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GMC 1989 Light Duty Truck Repair Manual

GMC 1989 Light Duty Truck Repair Manual

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Page 1 vr’V'-’ Light Duty Truck Unit Repair Manual...
Page 3 G M C T ru ck D ivision of G eneral M otors C orp. T his includes all text, illustrations, tables and charts. GMC TRUCK DIVISION TRUCK & BUS GROUP General Motors Corporation...
Page 4 CAUTION To reduce th e chan ce of personal injury a n d /o r p roperty dam age, the follo w in g instructions m ust be carefu lly o bserved. P roper service and rep air are im portant to th e s afety of th e service tech nician and th e safe, reliable op eratio n of all m otor veh icles.
Page 5 1989 TABLE OF CONTENTS SEC. SECTION NAME GENERAL INFORMATION AIR CONDITIONING UNIT REPAIR A6 Air Conditioning Compressor V5 Air Conditioning Compressor R-4 Air Conditioning Compressor HR -6 Air Conditioning Compressor S D -709 Air Conditioning Com pressor MANUAL STEERING 3B 2 Manual Steering G ear 3B 3 Power Steering...
Page 6 Mr. Goodwrench dealers selling Chevrolets, Pontiacs, Oldsmobiles, Buicks, you do the work yourself. Cadillacs, GMC and Chevy Trucks. That’s why Mr. Goodwrench wants to have a good stock of genuine GM Parts available. Everything from GM QUALITY...
Page 7: Table Of Contents
SECTION OA GENERAL INFORMATION CONTENTS SUBJECT PAGE Service Parts Identification L a b e l............................OA- 1 Vehicle Identification P la te ..............................OA- 1 Certification L a b e l..................................OA- 1 Engine Identification N u m b er..............................OA- 2 Model R e fe re n c e ..................................
Page 8: Engine Identification Number
8 Chevrolet Incomplete 0 Pontiac, Ml 5 Van C Chevrolet Truck 1 Oshawa, ON 6 Suburban D GMC Incomplete 2 Moraine, OH 7 Motor Home Chassis J GMC Bus' 3 Detroit, Ml K GMC MPV 8 Utility < Blazer / Jimmy)
Page 9: Fastener Strength Identification
GENERAL INFORMATION OA-3 L6 ENGINE 4. E n g in e I.D. (O p tio n a l L o ca tio n ) 5. E n g in e C ase Pad 6. E n g in e I.D. 1.
Page 10: Six Lobed Socket Head Fasteners
OA-4 GENERAL INFORMATION PREVAILING TORQUE FASTENERS A prevailing to rq ue nut is d esig n e d to d evelop an interference betw een the nut and bolt threads. This is most often accom plished by distortion of the top of an all-m etal nut by using a nylon patch on the th reads in the m iddle of the hex flat.
Page 11 GENERAL INFORMATION OA-5 Figure 8 — RV M odels...
Page 12 OA-6 GENERAL INFORMATION G VAN MODELS RALLY (SPO RTVAN ) VA N D U R A (C H E V Y VA N ) C U TA W AY VA N M A G N A V A N (HI-CUBE VA N ) P MODELS VA LU E VAN (STEP VA N ) M O TO R H O M E C H A S S IS...
Page 13 GENERAL INFORMATION OA-7 Figure 11— ST Models...
Page 14 OA-8 GENERAL INFORMATION Passenger Van Cargo Van 1. C u s to m a ry B o lt— 1/4-20 2. M e tric B o lt— M6.0x1 A. 1 /4-inch B. 6 m m C. 20 T hre a d s Per Inch D.
Page 15 GENERAL INFORMATION OA-9 A. M e tric Sizes 1. T op L o c k T ype 6. N ylon S trip O r P atch B. Inch Sizes 2. C e n te r L o c k 7. N ylo n W a s h e r In s e rt 3.
Page 16 CONVERSION TABLE to get equivalent to get equivalent num ber of: number of: Multiply M ultiply ACCELERATION LENGTH 0.304 8 m eter/sec2 (m /s2 ) 25.4 m illim eters (mm) Foot/sec2 Inch meters (m) Inch/sec2 0.025 4 m eter/sec2 0.304 8 Foot 0 .9 1 4 4 meters...
Page 17: Decimal And Metric Equivalents
GENERAL INFORMATION OA-11 DECIMAL AND METRIC EQUIVALENTS Fractions D ecim al In. M etric mm Fractions D ecim al In. M etric mm 33/64 13.09687 1/64 0.015625 0.39688 0.515625 17/32 1/32 0.79375 0.53125 13.49375 0.03125 35/64 3/64 1.19062 0.546875 13.89062 0.046875 1.58750 9/16...
Page 19: Air Conditioning
A-6 AIR CONDITIONING COMPRESSOR 1B1-1 SECTION 1 AIR CONDITIONING CONTENTS SUBJECT PAGE A-6 Air Conditioning C o m p re s s o r..............................1B1-1 V-5 Air Conditioning C o m p re s s o r..............................1B2-1 R-4 Air Conditioning C o m p re s s o r.............................. 1B3-1 HR-6 Air Conditioning C o m p resso r............................1B4-1 SD-709 Air Conditioning C om p res so r............................
Page 20 1B1-2 A-6 AIR CONDITIONING COMPRESSOR 1. N u t 2. C lu tc h 3. R ing 4. P u lle y B e aring R ing 5. B e aring 6. P ulley 7. C lu tc h C oil R ing 8.
Page 21: Air Conditioning C O M P Re S S O R
A-6 AIR CONDITIONING COMPRESSOR 1B 1 -3 MINOR REPAIR TO THE COMPRESSOR O perations to the clutch plate and hub, pulley and b e a r 9401-A Hub Drive Plate Rem over ing, and coil and housing are covered as “ M in o r” b e 2 5 0 3 0 Clutch Hub Holding Tool cause they m ay be perform ed w ithout purging the system.
Page 22 1B1-4 A-6 AIR CONDITIONING COMPRESSOR 36. Key 39. S h a ft F -01437 Figure 4— Aligning the Drive Plate Key Inspect • Allow the shaft key (36) to extend 4.5 mm (3/i6-in ch ) out of the bottom of the hub keyway •...
Page 23: Air Conditioning Compressor
A-6 AIR CONDITIONING COMPRESSOR 1B 1 -5 Figure 8— Removing the Pulley and Bearing Retainer Ring Install J 9395 over the end of the compressor • Place J 2 4 0 9 2 over J 9 3 9 5 for the m ulti-groove shaft (39) (figure 7).
Page 24: Clutch Coil And Housing Assembly Replacem Ent
1B1 -6 A-6 AIR CONDITIONING COMPRESSOR J 9481-A Pulley Bearing and Pulley Installer Im portant 1. B e a rin g (5) to th e p u lle y (6) w ith J 8 0 9 2 an d After applying Loctite D e p e n d , Loctite Trim J 9481-A (figure 10).
Page 25: Shaft Seal Replacement
A-6 AIR CONDITIONING COMPRESSOR 1B1-7 • P lace the clutch coil “ face d ow n” and apply • Align the coil locator projections on th e coil the ad h esive in a circular bead around the housing with the holes in the front head (16). three coil locator protrusions.
Page 26 1B1-8 A-6 AIR CONDITIONING COMPRESSOR J 9553 22974 13. Seal 15. Seal (O-ring) F-01581 Figure 14—Removing/Installing the Shaft Seal Seat and Seal J 2 4 3 4 0 R e tain e r Ring Pliers J 33011 Seal R em over 1.
Page 27: Pressure Relief Valve Replacement
A-6 AIR CONDITIONING COMPRESSOR 1B1-9 Dip th e seal (13) into cle an 5 2 5 viscosity • If the shaft has b een pushed b ack in th e refrigerant oil. axial plate (m e a s u re m e n t g re a te r th an 1.9 Install J 2 3 1 2 8 and th e seal (13) over the mm (0.0 7 5 -in c h ), d is as sem b le the co m ...
Page 28: Compressor Disassembly
1B1 -10 A-6 AIR CONDITIONING COMPRESSOR COMPRESSOR DISASSEMBLY 4 9. P la te 51. G e a r 5 2. S e a l R e a r H e a d 58. S c r e e F -01585 Figure 18—...
Page 29 A-6 AIR CONDITIONING COMPRESSOR 1B1 -11 J 21352-A P la te S c r e w d r iv e r F -01589 F igure 20— R em oving th e Rear S u ctio n Reed Plate Figure 22— R em oving the Rear S u ctio n Reed Plate Invert the co m p ressor and p lace the shaft end 11.
Page 30: Gaging Operation
1B 1-12 A-6 AIR CONDITIONING COMPRESSOR Figure 25— Identifying the Notch at the Front of the Piston GAGING OPERATION Install or C onnect (Figures 27 through 31) Tools R equired: J 9 3 9 6 C o m pressor H olding Fixture J 9 3 9 7 C om pressing Fixture J 9 4 3 2 N e e d le B earing Installer J 21352-A C o m p ressor Su pp o rt Block...
Page 31 A-6 AIR CONDITIONING COMPRESSOR 1B1-13 4 0 . R a c e 41. B e a rin g F -01595 Figure 27— Installing the Needle Bearing Figure 28— Installing the Rear Thrust Races and Bearing 1. N e ed le bearing (21) to the front cylinder (29) with J 9 4 3 2 (figure 27).
Page 32: Gaging Procedure
1B1-14 A-6 AIR CONDITIONING COMPRESSOR Figure 30— In sta lling the P iston d u rin g the G aging O peration GAGING PROCEDURE Im portant Tools R equired: • Do not install th e shoe discs (35) on the J 8001 Dial Indicator Set rear of th e piston (32).
Page 33 A-6 AIR CONDITIONING COMPRESSOR 1B1-15 SHOE DISC Identification Min. Feeler Part No. Gage Reading Ending In Stamp .0000 171/2 .0175 .0180 .0185 .0190 191 /2 .0195 .0200 201 /2 .0205 .0210 .0215 .0220 THRUST BEARING RACE Part No. Identification Dial Indicator Ending In Stamp Reading...
