTOMATIC TRANSMISSIONS Fig. 7 A -1 3 9 C --L o o se n in g C o lle t on T oo l J-2 1 57 1-8 Fig. 7A-1 4 0 C ~ C h e c k in g C o n ve rte r End C le a ran ce SNAP RING SPEEDOMETER...
Page 364 (400J7A-44 OVERHAUL MANUAL INTERNAL GEAR O.D. FLANGED RACE THRUST BEARING I.D. FLANGED RACE SNAP RING MAIN SHAFT Fig. 7 A - 1 4 2 C — In s ta llin g Rear In te rn a l G ear S nap Ring Converter End Clearance Check (Figs.
Page 365 AUTOMATIC TRANSMISSIONS (400)7A-45 facing forward or up (Fig. 7A-153C). b. Place thrust bearing against race. c. Place small race against bearing with inner flange facing into bearing or down. 4. Install output carrier over mainshaft so that pinions mesh with rear internal gear. 5.
Page 366 (400)7A-46 OVERHAUL MANUAL Fig. 7 A-1 4 9 C ~ ln s ta llin g R o lle r in to R oller C lu tch Cage Fig. 7 A - 1 5 1C— In s ta llin g C e n te r S u p p o rt to R eaction C a rrie r 17.
Page 367 AUTOMATIC TRANSMISSIONS (400)7A-47 RETAINING SPRING Fig. 7 A-1 5 3 C -M o d ific a tio n o f S ervice Case fo r C o rvette SHAFT M o d e ls ASSEMBLY OF UNITS TO TRANSM ISSIO N CASE NOTE: The first three steps can be omitted if the parts...
Page 368 (400)7A-48 OVERHAUL MANUAL CENTER SUPPORT LOCATING TOOL J-9539 Fig. 7A-1 6 0 C --ln s ta llin g C e n te r S u p p o rt B o lt center support locating tool into the case direct clutch passage, with the handle of the tool pointing to the right as viewed from the front of the transmission and parallel to the bell housing m ounting face.
Page 369 (400)7A-49 AUTOMATIC TRANSMISSIONS REAR END WASHER THICKNESS Identification Thickness Notches and/or Numeral .074 - .078 None ......1 .082 - .086 1 Tab S id e ......2 .090 - .094 2 Tab S id e ......3 .0 9 8 -.1 0 2 1 Tab O .D ......4 .1 0 6 -.1 1 0 2 Tabs O .D .......
Page 370 (400)7A-50 OVERHAUL MANUAL RONT SEA Fig. 7A-1 C ~ ln s ta llin g D ire c t C lu tch A ss e m b ly 17. W ith converter end of transmission up, carefully install direct clutch and intermediate roller assembly. It will Fig.
Page 371 (400)7A-51 AUTOMATIC TRANSMISSIONS FRO NT END WASHER THICKNESS Thickness Color .060 - .064 Y ellow .071 - .075 Blue .082 - .086 .093 - .097 Brown .1 0 4 - .108 Green .115 - .119 Black .1 2 6 - .130 Purple Fig.
Page 372 (400)7A-52 OVERHAUL MANUAL GASKET Fig. 7A-1 7 5 C --ln s ta llin g D e te n t S o le n o id and G asket 6. Install detent solenoid assembly with connector facing outer edge of case (Fig. 7A-175C). Do not tighten bolts at this time.
Page 373 AUTOMATIC TRANSMISSIONS (400)7A-53 TORQUE WRENCH Fig. 7 A-1 7 7 C --F ro n t Servo G ro u p -ln V e h icle In s ta lla tio n NOTE: The teflon ring allows the front servo piston to slide very freely in the case.
Page 374 (400)7A-54 OVERHAUL MANUAL REAR SERVO ASSEMBLY GOVERNOR SCREEN ASSY. GOVERNOR FEED PIPE HOLE Fig. 7A-1 1C— In s ta llin g Rear Servo A sse m b ly Fig. 7A-1 8 3 C — In s ta llin g G o ve rn o r Screen A sse m b ly If both steps are above the gauge surface, the short control valve assembly and governor pipes as outlined pin, identified by 1 ring, should be used.
Page 375 (400)7A-55 AUTOMATIC TRANSMISSIONS Fig. 7 A - 1 8 5 C — In s ta llin g D e te n t R o lle r and S p rin g A sse m b ly Fig. 7 A-1 8 7 C --ln s ta llin g G o ve rn o r A s s e m b ly INSTALLATION OF FILTER AND INTAKE PIPE NOTE: Models CA and CZ use a modulator that is...