Page 34: Piston Ring Replacement
1B1 -16 A-6 AIR CONDITIONING COMPRESSOR I. F ro n t th ru s t give s th e p ro p e rc le a ra n c e . J. C h e c k in g fo r sh oe th ic k n e s s “...
Page 35 A-6 AIR CONDITIONING COMPRESSOR 1B1-17 32 . P is to n F -01624 Figure 38— Sizing the Piston Ring • P u s h J 2 4 6 0 8 - 5 ( i n s t a l le r ) d o w n o v e r J 2 4 6 0 8 -2 (guide).
Page 36: Compressor Assembly
1B1-18 A-6 AIR CONDITIONING COMPRESSOR N O T IC E : Do n o t p u s h th e p is to n a n d ring 5. Piston (32) to J 24608-1 (figure 39). • T h e piston (32) should pass through the ring assem bly into J 2 4 6 0 8 -6 w ith o u t p o s itio n in g and rotating b ecause the n e ed le bearings o f the g ag e with a two to eight pound force.
Page 37 A-6 AIR CONDITIONING COMPRESSOR 1B1-19 4 6 . P la te F-01628 Figure 42— Installing the Suction Crossover Figure 43— In sta llin g the D ischarge C ro ssove r Tube Tube Plate • Lubricate all the m oving parts with clean 52 5 viscosity refrigerant oil.
Page 38 1B1-20 A-6 AIR CONDITIONING COMPRESSOR Figure 45— Installing the Front Discharge Valve Figure 47— Installing the Front Head Seal Plate Im portant • Do not let the sealing a re a around the center bore of the head touch the shaft as the head is low ered.
Page 39 A-6 AIR CONDITIONING COMPRESSOR 1B1-21 F -01393 Figure 48— Installing the Compressor Shell 19. Seal (31) and bushing (30) to the rear of the dis charge cross-over tu be (26). 20. R ear suction reed (48) over the dowel pins (45). •...
Page 40: Leak Testing
1B1-22 A-6 AIR CONDITIONING COMPRESSOR • Lubricate the surface of the rear head (54) with 5 2 5 viscosity refrigerant oil. 26. R e ar head (54) to the shell (9) (figure 51). • Align th e tw o low er th re a d e d co m p re s s o r m ounting holes with the com pressor sump.
Page 41: Specifications
A-6 AIR CONDITIONING COMPRESSOR 1B 1 -23 14. Attach the com pressor to J 9 3 9 6 and clam p the fix • A pressure reading of less than 3 4 2 kPa (50 ture in a vise so that the com pressor can be m a n u psi) would indicate one or m ore suction an d /o r ally turned with a w rench.
Page 42: Special Tools
1B1-24 A-6 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 9 43 2 J 513 9 J 9 4 5 9 J 540 3 1 5 . J 545 3 J 9553-01 J 6 08 3 J 9564-01 J 6271-01 J 9 6 2 5 J 2 1 3 5 2 J 9392-01 21 .
Page 43 A-6 AIR CONDITIONING COMPRESSOR 1B1-25 J 2 4 0 9 2 J 2 6 9 3 4 J 2 4 0 9 5 J 2 9 5 4 7 J 2 5 0 3 0 J 2 5 4 9 8 J 2 9 8 8 4 J 2 9 8 8 6 J 2 65 4 9 -B...
Page 45 V5 AIR CONDITIONING COMPRESSOR 1B2-1 SECTION 1B2 V5 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE D es crip tio n .....................................1B2- 1 Theory of O p e ra tio n ................................1B2- 1 Minor Repair to the C o m p re s s o r..............................1B2- 2 Clutch Plate and Hub Assembly Replacem ent........................
Page 46: Minor Repair To The Compressor
1B2-2 V5 AIR CONDITIONING COMPRESSOR proper service. The com pressor connections and the out side of the compressor should be cleaned before any “ on vehicle” repairs, or before removal of the compressor.The parts must be kept clean at all tim es and any parts to be 1.
Page 47 V5 AIR CONDITIONING COMPRESSOR 1B2-3 H igh P ressure R e lie f Valve H igh S ide Low P ressure Valve H igh S ide C u t-O ff S w itc h C o n tro l Valve S h a ft N u t C lu tc h Plate and H ub A s s e m b ly...
Page 48: Pulley And Bearing Assembly Replacement
1B2-4 V5 AIR CONDITIONING COMPRESSOR check that the shaft key (23) is properly in place • Back off J 33013-B body enough to allow the in the keyway, then install the clutch plate and center screw to be threaded agianst the end of hub assembly (22) to its final position.
Page 49 V5 AIR CONDITIONING COMPRESSOR 1B2-5 J-3 3 0 1 3 -B J -3 4 9 9 2 22. C lu tc h Plate and H ub A s s e m b ly A. A ir G ap 0.38-0.64 m m (,015-,025-inch) B.
Page 50 1B2-6 V5 AIR CONDITIONING COMPRESSOR Figure 11 — Removing the Bearing from the Pulley Figure 12— Installing the Pulley Rotor Bearing Rotor Assembly 33023-A Puller Pilot 34992 Com pressor Holding Fixture 21352-A Support Block 1. Pulley (26) on 21352-A (figure 12). NOTICE: Do n o t su p p o rt the ro to r by restin g the p u lley rim on a flat su rface d urin g b earing in stal...
Page 51: Clutch Coil R E P La C E M E N T
V5 AIR CONDITIONING COMPRESSOR 1B2-7 B-06546 Figure 14— Bearing Stake Locations CLUTCH COIL ASSEMBLY REPLACEMENT Remove or Disconnect (Figures 3 and 16) Tools Required: J 8433 Puller Bar J 33023-A Puller Pilot J 33025 Clutch Coil Puller Legs Clutch plate and hub assem bly (22). assembly (27) remains in position (figure 18).
Page 52: High-Side Pressure And High-Side Low-Pressure Cutoff Switches Replacement
1B2-8 V5 AIR CONDITIONING COMPRESSOR HIGH-SIDE PRESSURE AND HIGH-SIDE LOW-PRESSURE CUTOFF SWITCHES REPLACEMENT 4 - + Remove or Disconnect (Figures 1 and 3) Tool Required: J 5403 Snap Ring Pliers 1. Retainers (45) from switches (3) and (4). 2. Switches (3) and (4). 3.
Page 53: Control Valve Replacement
V5 AIR CONDITIONING COMPRESSOR 1B2-9 CONTROL VALVE REPLACEMENT 4 -+ Remove or Disconnect (Figures 1 and 3) Tools Required: J 5403 Snap Ring Pliers 1. Retainer ring with J 5403. 2. O-ring seal (44). 3. Valve (5). Install or Connect (Figures 1 and 3) Tools Required: J 5403 Snap Ring Pliers 1.
Page 54 1B2-10 V5 AIR CONDITIONING COMPRESSOR A. Seal R e ta in e r Ring J 540 3 J 349 9 2 F-06457 Figure 21— Removing or Installing the Shaft Seal Retainer • Dip the new O-ring seal in clean 525 viscosity refriger ant oil.
Page 55 V5 AIR CONDITIONING COMPRESSOR 1B 2 -1 1 A. O pening to Rear S uction Port (12 O ’C lock Position A sse m bly R eference) B. T hrough Bolt Hole (6) C. Suction P ressure (O utside C avity) D.
Page 56 1B2-12 V5 AIR CONDITIONING COMPRESSOR 7. Bearing (35) and thrust washers (36) in the same 2. Gasket (42) (figure 27). order as removed. • Place the elongated hole in the gasket over the 8. Shim (34). rod at the upper left position. 9.
Page 57 V5 AIR CONDITIONING COMPRESSOR 1B 2-13 SPECIFICATIONS Type — Harrison D A -V 5 ..............................Cylinder Axial D is p la c e m e n t.....................................9.2C u. In. R otation......................................Clockwise 525 Viscosity Com pressor Oil (Full C h a rg e )........................227 g (8 oz.) TORQUE SPECIFICATIONS Compressor Suction and Discharge C onnector B o lt..................34 N m (25 ft.
Page 58 1B2-14 V5 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 5 4 0 3 J 3 30 2 2 J 2 3 1 2 8 -A J 3 3 0 2 3 -A J 6 0 8 3 J 2 1 3 5 2 -A J 2 9 8 8 6 J 33011 J 3 30 2 4...
Page 59: General Description
R-4 AIR CONDITIONING COMPRESSOR 1B3-1 SECTION 1B3 R-4 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE R-4 Air Conditioning C o m p re s s o r............................1B3- 1 General D e s c rip tio n ................................1B3- 1 Id entificatio n ....................................1B3- 2 Disassembly of The Drive Com ponents..........................
Page 60: Air Conditioning C O M P Re S S O R
1B3-2 R-4 AIR CONDITIONING COMPRESSOR Figure 2— R-4 Compressor, Poly-Groove Pulley Figure 1— R-4 Compressor, V-Groove Pulley Type with 4 Pole Clutch and Driver Shown Type with Pole Clutch and Driver Shown 30 ml (1 oz.) is drained from the compressor, add the same amount of new 525 viscosity oil to the overhauled assem...
Page 61: Pole Clutch Rotor And/Or Bearing
R-4 AIR CONDITIONING COMPRESSOR 1B3-3 J 25031 Rotor and Bearing Remover 4. File away the old staked metal to provide a clearance J 29886 Driver Handle for the new bearing. 1. Snap Ring with J 6038 (figure 8). • Mark the location of the clutch coil term inals. 6 POLE CLUTCH ROTOR AND/OR BEARING Important...
Page 62: Clutch Coil And/Or Pulley Rim
1B3-4 R-4 AIR CONDITIONING COMPRESSOR 5. The bearing from the hub using J 9398-A and J 29886 (figure 13). 6. The staking metal. CLUTCH COIL AND/OR PULLEY RIM V-GROOVE DRIVE Remove or Disconnect 1. Pulley rim m ounting screws and washers. 2.
Page 63 R-4 AIR CONDITIONING COMPRESSOR 1B3-5 Figure 10— Removing the Clutch Rotor Assembly Figure 12— Pulley Rotor and Bearing Puller Installation SHAFT SEAL Remove or Disconnect (Figures 15 and 16) Tools required: J 5403 Snap Ring Pliers J 9553-01 O-ring Remover J 23128-A Seal Remover Retainer ring using J 5403.
Page 64: Disassembly Of The Compressor
1B3-6 R-4 AIR CONDITIONING COMPRESSOR Figure 14— Removing the Poly-Groove Clutch Coil DISASSEMBLY OF THE COMPRESSOR PRESSURE RELIEF VALVE Remove or Disconnect (Figure 1 7 ,1 8 and 19) Remove or Disconnect (Figure 4) Tool Required: J 24896 Bearing Remover 1.
Page 65: Discharge Valve Plate
R-4 AIR CONDITIONING COMPRESSOR 1B3-7 J 2 3 1 2 8 -A 12. Seal F-01461 Figure 15— Removing the Shaft Seal with J 23128-A Figure 18— Removing the Front Head Assembly 2. Compressor shell. DISCHARGE VALVE PLATE • Alternately tighten each screw 1/4 turn. Use care not to cock the shell, as normal removal *--►...
Page 66 1B3-8 R-4 AIR CONDITIONING COMPRESSOR J 2 4 8 9 6 Z Z F-06142 Figure 19— Removing the Bearing from the Front Head 31. Valve Plate 33. P isto n and Reed A s s e m b ly F-01793 Figure 23—...
Page 67: Cleaning And Inspection
R-4 AIR CONDITIONING COMPRESSOR 1B3-9 CLEANING AND INSPECTION CLEANING INSPECTION Clean Inspect The frictional surfaces of the clutch plate and the Front head for cracks or damage. clutch rotor. Com pressor shell for cracks or burrs. Shaft seal area thoroughly. Staked areas for burrs.
Page 68: High Side High Pressure Cutoff Switch
1B3-10 R-4 AIR CONDITIONING COMPRESSOR 8. O-ring into the groove of the front head (figure 18). 9. Front head aligning the marks made at disassembly. Figure 26— Replacing the Thrust and Belleville 10. Front head mounting screws (figure 17). Washers 3.
Page 69: Pole Clutch And/Or Bearing
R-4 AIR CONDITIONING COMPRESSOR 1B 3 -1 1 26271 -A F-06144 Figure 29— Installing the Rotor and Bearing Assembly — Poly-Groove Type • Make sure the protrusions on the rear of the coil align with the front head locator holes. 5.
Page 70: Pole Clutch Rotor And/Or Bearing-V-Groove
1B3-12 R-4 AIR CONDITIONING COMPRESSOR 4 POLE CLUTCH ROTOR AND/OR J 21352-A Support Block J 25008-A Holding Fixture BEARING-V-GROOVE J 29886 Driver Handle J 33019 Bearing Staking Tool -►4- Install or Connect (Figures 28 and 34) Pulley rotor on J 21352-A (Figure 30). Tools Required: NOTICE: Do n o t su p p o rt the ro to r by resting the J 6083 Snap Ring Pliers...
Page 71: Clutch Drive Hub
R-4 AIR CONDITIONING COMPRESSOR 1B3-13 C lu tc h Drive H ub R o to r B-08998 Figure 34— Installing the Shaft Key 6. Pulley rim m ounting screws and washers. Do not tighten. A i r G a p (.020 -.0 4 0 - i n c h ) •...
Page 72: Leak Testing
1B3-14 R-4 AIR CONDITIONING COMPRESSOR LEAK TESTING 12. Connect the charging station high pressure line or a Tools Required: high pressure gage and J 5420 to J 9625-A high side J 9625-A Pressure Test Set connector. J 5420 Straight Fitting J 25008-A Holding Fixture 13.
Page 73: Specifications
R-4 AIR CONDITIONING COMPRESSOR 1B3-15 SPECIFICATIONS Type C o m pre ssor............................Harrison Radial 4 Cylinder Part N u m b e rs ....................................1131593 ....................................1131610 ....................................1131611 ....................................1131616 ....................................1131623 ....................................3090927 ....................................3091278 D isplace m en t..................................10 cubic inches R otation......................................Clockwise Clutch Plate to Rotor G a p ..........................
Page 74 1B3-16 R-4 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 9 3 9 9 J 4 2 4 5 J 5 4 0 3 J 9 4 8 0 -B J 5 4 2 0 J 9 4 8 1 - A J 6 0 8 3 J 9 5 5 3 -0 1 J 9 6 2 5 -A...
Page 75 R-4 AIR CONDITIONING COMPRESSOR 1B3-17 J 2 4 8 9 6 J 3 3 0 1 9 §ei 1 8. J 2 5 0 0 8 -A 2 4 . J 3 3 0 2 0 J 2 5 0 3 1 2 5.
Page 76 1B3-18 R-4 AIR CONDITIONING COMPRESSOR N —...
Page 77 HR-6 AIR CONDITIONING COMPRESSOR 1B4-1 SECTION 1B4 HR-6 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE D es crip tio n ..................................... Minor Repair to the C o m p re s s o r..............................1B4- 2 Clutch Plate and Hub Assembly Replacem ent........................1B4- 2 Pulley and Bearing Assembly R e p la c e m e n t........................
Page 78: Minor Repair To The Compressor
1B4-2 HR-6 AIR CONDITIONING COMPRESSOR 19 m m M o u n tin g F la n g e Ear D isc h a rg e C avity Figure 1 — HR Compressor, V-Groove Pulley S u c tio n R e lie f B-06542 Figure 2 —...
Page 79 HR-6 AIR CONDITIONING COMPRESSOR 1B4-3 Shaft Nut C lutch Plate and H ub A ssem bly Puiley B earing R etainer Pulley Bearing Pulley C lutch Coil A sse m bly Through Bolts (6) Shaft Seal R etainer Ring S haft Lip Seal O-Ring Seal Front Head Head G asket...
Page 80 — 1B 4 -4 HR-6 AIR CONDITIONING COMPRESSOR 2. C lu tc h Plate and H ub A s s e m b ly 5. P ulley (R otor) 21. Key 35. Keyw ay (Shaft) F-04459 Figure 7 — Positioning the Shaft Key, Clutch Plate, and Hub Assembly Figure 8 —...
Page 81: Pulley And Bearing Assembly Replacement
HR-6 AIR CONDITIONING COMPRESSOR 1B4-5 PULLEY AND BEARING J 33023-A Puller Pilot J 8433-1 Puller Bar ASSEMBLY REPLACEMENT J 33026 Com pressor Holding Fixture J 6083 Snap Ring Pliers Remove or Disconnect (Figures 4 ,9 ,1 0 ,1 1 and 12) 1.
Page 82 1B4-6 HR-6 AIR CONDITIONING COMPRESSOR A. S ta k in g Pin B. R u b b e r Band B-06544 Figure 14 — Staking the Pulley Bearing in the Rotor Bore A. S take Three (3) L o c a tio n s 120°...
Page 83: Clutch Coil And Housing Assembly Replacement
HR-6 AIR CONDITIONING COMPRESSOR 1B4-7 Figure 16 — Installing the Pulley Bearing Assembly — The thread of the through bolts should Inspect engage the full thickness of J 33026. • Tighten the center screw in J 8433-1 to force the Clutch coil assembly (6).
Page 84: Major Repair To The Compressor
1B4-8 HR-6 AIR CONDITIONING COMPRESSOR J -3 3 0 2 6 6. C lu tc h C oil A s s e m b ly A. D rift P unch 3 m m (1 /s inch ) B. S take in F ro n t H ead (3 Places) F-04523 Figure 19 —...
Page 85: Shaft Seal Replacement
HR-6 AIR CONDITIONING COMPRESSOR 1B4-9 Figure 21 — Compressor Shaft Seal SHAFT SEAL REPLACEMENT Remove or Disconnect (Figures 4, 22, 23 and 24) Figure 22 — Removing or Installing the Shaft Lip Seal Retaining Ring Tools Required: J 5403 Snap Ring Pliers J 34614 Shaft Seal Protector J 23128-A Seal Remover and Installer •...
Page 86 1B4-10 HR-6 AIR CONDITIONING COMPRESSOR 9. O ne-Piece Seal A. J 23128-A Seal R em over and Installer B. J 34614 S haft Seal P rotector F-06507 Figure 23 — Removing or Installing the Shaft Tip Seal Figure 25 — Installing the Seal Seat O-Ring Figure 24 —...
Page 87: Compressor Disassembly- Internal Cylinder And S H A Ft
HR-6 AIR CONDITIONING COMPRESSOR 1B 4 -1 1 Figure 26 — HR Compressor Rear Head Detail COMPRESSOR D IS A S S E M B LY - INTERNAL CYLINDER AND SHAFT Remove or Disconnect (Figures 4, 27, 28, 29 and Mark the front head (11) alignm ent with cylinders (16) (23) and rear head (28) alignment.
Page 88: Compressor Assem Bly- Internal Cylinder And S H A F T
1B4-12 HR-6 AIR CONDITIONING COMPRESSOR 14. Cylinder seal (15). 15. Suction reed plate (14). 16. Valve plate (13). 17. Head gasket (12). 18. Front head (11). |nrj| Clean All parts. Inspect All parts and replace as necessary. COMPRESSOR A S S E M B L Y - 2 1 3 5 2 -A INTERNAL CYLINDER AND SHAFT...
Page 89 HR-6 AIR CONDITIONING COMPRESSOR 1B4-13 A. S u c tio n C ro sso ve r O p e n in g s B. T h ro u g h B o lt H ole (6) C. S u c tio n Port (3) in Valve Plate D.