Page 376 (400)7 A-56 OVERHAUL MANUAL 2. Install speedometer driven gear retainer and attaching certain that the converter hub drive slots are fully engaged bolt. with the pump drive gear tangs and the converter installed fully towards the rear of the transmission. INSTALL CONVERTER ASSEMBLY NOTE: W ith the transmission in cradle or portable jack, install...
Page 377 AUTOMATIC TRANSMISSIONS (400)7A-57 J-5154 or Extension Housing O il Seal Transmission H olding F ixtu re . J-8763-02 J -2 1426 Installer (Used w ith J-3289-20 Base) J-21359 Pump O il Seal Installer Transmission H olding F ix tu re .
Page 378 (400)7A-58 OVERHAUL MANUAL 1. J-61 16-01 Rear Unit Holding Fixture J-2 1795-2 Part of Above Holding Tool 2. J-8092 Driver Handle J-5384 Converter Holding Strap J-2 1359 Pump Oil Seal Installer J-2 1465-01 Bushing Tool Set J-2 1364 Holding Fixture Adapter (Used J-2 1465-5 Part of Bushing Tool Set with J-61 16-01 Fixture)
Page 379 (400)7A-59 AUTOMATIC TRANSMISSIONS C lu tc h S p rin g C om pressor J -2 1 6 6 4 T ransm ission H o ld in g F ix tu re . J-8763 A d a p te r Ring J-32 8 9 -1 4 H o ld in g F ix tu re Base C lu tc h S p rin g C om pressor...
Page 380 (400) 7A-60 OVERHAUL MANUAL SPECIFICATIONS TURBO-HYDRAMATIC "200" Pump Cover Bolts ......................... 24 N m (18 ft. lbs.) Pump to Case Attaching B olts..................... 24 N m (18 ft. lbs.) Parking Pawl Bracket B o lts ....................24 N m (18 ft.
Page 381: Special T O O
MANUAL TRANSMISSION 7B-1 S E C T IO N 7B MANUAL TRANSMISSION C O N T E N T S 3-Speed (Saginaw) 76mm Transm ission......7B-1 New Process Model 205 Transfer C ase......7B-52 New Process Model 203 Transfer C ase......7B-59 3-Speed (Tremac) 77mm Transm ission......
Page 382 1 1 12 13 15 16 Clutch G ear 1st Speed G ear S nap R in g -B e a rin g C lutch G ear Bearing M a g n e t B earing R etainer 1st Speed Blocker to M a in s h a ft S nap R in g -B e a rin g 2-3 Synch.
Page 383 7B-3 MANUAL TRANSMISSION Fig. 7 B -5 A -R e m o v in g C o u n te r G ear S h a ft Fig. 7 B -2 A -R e m o v in g C lu tc h G ear B e a rin g R e ta in in g Ring Fig.
Page 384: Transmission Case
7B-4 OVERHAUL MANUAL Make sure bearings are clean, then lubricate with light engine oil and check them for roughness by slowly turning the race by hand. Bearing Rollers All clutch gear and counter gear bearing rollers should be inspected closely and replaced if they show wear. Inspect counter shaft and reverse idler shaft at the same time, replace if necessary.
Page 385 7B-5 MANUAL TRANSMISSION J-5778 Fig. 7 B -1 3 A -R e m o v in g D rive G ear B e a rin g R e ta in e r Seal Fig. 7B-1 1 A -R e m o v in g o r In s ta llin g Rear E xtension B u sh in g spring should be installed into different key cavities on either old seal out (Fig.
Page 386 7B-6 OVERHAUL MANUAL Drive Gear 2-3 Synchronizer 1st Speed Blocker Reverse Gear Thrust Drive Gear Bearing Assembly Ring W asher 3rd Speed Blocker 2nd Speed blocker 1st Speed Spring W asher Ring Ring Synchronizer Rear Bearing M ainshaft Pilot 2nd Speed Gear Assembly Snap Ring Bearings (14)
Page 387 MANUAL TRANSMISSION 7B-7 M AIN DRIVE GEAR Fig. 7B-1 7 A ~ L o a d in g P ilo t B e a rin g s Fig. 7B-1 A -L o a d in g C o u n te rg e a r 6.