Page 90 1B4-14 HR-6 AIR CONDITIONING COMPRESSOR 52-A A. 12 o’c lo c k R eference P o s itio n A. 12 o’c lo c k R e fe re n ce P o s itio n B. S u c tio n C ro sso ve r O p e n in g s B.
Page 91: Leak Testing
HR-6 AIR CONDITIONING COMPRESSOR 1B4-15 • Leak test the compressor. • Refer to “ Leak T esting.” 14. Clutch coil assembly (6). 15. Pulley (5). 16. Clutch plate and hub assem bly (2). Figure 39 — installing the Compressor to J 33026 LEAK TESTING Tools Required: •...
Page 92: Specifications
1B4-16 HR-6 AIR CONDITIONING COMPRESSOR indicate one or more suction and/or discharge valves suction port adapter if the compressor is positioned leaking, an internal leak, or an inoperative valve. Dis with the suction port downward. assemble the compressor and repair as necessary. •...
Page 93: Special Tools
HR-6 AIR CONDITIONING COMPRESSOR 1B4-17 J 5403 J21352-A J 33020 J 23128-A J 33022 J 6 ° 8 3 J 33023-A J 8092 J 33024 J 23500-01 J 33025 J 8433-1 J 8433-3 J 8389 J 33011 J 9398-A J 33013-B J 9481-A J 33016 J 34614...
Page 94 1B4-18 HR-6 AIR CONDITIONING COMPRESSOR 15. Pulley and B earing A sse m bly Installer 1. Snap Ring Pliers 16. Hub and D rive Plate R em over and Installer 2. Snap Ring Pliers 17. C ylin de r A lign m en t Rods 3.
Page 95: Compressor Replacement
SD-709 AIR CONDITIONING COMPRESSOR 1B5-1 SECTION 1B5 SD-709 AIR CONDITIONING COMPRESSOR CONTENTS SUBJECT PAGE D e s c rip tio n ....................................1B5-1 In s p e c tio n .....................................1B5-1 Compressor R e p la c e m e n t............................... 1B5-1 Disassembly of the Clutch and Shaft S e a l..........................1B5-1 Assembly of the Clutch and Shaft S e a l ..........................
Page 96 1B5-2 SD-709 AIR CONDITIONING COMPRESSOR Figure 1 — Date Code Figure 3— Removing the Nut 14. Seal S nap Ring Seal C age 15. C ylin d e r Head 22. Shaft O -R ing Seal Coil Lead W ire S crew C lutch Plate and 16.
Page 97 SD-709 AIR CONDITIONING COMPRESSOR 1B5-3 Figure 7 — Removing the Rotor Pulley 1. Hex nut using a 19 mm socket. 3. Shaft key (27) by lightly tapping it loose with a slot screw driver and hammer (figure 5). 2. Clutch front plate using J 36045 (figure 4). •...
Page 98 1B5-4 SD-709 AIR CONDITIONING COMPRESSOR Figure 9— Removing the Coil Snap Ring ASSEMBLY OF THE • Turn the puller center bolt to the right with a socket wrench until the rotor pulley is free (fig CLUTCH AND ure 7). SHAFT SEAL 6.
Page 99 SD-709 AIR CONDITIONING COMPRESSOR 1B5-5 Figure 10— Removing the Felt Ring Metal Retainer J 29886 Driver Handle J 37796 Shaft Protector J 37791 Clutch Front Plate Spanner 1. Field coil and snap ring retainer. • The coil flange protrusion must match the hole in the front housing to prevent coil movement and to correctly place the lead wire.
Page 100 1B5-6 SD-709 AIR CONDITIONING COMPRESSOR Tighten • Nut the 36 N-m (27 ft. lbs.). • Check the air gap with a feeler gauge. It should be 0.49 to 0.79 mm (0.016 to 0.031 inch), if the gap is not consistent all around, pry up slightly at points of minimum variation.
Page 101 SD-709 AIR CONDITIONING COMPRESSOR 1B5-7 4. Clean refrigerant oil to the top of the valve plate. 5. Clyinder head (15) and cap screws (11). Tighten • Screws to 32 N-m (24 ft. lbs.) using the star configuration as shown in figure 17. Figure 17—...
Page 102: Special Tools
1B5-8 SD-709 AIR CONDITIONING COMPRESSOR SPECIAL TOOLS J 3 7 7 9 2 J 8 4 3 3 J 9 5 5 3 01 J 3 7 7 9 3 J 3 7 7 9 4 J 2 9 6 4 0 J 2 9 8 8 6 J 3 7 7 9 5 J 3 6 0 4 5...
Page 103 MANUAL STEERING GEAR 3B2-1 SECTION 3B2 MANUAL STEERING GEAR NOTICE: These fasteners are im p o rtan t attaching parts in that they c o u ld a ffe c t the p e rfo rm an ce o f vital c o m p o nents an d systems, a n d /o r c o u ld resu lt in m ajor re p a ir expense.
Page 104 USED ON SOME MODELS 1 - N U T , W O R M B R G . A D J U S T E R L O C K - B U S H I N G O R N E E D L E B R G . P I T M A N S H A F T 2 - A D J U S T E R , W O R M T H R U S T B R G .
Page 105 MANUAL STEERING GEAR 3B2-3 1. R EM O VE A N D IN STA LL W O R M SH A FT SEA L GEAR A SS EM B LE D REMOVE INSTALL Wrap 0.1 mm to 0.2 mm 1. Install parts as shown. (.005"...
Page 106 3B2-4 MANUAL STEERING GEAR IN S TA LL R E M O V E A S SE M B LE D IS A S S E M B LE L o o s e n lo c k nut U s e p u n c h Install parts as s h o w n Pry low er bearing retainer Press cup into adjuster...
Page 107 MANUAL STEERING GEAR 3B2-5 A D JU S T W O R M B E A R IN G PR E LO A D A D JU S T “OVER C E N T E R ” P R E LO A D T i g h te n w o r m b e a rin g ad juster until it b o t t o m s then l o o s e n o n e - q u a r t e r turn B a c k...
Page 108 3B2-6 MANUAL STEERING GEAR 1. W orm B earing A d ju s te r L o c k n u t 2. W orm B earing A d ju s te r 3. L ow er W orm B e aring C up L ow er W orm B earing Low er B earing R e ta in e r Ball N ut...
Page 109 MANUAL STEERING GEAR 3B2-7 1. R E M O V E A N D IN STA LL W O R M S H A FT SEA L G EA R A S S E M B L E D REMOVE INSTALL 1.
Page 110 3B2-8 MANUAL STEERING GEAR 4. DISASSEMBLE AND ASSEMBLE WORM 3. REMOVE AND INSTALL WORMSHAFT AND BALL NUT BEARING ADJUSTER REMOVE INSTALL DISASSEMBLE ASSEMBLE Pry lower bearing retainer 1. Loosen lock nut. Use punch 1. Install parts as shown. Press cup into adjust against edge of slot.
Page 111 MANUAL STEERING GEAR 3B2-9 . R EM O VE A N D IN S T A L L PITM A N S H A FT 7. A D JU S T W O R M B E A R IN G PR E LO A D S E A LS A N D B EA R IN G 1.
Page 112 3B2-10 MANUAL STEERING GEAR SPECIFICATIONS ADJUSTMENT ADJUSTMENT TORQUE TO TURN WORM SHAFT Worm B e a rin g ............................0.6-1.0 N m 5-8 In. Lbs. Over Center P reload..........................0.5-1.2 N m 4-10 In. Lb.s In excess of Worm Bearing Preload Total Steering Gear P re lo a d ........................
Page 113 MANUAL STEERING GEAR 3B2-11 SPECIAL TOOLS J 29369-1 1. W orm B earing A d ju s te r C up P u lle r (Use w ith J-2619-01) J 627 8 2. P itm a n S h a ft B e aring R em over 3.
Page 115: Power Steering
POWER STEERING 3B3-1 SECTION 3B3 POWER STEERING The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the term inology “ NOTICE: Refer to Notice on page 3B3-1 of this Section.” N O TIC E: A ll steering fasteners are im p o rta n t a ttac h in g p a rt in that it c o u ld a ffe c t the p erfo rm an ce o f vital co m p o n en ts an d systems, a n d /o r c o u ld res u lt in m ajo r re p a ir exp ense.
Page 116: Description
3B3-2 POWER STEERING DESCRIPTION with the sector, which is part of the pitman shaft. Turning The hydraulic power steering system consists of a pump, the worm shaft turns the pitm an shaft, w hich turns the an oil reservoir, a steering gear, a pressure hose, and a wheels through the steering linkage.
Page 117 POWER STEERING 3B3-3 203. N ut 204. S p rin g W a sh er 205. R e ta in in g R ing W a sh er 208. Seal 209. B earing 210. Screw C lam p 212. Ball G u ide 213.
Page 118 3B3-4 POWER STEERING A. H a m m e r B. P unch 220. R e ta in in g R ing F-01805 Figure 5— Removing the Pitman Shaft Bearing Figure 2— Unseating the Retaining Ring A. S c re w d riv e r B.
Page 119: Cleaning And Inspection
POWER STEERING 3B3-5 • Seal (239) and needle bea rin g (241). Use J 8524-1 and J 7079-2 (figure 14. Valve (250) and w orm shaft (248) as an assembly, with both races (246) and bearing (247). • W ormshaft (248) from valve assembly (figure 9). •...
Page 120: Assembly
3B3-6 POWER STEERING 4. Valve and stub shaft. — Sealing and bearing surfaces of the pitman — Seals (231) and rings (232). shaft ( ) for roughness, nicks, or other dam — Shaft pin for wear or cracks. If excessively worn age.
Page 121 POWER STEERING 3B3-7 A. J-7079-2 B. J-8524-1 C. B e aring w ith Id e n tific a tio n Tow ards Tool D. W ood B lo ck 240. A d ju s te r Plug 251. S tu b S h a ft B-06503 B-06531 Figure 14—...
Page 122 3B3-8 POWER STEERING A. Torque W re nch 2 2 2 B. 12 P o in t S o c k e t 227. N ut 222. A d ju s tin g S cre w 251. S tu b S h a ft Jhsa B ----------------- F-04929...