Page 388 7B-8 OVERHAUL MANUAL Snap R ing Bearing Retainer Bolts and Washers (4) Thrust Washer S ynchronizer Ring Front Bearing Retainer Countergear Shaft 2 -3 Synchronizer. Sleeve Bearing Retainer Gasket Countergear Shaft Key S ynchronizer Key Spring Bearing Retainer O il Seal Idler Shaft Key S ynchronizer H ub and Keys Snap Ring...
Page 389 7B-9 MANUAL TRANSMISSION 3 SPEED (TREMAC) 7 7 M M TRANSMISSION INDEX R epairs.................7B-13 Overhaul O perations............7B-9 Synchronizer Keys and Spring........7B-13 Transmission Disassembly..........7B-9 Extension Oil Seal or B u sh in g ........7B-14 Mainshaft Disassem bly...........7B-13 Clutch Bearing Retainer Oil Seal.......7B-14 Cleaning and Inspection..........
Page 390 7B-10 OVERHAUL MANUAL 1. MAINSHAFT ROLLER BEARINGS 35. EXTENSION HOUSING TO CASE GASKET 2. 2ND & 3RD SYNCHRONIZER RETAINING RING 36. SPEEDOMETER DRIVER GEAR RETAINING CLIP 3. SYNCHRONIZER BLOCKER RINGS 37. TRANSMISSION REAR BEARING LOCK RING 4. 2ND ft 3RD SYNCHRONIZER SPRING 38.
Page 391 7B-11 MANUAL TRANSMISSION A L IG N M E N T M A R K S R E A R i F,LL I 1 P LU G 1 D R A IN B O L T Fig. 7 B -3 B -D ra in T ra n sm issio n Fig.
Page 392 7B-12 OVERHAUL MANUAL B E A R IN G R E M O V E R FIRST-REVERSE J - 8 1 5 7 - 0 1 T O O L SLEEVE AND GEAR IN FORWARD POSITION TO CLEAR CASE P U L L E R SCREW S Fig.
Page 393 7B-13 MANUAL TRANSMISSION S P R IN G - F IR S T -R E V E R S E U N D E R L IP O F S L E E V E A N D G E A R K E Y S H U B A L IG N R O L L PIN...
Page 394 7B-14 OVERHAUL MANUAL A L IG N M E N T K E Y S < 3 > M A R K S J-5154 S P R IN G (U N D E R LIP O F K E Y S ) S L E E V E Fig.
Page 395 7B-15 MANUAL TRANSMISSION T A B B E D T H R U S T Fig. 7 B -2 0 B -M e a s u rin g O u tp u t S h a ft End Play Fig. 7B-1 B --In sta llin g T a b b e d T h ru s t W a s h e r 7.
Page 396 7B-16 OVERHAUL MANUAL J-24433 Fig. 7B-2 1 B - ln s ta lla tio n S e q u e n ce - D e te n t Plugs and S p rin g s Fig. 7 B - 2 2 B - ln s ta llin g F ro n t B earing Before countershaft is completely installed make sure that of case.
Page 397 7B-17 MANUAL TRANSMISSION 25. Install smaller snap ring on clutch gear shaft. 26. Position bearing retainer gasket on case. Be sure cut out in gasket is aligned with oil return hole in case. 27. Install front bearing retainer and tighten attaching bolts to 30 to 36 foot-pounds of torque.
Page 398 D riv e G ear 1st S peed Rear B e a rin g -to -S h a ft 2 1 . R everse Id le r S h a ft D riv e G ear B e a rin g S y n c h ro n iz e r Ring S n a p R ing 2 2 .
Page 399 7B-19 MANUAL TRANSMISSION CLEANING AND INSPECTION Transmission Case 1. Wash the transmission thoroughly inside and outside with cleaning solvent, then inspect the case for cracks. 2. Check the front and rear faces for burrs, and if present, dress them off with a fine mill file. 3.
Page 400 7B-20 OVERHAUL MANUAL Drive Gear Bearing Retaining Clip Snap Ring Shoulder (Part of Snap Ring Mainshaft 1st Speed M ainshaft) Drive Gear Bearing Speedo Drive Gear Synchronizer 2nd Speed Gear Oil Slinger Snap Ring Assembly 2nd Speed Blocker 3rd Speed Blocker Rear Bearing 1st Speed Blocker Ring...
Page 401 MANUAL TRANSMISSION 7B-21 align with the keys o f the syncrhonizer assembly. 4. Using snap ring pliers, expand the snap ring in the extension and assemble extension over rear of mainshaft and 4. Install synchronizer hub to mainshaft snap ring. Both onto rear bearing.
Page 402 7B-22 OVERHAUL MANUAL S y n c h ro n iz e r Keys G a ske t C o u n te rg e a r 3 5 . B e a rin g R e ta in e r 1st and Reverse 2 n d and 3 rd S h ifte r C o u n te rs h a ft...
Page 403 7B-23 MANUAL TRANSMISSION 4-SPEED (SAGINAW) 7 6 M M TRANSMISSION INDEX Repairs................. ..7B-23 Disassembly of T ransm ission..........7B-23 Clutch Keys and Springs R eplacem ent....7B-23 Disassembly of M ainshaft..........7B-23 Extension Oil Seal or B ushing........7B-26 Cleaning and Inspection............7B-23 Clutch Bearing Retainer Oil Seal......
Page 404 D riv e G ear 2 n d S peed B lo c ke r E xte n sio n 2 7 . T h ru s t W a s h e r-F ro n t C o u n te rg e a r B e a rin g R e ta in e r Ring V e n t...
Page 405 7B-25 MANUAL TRANSMISSION PULL M A IN J - 2 2 2 4 6 DRIVE GEAR FORWARD Fig. 7 B -5 J--R e m oving C o u n te rs h a ft Fig. 7 B -2 J--R e m oving C lu tch G ear B e a rin g Fig.
Page 406 7B-26 OVERHAUL MANUAL Fig. 7 B -1 0 J--R e m o vin g 1st and 2 n d S y n c h ro n iz e r S nap Ring NOTE: A groove around the outside of the synchronizer Fig.
Page 407 MANUAL TRANSMISSION 7B-27 SCREWDRIVER Fig. 7B-1 4 J--R em oving B e a rin g R e ta in e r O il Seal Fig. 7B-1 2 J~ E xte n sio n B u sh in g R eplacem ent Clutch Gear Bearing Retainer Oil Seal Be sure the notches o f the blocker ring CAUTION:...
Page 408 7B-28 OVERHAUL MANUAL Drive Gear Bearing First Speed Gear Drive Gear Thrust Washer Mainshaft Pilot Spring Washer Bearings Rear Bearing 3-4 Synchronizer Speedo Drive Gear AssenWy Mainshaft Third Speed Gear Snap Ring Second Speed Gear Synchronizing 1-2 Synchronizer and “ Blocker” Ring Reverse Gear Assembly Fig.
Page 409 B e a rin g R e ta in e r T h ru s t W a s h e r -F r o n t 2 9 . 3 r d S p e e d B lo c k e r 4 2 .
Page 410 7B-30 OVERHAUL MANUAL MAIN DRIVE GEAR Fig. 7 B -2 0 J --L o a d in g M a in s h a ft B e a rin g s Fig. 7 B -1 9 J --L o a d in g C o u n te rg e a r B e a rin g Be sure the notches in the blocker ring CAUTION: 10.
Page 411 Clutch G ear Bearing Retainer 12 1 st & 2nd Speed Clutch Assy. Thrust W asher Retainer Lip Seal 13 1 st Speed Synochronizer Ring Thrust W asher Snap Ring and Washer 14 1 st Speed G ear Idler Shaft Roll Pin Clutch G ear Bearing 15 1st Speed G ear Bushing Rear Idler G ear...
Page 412 7B-32 OVERHAUL MANUAL & x 7] 1. Bearing Retainer First and Second S peed 4 4 . Rear B earing R etainer To 6 3 . C o u n tersh aft 2 . G a s k et Clutch Sliding Sleeve Case Extension G a s k e t 6 4 .
Page 413 MANUAL TRANSMISSION 7B-33 REVERSE SHIFTER SHAFT PIN REVERSE IDLER G E A R REVERSE GEAR Fig. 7B -3 K ~ R e m o vin g Reverse S h ifte r S h a ft Lock Pin Fig. 7 B -5 K -R e m o v in g Reverse Gear 5.
Page 414 7B-34 OVERHAUL MANUAL Using a dummy shaft J-24658 drive countergear 2. Spread rear bearing retainer snap ring (Fig. 7B-10K) shaft of countergear (Fig. 7B-7K) remove and slide retainer from mainshaft. countergear and tanged thrust washers from case. Check 3. Remove rear bearing-to-mainshaft snap ring (Fig. 7B- bottom of case for pilot bearings or other loose components.