Page 123: Saginaw Integral Power Steering Gear-Ck (Gmt 4 0 0 )
POWER STEERING 3B3-9 3. Check the com bined ball and bearing preload by turning the torque wrench through the center of travel. Note the highest reading. 4. Tighten the a djustin g screw (222) until the torque wrench reads 0.6-1.2 N m (6-10 in. lbs.) higher than the reading noted in step “...
Page 124 Key No. Part Name K ay No. P art Nam e K a y N o. P art Nam e 19 _ SCREW A S M , LOCKWASHER 4 (2) PLUG , AD JU S TER — 1 — H O U S IN G . STEE R IN G G EAR PLUG, RACK PISTON —...
Page 125 POWER STEERING 3B3-11 1. REMOVE AND INSTALL PITMAN SHAFT AND SIDE COVER REMOVE INSTALL 1. If pitm an sha ft and If rem oved, install side cover are to be gasket seal by separated, rem ove b e nding tabs around preload ad ju ste r nut cover edges.
Page 126 3B3-12 POWER STEERING REMOVE AND INSTALL ADJUSTER PLUG 6. REMOVE AND INSTALL BEARING, WORM, ASSEMBLY AND VALVE ASSEMBLY INSTALL REMOVE REMOVE INSTALL 1. L o o s e n lo c k nut. 1. Install p arts 1. G ra sp stu b sh aft and 1.
Page 127 POWER STEERING 3B3-13 DISASSEMBLE AND ASSEMBLE RACK 9. REMOVE AND INSTALL PITMAN SHAFT PISTON SEALS AND BEARING REMOVE INSTALL DIS A SS E M B LE ASSEMBLE 1 Coat seal lip and washer face 1. Clean end of housing 1. D is a s s e m b le p a rts A s s e m b le p arts thoroughly to prevent dirt with anhydrous calcium grease.
Page 128 3B3-14 POWER STEERING 12. PITM AN SHAFT “OVER-CENTER 10. REM OVE AND IN STA LL C H EC K SECTOR ADJU STM EN T VALVE R EM O V E IN STA LL 1. R e m o v e p a rts a s s h o w n . 1.
Page 129 POWER STEERING 3B3-15 Used On S om e M o d e ls H o u sin g Sleeve D ow el Pin O -R ing Seal P ressure Plate S p rin g O -R ing Seal P ressure Plate D ow el Pin Vane R otor...
Page 130 3B3-16 POWER STEERING F. Press G. S u p p o rt R ing 17. D rive S h a ft 18. B earing F-01880 Figure 33— Remove and Install Driveshaft Bearing Figure 31— Removing the Fitting, Control Valve, Spring and Seal Figure 34—...
Page 131: Cleaning And Inspection
POWER STEERING 3B3-17 — Rotor slots for burrs and excessive wear at the thrust faces. — Inner surface of the pump ring ( ) for scoring or wear. — Thrust plate (13) and pressure plate (7) for wear on the plate surfaces. —...
Page 132 3B3-18 POWER STEERING 18. Flow control spring (20). with the bolt holes in the housing and that the 19. Flow control valve (21). thrust plate engages the pump ring dowel pins. 20. O-ring seal (22). 14. Retaining ring (14). 21. O-ring (25). •...
Page 133: Saginaw Power Steering Pump Model P
POWER STEERING 3B3-19 Figure 43— Installing the Rotor Figure 45— Installing the Retaining Ring --------- N. H o u s in g A lig n m e n t In d e n ta tio n s P . Id e n tific a tio n M arks on P um p R ing .
Page 134: Assembly
3B3-20 POWER STEERING 50. D rive S h a ft 51. Seal 52. O -R in g Seal 53. H o u s in g O -R ing Seal T h ru s t Plate F ille r C ap F lo w C o n tro l Valve F lo w C o n tro l S p rin g O -R in g Seal...
Page 135: Specifications
POWER STEERING 3B3-21 SPECIFICATIONS FASTENER TORQUE Integral Power Steering Gear Pitman Shaft Over Center P re lo a d .......................0.6-1.2 N-m ( 0 in. lbs.) Pitman Shaft Preload Adjuster Screw Jam N u t ....................27 N-m (20 in. lbs.) Side Cover B olts................................60 N-m (40 ft. lbs.) Pitman Shaft N u t ..............................
Page 136: Special Tools
3B3-22 POWER STEERING SPECIAL TOOLS J 4245 J 6278 J 6217 J 29107 J 21552 J 6219 J 7576, J 8947 J 8524-1 J 8092 J 22407 S r= J 7624 J 7728 J 7079-2 . P itm a n S h a ft B earing P u lle r .
Page 137: Rear Axle
AND 7 /8-INCH RING GEAR AXLES 4B1-1 SECTION 4B REAR AXLE CONTENTS SUBJECT PAGE 7 1/ 2 and 7 /a-inch Ring Gear A xle s ...........................4B1-1 -inch Ring Gear A x le ..............................4B2-1 -inch Ring Gear A x le ..............................4B3-1 1 0 1 4 - 1 -inch Ring Gear A x le ..............................
Page 138: 1 / 2 -Inch Ring Gear A X Le
4B1-2 71 fe AND -INCH RING GEAR AXLES • Mark the races and the shims as left and right, CHECKING THE AXLE and place them with the bearing caps. BEFORE DISASSEMBLY 11. D iffe re n tia l side b e a rin g s using J 8107-2 and J 22888 (figure 3).
Page 139 71 / 2 AND 7 /8-INCH RING GEAR AXLES 4B1-3 Brake D rum S him A x le S h a ft P in io n and R ing G ear Set “ C ” L ock S h im W h e el S tud D iffe re n tia l S ide B earing B a c k in g Plate B o lt...
Page 140: And 7 5 /S-Inch Ring Gear Axles
4B1-4 71 fe AND 7 /s-INCH RING GEAR AXLES F igure 5— P inion C ollapsable Spacer AXLE HOUSING In s p e c t • The carrier bore for nicks or burrs that would prevent the outer diameter of the pinion seal from sealing.
Page 141: Assembly Of The Rear Axle
AND 7 /8-INCH RING GEAR AXLES 4B1-5 PINION AND RING GEAR Inspect Pinion and ring gear teeth for cracking, chipping, scoring, or excessive wear. Pinion splines for wear. Pinion flange splines for wear. The fit of the pinion on the pinion flange. The sealing surface of the pinion flange for nicks, burrs, or rough tool marks which would cause damage to the seals’...
Page 142 4B1-6 71/z AND 7 /s-INCH RING GEAR AXLES DIFFERENTIAL CASE ASSEMBLY T ighten ■H- Install or C onnect (Figure 1) • Stud nut to 2.2 N m (20 in. lbs.). . R otate th e gage p la te and b e a rin g s several Tools Required: complete revolutions to seat the bearings.
Page 143 71/2 AND 7 /8-INCH RING GEAR AXLES 4B1-7 Figure 10— Checking Pinion Depth • Production shims are cast iron and are not to be 1. Place the case with the bearing cups installed into reused. Measure the production shims and spacers the axle housing (figure one at a time, and add the measurements together •...
Page 144 71 fe AND /s-INCH RING GEAR AXLES 4.32 M M (0.170-IN C H ) SERVICE SPACER Total Thickness of Total Thickness of Both Prod. Shims Service Shims To Be Used As A Starting Point Removed 1.52 mm (0.060-inch) 10.57 mm (0 420-inch) 1.78 mm (0.070-inch) 10.92 mm (0.430-inch) 2.03 mm (0.080-inch)
Page 145 7’ fe AND 7 /s-INCH RING GEAR AXLES 4B1-9 Figure 17— Installing the Differential Bearing Preload Shim Preload should be at or below 2.7 to 3.6 N m (24 to 32 in. lbs.) on new bearings, or 1.0 to 1.4 .
Page 146: Gear Tooth Pattern Check
7 1/2 4B1-10 AND 7 /s-INCH RING GEAR AXLES distance will move the pinion closer to the centerline of the ring gear. Increasing the distance will move the pinion farther away from the centerline of the ring gear. Backlash is adjusted by means of the side bearing adjusting shims which move the entire case and ring gear assembly closer to, or farther from, the drive pinion.
Page 147: Specifications
71 / 2 AND 7 /s-INCH RING GEAR AXLES 4B 1 -1 L O W F L A N K C O N T A C T D E C R E A S E P IN IO N S H IM •...
Page 148: Special Tools
1-12 AND 7 /s-INCH RING GEAR AXLES SPECIAL TOOLS J -7 8 1 7 J-23911 J-2 5 2 9 9 J-7 8 1 8 J-8 1 07 -2 J-2 5 3 2 0 J -8 0 9 2 J-8614-01 J-8001 J-2 2 8 8 8 ------- fc J -5 5 9 0...
Page 149 -INCH RING GEAR 4B2-1 SECTION 4B2 8 V 2 -INCH RING GEAR CONTENTS S U B J E C T P A G E D escription....................................4B 2- 1 Checking the Axle Before Disassembly........................... 4B 2- 1 Disassembly of the Rear A xle ............................. 4B 2- 1 C le a n in g ....................................
Page 150 4B2-2 -INCH RING GEAR . P in io n G ear . A x le H o u s in g . S ide G ear . A ir V e n t 3. Plug 23. R ing G ear B o lt 24.
Page 151 -INCH RING GEAR 4B2-3 • Refer to “ Checking the Axle Before Disassembly” in Inspect this section. • Drive pinion bearing preload (figure 4). 4. Pinion shaft lock screw (15). • For looseness of pinion assembly by moving it 5. Pinion shaft (17). back and forth.
Page 152 4B2-4 1 / 2-INCH RING GEAR Figure 5— Removing the Drive Pinion Nut 20. Bearing cups (5) and (39) from the axle housing CLEANING using a hammer and a punch. • Work the cups out of the housing evenly, Do not steam clean drive parts having ground and moving the punch back and forth between one polished surfaces such as gears, bearings, and shafts.