Page 415 7B-35 MANUAL TRANSMISSION B E A R IN G RETAINER S N A P R IN G PLIERS Fig. 7 B -1 0 K --R e m o vin g Rear B e a rin g R eta in e r CLEANING AND INSPECTION Transmission Case 1.
Page 416 7B-36 OVERHAUL MANUAL J - 2 1465-17 W/HANDLE J—21 J-8092 Fig. 7 B -16 K— I nsta llin g D rive G ear B e a rin g R etainer Seal CAUTION: Do not alio w the bearings to spin. Turn them slowly by hand.
Page 417 MANUAL TRANSMISSION 7B-37 Fig. 7 B -1 K— S h ift C over A sse m b ly drive the pin into the extension until the shaft is securely locked in place. Install new welch plug, with sealer, in boss Fig.
Page 418 7B-38 OVERHAUL MANUAL ROLLERS SPACERS Fig. 7 B -1 9 K ~ C o u n te rg e a r C ross S ection Fig. 7B -2 1 K— I nsta 1 1 i ng 1st G ear Sleeve ASSEMBLY OF M AINSHA FT 7.
Page 419 MANUAL TRANSMISSION 7B-39 USE SEALER O N THIS BOLT ¥ Fig. 7 B -2 4 K --E xte n sio n B o lt Fig. 7 B -2 3 K --ln s ta llin g F ro n t M ain B e a rin g lines up with hole in boss.
Page 420 7B-40 OVERHAUL MANUAL 4-SPEED (MUNCIE CH465) 1 1 7 M M TRANSMISSION INDEX Disassembly of T ransm ission..........7B-40 Drive G ear Bearing Retainer Oil Seal......7B-46 Subassembly O p eratio n s............7B-40 M ainshaft................7B-47 Transmission C o v e r............7B-40 Disassembly..............
Page 421 7B-41 MANUAL TRANSMISSION K” MODELS T h ru st W a sh e r Reverse Driven Gear M a in s h a ft Rear M ain Drive Gear B earing S nap Ring P oppet S pring Drive Gear B earing F ront C o u n te rs h a ft P oppet Ball Rear B earing Snap...
Page 422 Drive Gear Bearing 1st-2nd Speed 2nd Speed Gear Snap Ring Rear Retainer Gasket Retainer Synchronizer Hub 3rd Gear Bushing Snap Ring Rear Retainer Synchronizer Keys Retainer Gasket Thrust Washer Thrust Washer Retainer Bolts Lip Seal Synchronizer Spring 3rd Speed Gear Clutch Countergear Retainer Lip Seal Snap Ring...
Page 423 7B-43 MANUAL TRANSMISSION REVERSE J-8433-1 3 R D /4 T H 1ST/2ND Fig. 7 B -5 L -C o v e r A sse m b ly Fig. 7B-3L--R em oving C o u n te rg e a r Rear B e a rin g 2.
Page 424 7B-44 OVERHAUL MANUAL Transm ission Cover 3 rd -4th S hifter Fork In terlo ck Plunger Interlock Balls ”C ” Ring Lock Clip Spring 3 rd -4th S hifter Shaft Reverse S hifter Fork Reverse Interlock Reverse S hifter S haft S hifter S haft Hole Plunger Fork Retaining Pin...
Page 425 MANUAL TRANSMISSION 7B-45 OIL SLINGER RETAINER RING SNAP RING Fig. 7B-8L--D rive Gear A sse m b ly Inspection 1. Wash all parts in clearing solvent. 2. Inspect roller bearings for pits or galling. 3. Inspect bearing diameter in shaft recess for galling. 4.
Page 426 7B-46 OVERHAUL MANUAL CAUTION: The bearing m ust turn freely, after it is installed on the shaft. 4. Install snap ring on I.D. of mainshaft pilot bearing bore in clutch gear (if previously removed). 5. Apply a small am ount of grease to bearing surface in shaft recess, install transmission mainshaft pilot roller bearings (17) and install roller bearing retainer (Fig.
Page 427 7B-47 MANUAL TRANSMISSION 1 3. 4th Speed Blocker 2nd Speed Blocker 3rd Speed Blocker 1 st Speed Gear Ring Ring Ring Reverse Driven Gear Snap Ring 2nd Speed Gear 1 1. 3rd-4th Speed 1 st Gear Bushing Synchronizer Hub M ainshaft Thrust W asher 1st-2nd Gear Assembly...