Page 153 81/2-INCH RING GEAR 4B2-5 • The fit of the side gears on the axle shafts. • Differential case for cracks and scoring. • Replace all worn parts. PINION AND RING GEAR Inspect • Pinion and ring gear teeth for cracking, chipping, scoring, or excessive wear.
Page 154 4B2-6 1 / 2-INCH RING GEAR 14. At the point of greatest deflection, set the dial indicator to zero. Repeat the rocking action of the gage shaft to verify the zero setting. 15. Rotate the gage shaft until the dial indicator rod does not touch the gage block.
Page 155 -INCH RING GEAR 4B2-7 Dial in d ic a to r and a rb o r p o s itio n e d on th e gage b lo c k . M e a su re m e n t a fte r th e a rb o r is m oved o ff o f th e gage b lo c k F-04682 Figure 13—...
Page 156 4B2-8 1 / 2-INCH RING GEAR Tighten DIFFERENTIAL CASE ASSEMBLY -►+ Install or C onnect (Figure 1) • T h e ring g ear bolts in se q u e n c e to 8 0 N-m (60 ft. lbs.). Tools Required: 7.
Page 157 -INCH RING GEAR 4B2-9 Figure 21— Measuring Side Bearing Shim Requirements • Service shims are available from 0.040 to -inch. • Be sure that the side bearing surfaces are clean and • Leave the tool in place. free of burrs. .
Page 158 4B2-10 1 / 2-INCH RING GEAR . If the backlash is not within specifications, move the 11. For an initial backlash setting, move the ring gear away from the pinion by subtracting -inch from ring gear in or out from the pinion by increasing the th ic k n e s s of one s h im , and d e c re a s in g th e the ring gear side shim pack and adding -inch...
Page 159 -INCH RING GEAR 4B 2 -11 ADJUSTMENTS AFFECTING TOOTH CONTACT Two adjustments can be made which will affect tooth contact pattern: backlash, and the position of the drive pinion in the carrier. The effects of bearing preloads are not readily apparent on hand loaded tooth contact pattern tests;...
Page 160 4B2-12 1 / 2-INCH RING GEAR SPECIFICATIONS 81/2-INCH RING GEAR AXLE FT. LBS FASTENER Ring Gear Bolts. . . Bearing Cap Bolts. Axle Cover Bolts . . SIZE SPACER AND SHIM SIZES Differential Side Bearing S p a c e r............................0.170-inch Differential Side Bearing Shim K its ...........................
Page 161 -INCH RING GEAR 4B2-13 SPECIAL TOOLS J-8092 J-22399 r r f l s ^ 3 1 - ^ J-8001 f f i f f J-22761 J-8609-01 J-22779 "" J-8614-01 J-5590 J-8107-4 . F ro n t P in io n B e aring C up In s ta lle r 11.
Page 163 /2-INCH RING GEAR 4B3-1 SECTION 4B3 9 1 /2-INCH r in g g e a r CONTENTS S U B J E C T P A G E Description....................................4 B 3 - 1 Checking the Axle Before Disassem bly........................... 4 B 3 - 1 Disassembly of the Rear A xle .............................
Page 164 4B3-2 9 fa-INCH RING GEAR R ing G ear B o lt 1. Brake Drum D iffe re n tia l C ase S h im 2. W heel S tud P in io n S h a ft R ing and P in io n G ear Set 3.
Page 165 /2-INCH RING GEAR 4B3-3 NOTICE: Do n o t pry the ring g ear from the case. T h is w ill d a m a g e th e r in g g e a r a n d th e d ifferen tial case.
Page 166 4B3-4 -INCH RING GEAR INSPECTION It is very important to carefully and thoroughly inspect all drive unit parts before reassembly. Thorough inspection of the drive parts for wear or stress and subsequent replacement of worn parts will eliminate costly drive component repair after reassembly. AXLE HOUSING Inspect •...
Page 167 /2-INCH RING GEAR 4B3-5 Figure 9— Installing the Front Pinion Bearing Cup Figure 11— Gage Plate Tools • If the rear axle was operated for an extended period J 8092 Driver Handle of time with very loose bearings, the ring gear and 1.
Page 168 4B3-6 -INCH RING GEAR 15. Rotate the gage shaft until the dial indicator rod does not touch the gage block. 16. Record the actual number on the dial indicator and not the number which represents how far the needle travels. This is the nominal pinion setting. EXAMPLE: If the indicator needle moved to the left 1.70 mm (0.067-inch) to a dial reading of 0.84 mm (0.033-inch) as shown in figure 13, record the dial...
Page 169 /2-INCH RING GEAR 4B3-7 Figure 14— Installing the Pinion Inner Bearing PINION INSTALLATION |-n -| Install or C onnect Tools Required: J 22388 Pinion Oil Seal Installer J 22804-1 Pinion Oil Seal Spacer J 5590 Rear Pinion Bearing Cone Installer •...
Page 170 4B3-8 91 /2-INCH RING GEAR tightening. Each tightening increases the bearing preload by several pounds. If the A. L e ft H and S tu d s bearing preload is exceeded, the pinion will 20. R ing G ear have to be removed, and a new collapsible 24.
Page 171 9Vz-INCH RING GEAR 4B3-9 J -2 4429 F-04733 Figure 21—Adjusting the Nut . Differential case (27) to the axle housing. Refer to BACKLASH ADJUSTMENT “ Side Bearing Preload A djustm ent” in this section. 1. Install a dial indicator to the case using a magnetic base.
Page 172 4B3-10 91 / 2-INCH RING GEAR distance will move the pinion closer to the centerline of the ring gear. Increasing the distance will move the pinion farther away from the centerline of the ring gear. Backlash is adjusted by means of the side bearing adjusting shims which move the entire case and ring gear assembly closer to, or farther from, the drive pinion.
Page 173 91 / 2-INCH RING GEAR 4B3-11 L O W F L A N K C O N T A C T D E C R E A S E P IN IO N S H IM T O E C O N T A C T IN C R E A S E B A C K L A S H H E E L C O N T A C T D E C R E A S E B A C K L A S H...
Page 174 4B3-12 91 / 2-INCH RING GEAR SPECIFICATIONS 9 1/2-INCH RING GEAR AXLE FT. LBS. FASTENER Ring Gear Bolts..... Bearing Cap B olts..Axle Cover B o lts ... Adjusting Nut Lock Bolt SIZE SPACER AND SHIM SIZES 0170- inch Differential Side Bearing Spacer 0.040-0.044- inch 5 59 mm ( - nch)
Page 175 9V2-INCH RING GEAR 4B3-13 SPECIAL TOOLS J -8 1 0 7 -3 © = ___!? * J -8 0 0 1 -M < OM ; — " ' J-8614-1 . D iffe re n tia l S ide B e aring Plug .
Page 176 4B3-14 91 / 2-INCH RING GEAR...
Page 177 1Q1/2-INCH RING GEAR 4B4-1 SECTION 4B4 101/2-INCH RING GEAR CONTENTS S U B J E C T P A G E D escrip tion ....................................4 B 4 - 1 Checking the Axle Before Disassembly........................... 4 B 4 - 1 Disassembly of the Rear A xle.............................
Page 178: Disassembly Of The Rear Axle
4B4-2 1 / 2-INCH RING GEAR 8614-01 Pinion flan ge nut and w asher using DISASSEMBLY OF THE to hold the flan ge (figure REAR AXLE 8614-01 Pinion flan ge using (figure (14) (10). Pinion from the pinion ca g e R em ove or D isconnect (Figure 1) •...
Page 179 -INCH RING GEAR 4B4-3 Pinion Pilot Bearing Axle Vent Tube Axle Housing D ifferential Side Bearing Bearing Adjusting Nut Bearing Cap A djusting Nut Lock Bolt G asket Cover Bolt Brake Line Clip W asher Bolt Side G ear Side G ear Thrust W ash er Pinion G ear Thrust W asher Pinion G ear Set Pinion Cross Shaft...
Page 180 4B4-4 lO ’ /z-INCH RING GEAR Figure 2— Removing the D ifferential Side Bearings Figure 7 — Pressing th e Drive Pinion from the Cage...
Page 181: Assembly Of The Rear Axle
/2-INCH RING GEAR 4B4-5 PINION AND RING GEAR BEARINGS Inspect Inspect • Pinion and ring g ear teeth for cracking, chipping, B earings visually and by feel. scoring, or excessive wear. T h e b earing s should feel sm ooth w hen oiled and rotated w hile applying as much hand pressure as •...
Page 182 4B4-6 1 / 2-INCH RING GEAR PINION INSTALLATION 2. O u te r pinion b earin g cup (6) using J 8 6 0 8 and J 80 92 . I+ + I Install or C onnect 3. inn er pinion bearing cup (13) using J 2 4 4 3 2 and Tools Required: J 80 92 .
Page 183 /2-INCH RING GEAR 4B4-7 A. Press B. A d a p to r Plug Figure 16— Installing the Ring Gear to Case (30) 2. Differential side g ears (29) and thrust w ashers to th e d iffe re n tia l c a s e h alve s in th e ir o rig in al CODE N U M B ER ON O RIG INA L PINIO N locations.
Page 184 4B4-8 101 / 2-INCH RING GEAR T ighten • Do not tighten. Tighten the right adjusting nut firm ly to force the • T h e ring g ear bolts in seq u en ce to 163 N-m case into solid contact with the left adjusting nut. (120 ft.
Page 185: Gear Tooth Pattern Check
lO ’ fe-INCH RING GEAR 4B4-9 5. If the reading is too high, rem ove the adjusting nut 4. Expand the brake shoes until a torque of 40 to 50 ft. locks, and loosen the right nut one slot, and tighten lbs.
Page 186 4B4-10 -INCH RING GEAR L O W F L A N K C O N T A C T I * / 1 1 * 1 D E C R E A S E P IN IO N S H IM ------- / / / >...
Page 187: Specifications
-INCH RING GEAR 4B4-11 SPECIFICATIONS 101/2-INCH RING GEAR AXLE (CORPORATE) FASTENER FT. LBS. Ring Gear Bolts....Bearing Cap B olts... Axle Cover B o lts ..... Adjusting Nut Lock Bolts SPACER AND SHIM SIZES SIZE Pinion Bearing Shim s... 0006- nch 0.007- nch 0.008- nch 0.009- nch...
Page 188: Special Tools
4B4-12 -INCH RING GEAR SPECIAL TOOLS J-8092 J-24433 J-8608 J-24429 1. P in io n F lan ge R em over 2. S ide B earing R em over 3. Rear P in io n B earing C up In s ta lle r 4.
Page 189 DANA REAR AXLES 4B5-1 SECTION 4B5 DANA REAR AXLES CONTENTS S U B J E C T P A G E 93/4-lnch Ring G e a r ..................................4B 5- 1 D escriptio n ....................................4 B 5 - 1 Checking the Axle Before Disassembly...........................
Page 190: Cleaning
4B5-2 DANA REAR AXLES 12. Lock pin (29) from the differential using a hammer Determine the cause of the axle problem before and a punch (figure 8). disassem bly if possible. 13. Pinion shaft (28) using a hammer and a brass drift DISASSEMBLY OF THE (figure 9).
Page 191 DANA REAR AXLES 4B5-3 1. A x le H o u s in g 11. W a sh er 22. D iffe re n tia l C ase 2. R ing G ear and P in io n Set 12. P in io n N u t 23.
Page 192 4B5-4 DANA REAR AXLES Figure 7 — R em oving the Ring G ear Figure 4— Spreading th e D ifferen tial Case...
Page 193 DANA REAR AXLES 4B5-5 Figure 9— Removing the Pinion Shaft Figure 10— R em oving th e Pinion Gears Figure 13 — R em oving th e Pinion Flange...
Page 194 4B5-6 DANA REAR AXLES AXLE HOUSING Inspect • The ca rrier bore for nicks or burrs that w ould prevent the outer diameter of the pinion seal from sealing. Remove any burrs that are found. • The bearing cup bores for nicks or burrs. Remove any burrs that are found.
Page 195: Assembly Of The Rear Axle
DANA REAR AXLES 4B5-7 Figure 17— Installing the Pinion Gears Figure 18— Installing the Lock Pin SHIMS • Press the ring gear onto the case, and align the holes in the case with the studs. Inspect 8. New ring gear bolts (23) (figure 19). •...
Page 196 4B5-8 DANA REAR AXLES Figure 20— Differential with the Master Bearings PINION DEPTH ADJUSTMENT 2. Mount a dial indicator having a minimum travel of 0.200-inch with a magnetic base on the ring gear Tools Required: D-120 Master Pinion Block (Miller) bolt side of the housing (figure 21).
Page 197 DANA REAR AXLES 4B5-9 8. R ecord the re a d in g at th e p o in t of g re a te s t d e fle c tio n (when the dia l in d ic a to r nee dle is centered between movement to the left and to the right).
Page 198 4B5-10 DAN A REAR AXLES F-04719 Figure 30— Installing the Inner Bearing Drive the inner bearing cup into the axle assembly 9. P inion dep th c h e c k in g to o ls D-116-1, D-116-2, using D-111 and C-4171. The cup must be seated on D-115-3, and D-115 to the top of the pinion.
Page 199 DANA REAR AXLES 4B5-11 Figure 32—Checking the Pinion Depth Setting Figure 34— Tightening the Pinion Nut ASSEM BLING THE DIFFER EN TIA L TO THE AXLE Remove the pinion nut (12), washer (11), pinion HOUSING flange (10), slinger (8) and bearing cone (7). Tools Required: Preload shims (6).
Page 200 4B5-12 DANA REAR AXLES 12. Assemble J 24385-01 to the axle housing as shown 7. Remove the indicator and the differential case from in figure 38. the carrier. 13. Assemble the dial indicator as shown in figure 38. 8. Remove the master bearings from the differential Preset the gage at least 0.020-inch, and then rotate case.
Page 201: Description
DANA REAR AXLES 4B5-13 F-04755 Figure 40— Measuring Backlash Figure 41— Installing the Axle Cover Tighten 6. To adjust the backlash, the differential case must be removed from the housing, then the differential The bearing cap bolts (19) to 115 N-m (85 ft. bearings removed, and the proper number of shims lbs.).
Page 202 4B5-14 DANA REAR AXLES 30. B o lt 16. Plug 1. A x le H o u s in g 17. B o lt 31. N ut 2. R ing and P in io n G ear Set 18. B earing Cap 32.
Page 203: Disassembly Of The Rear Axle
DANA REAR AXLES 4B5-15 Figure 44— Removing the Bearing Cap All Dana axles are identified by the part number on the 3. Bearing cap bolts (19) (figure 44). right axle tube next to the carrier. The model number is 4. Bearing caps (18). cast on the carrier.
Page 204 4B5-16 DAN A REAR AXLES 12. Lock pin (29) from the differential using a hammer Bearing cups (20). and a punch (figure 49). • Mark the cups as left and right, and place • Turn the differential over on D-166. them with the proper bearing caps.
Page 205 DANA REAR AXLES 4B5-17 F-04693 F igure 50— R em oving the P inion S haft Figure 53— Removing the Drive Pinion Nut 17. Pinion flange (10) using J 8614-01 (figure 54). 18. Pinion (2) from the carrier using a rawhide hammer to tap the pinion (figure 55).
Page 206: C Le A N In
4B5-18 DANA REAR AXLES CLEANING Do not steam clean drive parts having ground and polished surfaces such as gears, bearings, and shafts. These parts should be cleaned in a suitable solvent. All parts should be disassembled before cleaning. Parts should be thoroughly dried immediately after cleaning.
Page 207: Assembly Of The Rear Axle
DANA REAR AXLES 4B5-19 Figure 59— In s ta llin g the Lock Pin BEARINGS 3. Pinion gears (24) to the differential without the thrust washers (26). Inspect • Place the pinion gears onto the side gears so Bearings visually and by feel. that the holes in the pinion gears are 180 The bearings should feel smooth when oiled and degrees apart.
Page 208 4B5-20 DANA REAR AXLES Figure 60— Installing the Ring Gear Bolts DETERMINING TOTAL DIFFERENTIAL SHIM 7. Remove the dial indicator from the axle. PACK SIZE — B OR U MODEL 8. Remove the differential case from the axle housing. 1. Assem ble the differential case (22) to the axle •...
Page 209 DANA REAR AXLES 4B5-21 Figure 63— Master Pinion Block D-115 Scooter Gage (Miller) 1. Clean the carrier bores and all the tools. The pinion bore must be free of nicks and dirt. 2. Install D-120 or D-137 to the pinion bore (figure 63). 3.
Page 210 4B5-22 DANA REAR AXLES • This reading indicates the amount of shims Drive the inner bearing cup into the axle assembly using C-4204 and C-4171. The cup must be seated needed for a nom inal pinion setting. The pinion marking may change the pinion depth on the shims (figure 69).
Page 211 DANA REAR AXLES 4B5-23 F-04719 Figure 71— Installing the Inner Bearing specifications, change the shim pack by the pinion (figure 72). Rotate the pinion several amount the indicator needle is from the pinion times to seat the bearings and assure a more marking.
Page 212 4B5-24 DANA REAR AXLES 6. Force the differential case away from the pinion • Remove shims to increase the preload. gear to obtain an indicator reading. Repeat this • Add shims to decrease the preload. action until a consistant reading is obtained. 7.
Page 213 DANA REAR AXLES 4B5-25 11. Place the proper shim s on the differential side bearing hub (opposite the ring gear) and drive the differential bearing onto the hub using J 23690 and J 8092. • If installing a new bearing, be certain that it is the same width as the old bearing.
Page 214 4B5-26 DANA REAR AXLES 20. Drive the outboard spacers (43) into the proper 1. Assem ble the differential case (22) with master sides using C-4205 and C-4171. bearings installed to the axle housing. The pinion 21. Remove the spreader. must be installed. 22.
Page 215 DANA REAR AXLES 4B5-27 SPECIFICATIONS 93/4-INCH r in g g e a r a x l e FASTENER FT. LBS. Ring Gear Bolts............................Bearing Cap B o lts............................ Axle Cover B o lts ............................SIZE Differential Bearing Adjusting S h im ............................ 0.003-inch 0.005-inch 0.010-inch 0.030-inch...
Page 216 4B5-28 DANA REAR AXLES SPECIAL TOOLS D-116-2 D-115-3 J-8092 D-116-1 J-5590 D-115 J-8614-01 J-23690 D-117 J-29721 D-120 J-24385-01 D-111 J-29721-70 C-4171 J-8107-03 J-7818 9. D iffe re n tia l S ide B e aring R em oval Plug 1. M a s te r D is c s (M iller) 10.
Page 217 DANA REAR AXLES 4B5-29 SPECIAL TOOLS D-116-2 J-8107-3 D-115-3 J-8092 D-116-1 1 2 . J-7817 D-115 J-5590 1 3 . D-136 or D-117 J-8614-01 (Heavy Duty Axles) D-120 J-23690 1 5 . C-4204 J-29721 C-4171 J-24385-01 4205 J-29721-70 1. M a ste r D iscs (M iller) D iffe re n tia l S ide B earing R em over Plug 2.
Page 218 ------------------...
Page 219 12-INCH RING GEAR (ROCKWELL) 4 B 6 -1 ■ • : /■ T ,» ^'V ." SECTION 4B6 12-INCH RING GEAR (ROCKWELL) CONTENTS S U B J E C T P A G E D escription....................................4B 6- 1 Disassembly of the Rear A xle............................. 4B 6- 1 C le a n in g ....................................
Page 220 4B6-2 12-INCH RING GEAR (ROCKWELL) F-04734 Figure 1— Rear A xle C om ponents...