Page 428 7B-48 OVERHAUL MANUAL 3. Inspect clutch hub -and clutch sleeve for excessive wear and make sure sleeve slides freely on clutch hub. Also J -2 2 8 7 3 check fit of clutch hub on mainshaft splines. NOTE: T hird and fourth speed slutch sleeve should slide freely on third and fourth speed clutch hub but 2N D GEAR clutch hub should be snug fit on shaft splines.
Page 429 7B-49 MANUAL TRANSMISSION 3RD & 4TH GEAR I SYNCHRONIZER 3RD GEAR BUSHING Fig. 7B-1 9L— Installing 3rd and 4th Gear Synchronizer Assembly 1. Position 3rd speed countergear and shaft in arbor press and press the gear onto the shaft. Gear should be installed on shaft with the side having the splines extending the full length of the bore towards the front of the shaft.
Page 430 7B-50 OVERHAUL MANUAL Install clutch countergear thrust washer and front retaining ring using Tool J-22830 and J-22873 (Fig. 7B-21L). Do not over stress snap ring. Ring CAUTION: should be tight in groove without side play. ASSEMBLY OF TRANSMISSION 1. Lower the countergear into the case until it rests on bottoms of case.
Page 431 MANUAL TRANSMISSION 7B-51 J-22874-2 Fig. 7B-24L--Countergear Front Support Tool Fig. 7 B-2 5 L— I nsta 1 1 i ng Countergear Rear Bearing 7. Install drive gear bearing retainer using a new gasket. reverse idler gear which should be engaged approximately 3/8 of an inch (leading edge of reverse idler gear teeth lines Install bolts and tighten to 15-18 ft.
Page 432 7B-52 OVERHAUL MANUAL NEW PROCESS MODEL 205 (PART TIME) TRANSFER CASE INDEX Assembly of Transfer Case..........7B-55 Disassembly of Transfer C ase..........7B-52 Rear O utput Shaft A ssem bly........7B-52 Idler G e a r................7B-55 Front O utput Shaft A ssem bly........7B-52 Shift Rail and Fork A ssem blies........7B-55 Shift Rail and Fork A ssem blies........7B-52 Front O utput Shaft A ssem bly........7B-57...
Page 433 MANUAL TRANSMISSION 7B-53 43 414241 S lid in g C lu t ch Rea r Be ar i n g 3 2 . I d l e r G e a r S h a f t B e a r i ng I np u t S ha ft R e ta in er Fr on t W h e e l H i-G eai...
Page 434 7B-54 OVERHAUL MANUAL SNAP RING REAR OUTPUT ASSEMBLY IDLER SHAFT COVER FRONT OUTPUT SHAFT REAR BEARING RETAINER Fig. 7B -2R ~R ear V ie w o f T ra n s fe r Case Fig. 7 B -5 R -R e m o v in g G ear R e ta in in g Ring POPPET NUTS SHIFT RAIL LINK...
Page 435 MANUAL TRANSMISSION 7B-55 2. Assemble the two bearing cones, spacer, shims and idler gear on dumm y shaft J-23429 with bore up. Check end play (Fig. 7B-11R). Limits are .001 to .002 inch. 3. Install idler gear assembly with dummy shaft into case through front output bore, large end first (Fig.
Page 436 7B-56 OVERHAUL MANUAL Rear O u tp u t S h a ft L o c k n u t S lid in g C lu tch C o ve r G a s ke t W a s h e r In p u t S h a ft Rear C o ve r Y oke...
Page 437 7B-57 MANUAL TRANSMISSION Fig. 7B-1 2R— In s ta llin g Id le r Gear Front Output Shaft and Gear Assembly 1. Install two rows of needle bearings (32 each) separated by a spacer in the front low output gear and reatin with a sufficient am ount of grease.
Page 438 7B-58 OVERHAUL MANUAL J-23431 BEARING Fig. 7B-1 5 R --In sta llin g S h ift Rail Lock Pins 4. Line up washer, high gear, and sliding clutch with bearing bore. Insert front output shaft and low gear assembly through the high gear assembly. 5.
Page 439 7B-59 MANUAL TRANSMISSION 7. Install rear bearing retainer seal using Tool J-2 1359 or J-22834-2 (Fig. 7B-19R). 8. Install bearing retainer assembly onto housing with one or two gaskets, depending on clearance. Torque bolts to 30 ft. lbs. 9. Install yoke, washer, and lock nut output shaft. 10.
Page 440 7B-60 OVERHAUL MANUAL Adapter Oil Pump Magnet Speedometer Drive Gear Input Drive Gear Pilot Brgs. Drive Chain Range Selector Sliding Clutch Brg. Retainer Ring Gasket Rear O u tp ut Rear Brg. Range Selector Housing Brg. Outer Ring Low Speed Gear Bushing Rear O u tp ut Shaft F ront O u tp u t F ront Brg.
Page 441 MANUAL TRANSMISSION 7B-61 INPUT GEAR FRONT OUTPUT SHAFT ASSY. CHAIN H OUSING RANGE SELECTOR COUNTER GEAR H O USIN G Fig. 7 B -5 S -R e m o v in g F ro n t O u tp u t S h a ft F ro n t B e a rin g Fig.
Page 442 7B-62 OVERHAUL MANUAL bearing retainer to transfer* case. Tap on front of shaft or carefully pry retainer away from case. Remove retainer from shaft and discard gasket. Recover any roller bearings which may fall from rear cover. NOTE: If necessary to replace rear bearing, support cover and press bearing from cover.
Page 443 MANUAL TRANSMISSION 7B-63 Slide drive sprocket on to clutch splines and install CASE, COVER A N D H O U SIN G S-T ransfer case, retaining ring. cover, and housings must be thoroughly cleaned in solution to remove all accum ulation of lubricant and dirt. Remove all Input Shaft Assembly (Fig.
Page 444 7B-64 OVERHAUL MANUAL Fig. 7 B -1 1 S -M o d e l 2 0 3 T ran sfer Case E xp lod ed V ie w...
Page 445 7B-65 MANUAL TRANSMISSION 48. T h ru st Washer 1. Adapter 49. L ub ricating T h ru st Washer 2. In p u t Gear Bearing Retainer 50. Retaining Ring 3. In p u t Gear Bearing R etainer Gasket 51.
Page 446: Input Gear Bearing Replacement
7B-66 OVERHAUL MANUAL Fig. 7 B -1 3 S -R e m o v in g In p u t S h a ft-to -B e a rin g S nap Ring Fig. 7B-1 5S--R em oving C lu s te r Gear S h a ft Removing Input Gear Assembly Assembly (Fig.
Page 447 MANUAL TRANSMISSION 7B-67 2. Using snap ring pliers, remove snap ring retaining bearing on shaft. Discard snap ring. 3. Using a screwdriver or other suitable tool, pry the bearing from case and remove it from the shaft. NOTE: Inspect input gear for defects such as burrs, scoring, heat discoloration, etc.
Page 448 7B-68 OVERHAUL MANUAL J—2 2 8 3 6 J—2 2 3 8 8 SEAL Fig. 7 B -2 0 S ~ ln s ta llin g F ro n t O u tp u t B e a rin g R etainer Seal Fig.
Page 449 MANUAL TRANSMISSION 7B-69 10. Install front output shaft bearing. 11. Install front output shaft bearing retainer, gasket and retaining bolts. 12. Install the front output shaft flange, gasket, seal, washer and retaining nut. Tap dust shield back in place after installing bolts in flange.
Page 450 » 7B-70 OVERHAUL MANUAL 20. Install shift levers on the range box shifter shaft, if 22. Fill transfer case to proper level with specified not left on linkage in vehicle. lubricant. 21. Torque all bolts, locknuts and plugs (except filler 23.
Page 451 7B-71 MANUAL TRANSMISSION ADAPTERS USED W ITH AUTO M ATIC TRAN SM ISSIO NS All Except Full Time 4-Wheel Drive Units Disassembly of Adapter (Fig. 7B-4T) 1. Using a brass drift or other suitable tool, tap sleeve through seals and out of adapter. 2.
Page 452: Specifications
7B-72 OVERHAUL MANUAL SPECIFICATIONS THREE SPEED SAGINAW (76mm) THREE SPEED TREMEC (77mm) Clutch Gear Retainer to Case B o lts ....15 ft. lbs. Clutch Gear Retainer to Case B o lts ....35 ft. lbs. Side Cover to Case B o lts ........15 ft.
Page 453 7B-73 MANUAL TRANSMISSION FOUR-SPEED (SAGINAW) 76mm Clutch Gear Retainer to Case B o lts .............................15 ft. lbs. Side Cover to Case Bolts ..............................15 ft. lbs. Extension to Case Bolts ............................... 45 ft. lbs. Shift Lever to Shifter Shaft B o lts ............................25 ft. lbs. Lubrication Filler P l u g ................................
Page 454 7B-74 OVERHAUL MANUAL SPECIAL TOOLS 1. J-1 1 2 6 Transm ission G uide Pins 7. J -1453-01 Speedom eter D rive Gear Press Plates and 2. J-8059 R etainer Snap Ring Pliers Press Plate H olde r J-358-1 3. J-22246/J-22379 Countergear Loading Tool 8.
Page 455 7B-75 MANUAL TRANSMISSION Countergear Rear Bearing Remover . J-22874-1 Bearing Installer . J-22832 Bearing Puller 9. J-22874-5 M ainshaft Support Tool . J 8433-1 Clutch Gear Bearing Remover and Installer . J-22874-2 Countershaft Support Tool 3. J-22872 Front Bearing Retainer Seal Installer Rear Bearing Retainer Seal Installer 4.
Page 456 7B-76 OVERHAUL MANUAL . J-23432-1 Snap Ring Picks. . J-23432 Snap Ring Pliers. 3. J 8092 Handle. 4. J 23429 Interm ediate Shaft Remover and Installer. 5. J-22836 Front O utput Shaft Bearing Retainer Seal Installer. . J 21359 Rear O utput Shaft Bearing Retainer Seal Installer. J 23431 Rear Output Shaft Housing Bearing Remover and Installer .
Page 457 1. J-22836 — F ront O u tp ut Shaft Bearing Retainer Seal Installer 2. J-22388 — Rear O u tp ut Shaft Seal Installer 3. J-21359 — In p ut gear Bearing Retainer Seal Installer 4. J-24745 — Cluster Gear Loading Tool 5.
Page 459 7C-1 CLUTCHES SECTION 7C CLUTCHES CONTENTS Single Plate Diaphragm Spring C lu tc h ..........7C-1 Single Plate Coil Spring C lu tch .............. 7C 4 Special T ools....................7C-7 SINGLE PLATE DIAPHRAGM CLUTCH NDEX D isassem bly..................7C-1 Inspection... ,.................7C-1 Assem bly...........
Page 460 7C-2 OVERHAUL MANUAL BENT FINGER Flywheel Pressure Plate Throwout Bearing Dowel-hole Diaphragm Spring Fork Pilot Bushing Cover Retracting Spring Driven Disc Fig. 7 C -2 A ~ B e n t F in g e r C lu tch C ro ss-S ectio n (T yp ica l) Check throw out bearing for roughness and free fit on 5.
Page 461 7C-3 CLUTCHES PILOT BEARING REPLACEMENT The clutch pilot bearing is an oil impregnated type bearing pressed into the crankshaft. This bearing requires attention when the clutch is removed from the vehicle, at which time it should be cleaned and inspected for excessive wear or damage and should be replaced if necessary.
Page 462 7C-4 OVERHAUL MANUAL SINGLE PLATE COIL SPRING CLUTCH INDEX D isassem bly........7C 4 Inspection.......... 7C-4 Assem bly........... 7C-5 Adjusting Levers......7C-6 DISASSEMBLY 1. Place the cover assembly on the bed of an arbor or drill press with a block under the pressure plate so arranged that the cover is left free to move down.
Page 463 7C-5 CLUTCHES EYEBOLT RELEASE LEVER STRUT Fig. 7 C -7 E --In s ta llin g Lever Fig. 7 C -5 E -R e m o v in g o r In s ta llin g Lever 9 SPRINGS 3 SPRINGS 5.
Page 464 7C-6 OVERHAUL MANUAL Fig. 7C-1 O E -A sse m b lin g C over and Pressure Plate Fig. 7 C -1 2 E --D epressing Lever 8. Lower the cover on top of the assembled parts, as in NOTE: On assemblies with three levers, the three flat Fig.
Page 465 7C-7 CLUTCHES SPECIAL TOOLS 1. J-6456-01 Height Gauge 2. J-1048 Gauge Plate 3. J-1522 Pilot Bearing Driver 4. J-23720 Clutch P ilot Tool 5. J-1448 P ilot Bearing Puller Fig. 7C-1 ST--C lutch S p e cia l T o o ls...

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Chevrolet Chevelle 1977 Repair Manual

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