Page 221 12-INCH RING GEAR (ROCKWELL) 4B6-3 1. B o lt 22. A x le V e n t 43. S ide G ears 2. W a sh er 23. B o lt 44. B o lt 3. H ub C ap 24.
Page 222 4B6-4 12-INCH RING GEAR (ROCKWELL) F-04770 Figure 10— R em oving the D ifferen tial S ide B earing Figure 7 — R em oving the D ifferen tial...
Page 223 12-INCH RING GEAR (ROCKWELL) 4B6-5 16. Pinion shaft nut (62) and washer (61) using J 3453 CLEANING to hold the pinion yoke (figure 11). Do not steam clean drive parts having ground and 17. Pinion yoke (60) using J 7804-01 (figure 12). polished surfaces such as gears, bearings, and shafts.
Page 224 4B6-6 12-INCH RING GEAR (ROCKWELL) AXLE HOUSING Inspect • T h e c a rrie r bore for nicks or burrs th at w ould prevent the outer d ia m e te r of the pinion seal from sealing. R em ove any burrs that are found. •...
Page 225 12-INCH RING GEAR (ROCKWELL) 4B6-7 Figure 18— Removing the Pinion Nut — Divide the diameter by 2 to find the radius in Pinion washer (61) and a new nut (62) using J 3453 inches. to hold the pinion (figure 17). —...
Page 226 4B6-8 1 -INCH RING GEAR (ROCKWELL) & T ighten 3. Cage bolts (56). • Bolts (44) to 61 N m (45 ft. lbs). & Tighten • Check that the mating surfaces of the differential • Bolts to 48 N-m (35 ft. lbs.). case and the ring gear are clean and burr free.
Page 227 -INCH RING GEAR (ROCKWELL) 4B6-9 Press the bearings on using a suitable tool. DIFFERENTIAL INSTALLATION |-n -| Install or C onnect 1. Bearing cups (33) to the carrier (36). 2. Adjusting nuts (32). 3. Bearing caps (25). 4. Cap bolts (23). &...
Page 228 4B6-10 12-INCH RING GEAR (ROCKWELL) 2. Drive axles. Refer to the proper service manual. FINAL ASSEMBLY 3. The axle housing to the v ehicle. Refer to the proper +«- Install or C onnect service manual. 4. Lubricant to the rear axle. Carrier (46) to the axle housing.
Page 229 12-INCH RING GEAR (ROCKWELL) 4 B 6 -11 SPECIAL TOOLS Special T ools...
Page 230 4B6-12 12-INCH RING...
Page 231: Locking Differential
4B7-1 SECTION 4B7 LOCKING DIFFERENTIAL CONTENTS S U B J E C T P A G E Locking D ifferentials.................................. 4 B 7 - 1 -lnch Ring G e a r..........................4B 7- 1 -lnch Ring G e a r ................................4B 7- 5 S p e c ific a tio n s .....................................
Page 232 4B7-2 LOCKING DIFFERENTIALS . P in io n T h ru s t W a sh er 16. Cam Plate 7. P in io n G ear 17. T h ru s t B lo c k -ln ch R ing G ear .
Page 233 LOCKING DIFFERENTIALS 4B7-3 Figure 4 — Removing the Thrust Ring Figure 5—Checking Cam Gear Backlash CAM UNIT ASSEMBLY - 7Vz AND 8 V -INCH ADJUSTMENT OF THE DIFFERENTIAL • If it is necessary to replace the cam gear, the right -►+ Install or C onnect side gear, or the thrust block, the entire differential must be adjusted.
Page 234 4B7-4 LOCKING DIFFERENTIALS 11. If the backlash is too low, use a thinner thrust washer. Right Side Gear Backlash Adjustment 1. Assemble the clutch plates. • Alternate the plates as shown in figure 1. 2. Assemble the guide clips (19) to the plates. •...
Page 235 LOCKING DIFFERENTIALS 4B7-5 10. Right cam unit from the differential. 11. Right thrust washer (36). • Measure and record the overall length of the gear assembly from the front of the gear to the back of the thrust sleeve (35) including the side gear washer (36).
Page 236 4B7-6 LOCKING DIFFERENTIALS 43. Governor and Latching Bracket 37. Plates 31. Differential Case Halves 44. Plates 38. Pinion Thrust Washer 32. Screw 45. Side Gear Thrust Washer 39. Pinion Gear 33. Cam Plate 46. Side Gear 40. Side Cam Gear 34.
Page 237 LOCKING DIFFERENTIALS 4B7-7 • There are three adjustments to be made: (1) Left side gear backlash. (2) Right side gear backlash. (3) Thrust block clearance. Right Side Gear Blacklash Adjustment . Install the cam unit and thrust washer (36) to the right case half.
Page 238 4B7-8 LOCKING DIFFERENTIALS . Pull the pinion gear firmly into its seat, and rotate the gear back and forth while reading the dial indicator. Record the reading. • Do not unseat the pinion yoke. This will make the backlash reading inaccurate. 9.
Page 239 LOCKING DIFFERENTIALS 4B7-9 5. Left side gear (46) . Case halves (31) together. . Latching bracket assembly (43). • Hold the side gear in the left side case half. 7. Governor assembly (48). 9. Case screws (32). • The straight end of the latching bracket spring 10.
Page 240 4B7-10 LOCKING DIFFERENTIALS SPECIAL TOOLS Special Tools...
Page 241: Front Axle
4C1-1 SECTION 4C FRONT AXLE CONTENTS SUBJECT PAGE -lnch Ring Gear Front A x le ............................4C1-1 -lnch Ring Gear Front A x le ............................4C2-1 T Truck Front A x le ................................4C3-1 K Truck Front A x le ................................4C4-1 SECTION 4C1 8V2-INCH RING GEAR CONTENTS...
Page 242 4C1-2 1/2-INCH RING GEAR The front axle is sealed with a pinion seal, a seal at which are pressed onto the differential case. Two bearing each axle shaft, and by a gasket between the front cover caps are used to hold the differential into the front axle and the axle housing.
Page 243 -INCH RING GEAR 4C1-3 22. S ide G ear 1. A xle H o u s in g 11. G a sket 23. R ing G ear B o lt 2. A ir V e n t 12. C over 24.
Page 244 4C1-4 1/2-INCH RING GEAR • Work the cups out of the housing evenly, moving the punch back and forth between one side of the cup and the other. 20. Axle seals. F-04694 Figure 6 — Pinion Flange R em oval...
Page 245: Cleaning And Inspection
-INCH RING GEAR 4C1 -5 CLEANING AND INSPECTION PINION AND RING GEAR CLEANING Inspect • Do not steam clean drive parts having ground and Pinion and ring gear teeth for cracking, chipping, polished surfaces such as gears, bearings, and scorring, or excessive wear. shafts.
Page 246: Assembly Of Axle
4C1-6 -INCH RING GEAR ASSEMBLY OF AXLE Figure 9 — Installing Front Pinion Bearing Cup PINION DEPTH ADJUSTMENT Im portant Lubricate all seal lips, gears, and bearing surfaces Tools Required: with axle lubricant prior to assembly. J 8001 Dial Indicator Set J 21777-1 Arbor PINION BEARING CUP J 21777-29 Plate...
Page 247: Pinion Installation
-INCH RING GEAR 4C1-7 PINION INSTALLATION -► <- Install or C onnect Tools Required: J 8609-01 Rear Pinion Bearing Cone Installer J 22388 Pinion Oil Seal Installer J 8614-01 Pinion Flange Remover J 5590 Rear Pinion Bearing Cone Installer • The bearing cups should have been installed in “...
Page 248 4C1-8 1/2-INCH RING GEAR Dial in d ic a to r and a rb o r p o s itio n e d on th e gage b lo c k . M e a su re m e n t a fte r th e a rb o r is m oved o ff o f th e gage b lo c k F-04682 Figure 13—...
Page 249: Side Bearing Preload Adjustment
1/2-INCH RING GEAR 4C1-9 • Press the ring gear onto the case far enough SIDE BEARING PRELOAD to start the bolts using J 8107-4 to protect the ADJUSTMENT differential from the press ram (figure 18). 7. New ring gear bolts (23). Tool Required: •...
Page 250: Backlash Adjustment
4C1-10 -INCH RING GEAR • Push the feeler gage downward so that it • Support the case to keep it from falling into the contacts the shim at the top and bottom, and axle housing. then contacts the axle housing. 2.
Page 251: Gear Tooth Contact Pattern Check
-INCH RING GEAR 4C1-11 Tighten thickness of the other shim by the same amount. This will maintain the correct front axle side bearing • The bolts to 80 N m (60 ft. lbs.) preload. 6. Check and record the backlash at three or four •...
Page 252: Final Assembly
4C1-12 1/2-INCH RING GEAR F-02018 Figure 26— Gear Tooth Contact Pattern Backlash is adjusted by means of the side bearing 4. Apply a load until a torque of 54-70 N-m (40-50 ft. lbs.) is required to turn the pinion. adjusting shims which moves the entire case and ring gear assembly closer to, or farther from the drive pinion.
Page 253 1/2-INCH RING GEAR 4C1-13 SPECIFICATIONS 8 1/2 INCH RING GEAR FRONT AXLE TORQUE SPECIFICATIONS Fastener Ft. Lbs. Ring Gear Bolts............................Bearing Cap B o lts............................ Axle Cover B o lts ............................AVAILABLE SHIM AND SPACER SIZES ..Differential Side Bearing Spacer......................0 170-inch-0.172- nch Differential Side Bearing K its........................
Page 254 4C1-14 1/2-INCH RING GEAR SPECIAL TOOLS J 8 60 8 J 8611-01 Sail J 2 2 8 8 8 J 8 6 1 2-B J 2 2 3 9 9 J 8 09 2 J 22761 J 8001 J 2 2 7 7 9 J 8609-01 J 5 59 0 J 8614-01...
Page 255 4C2-1 SECTION 4C2 93/4-INCH r in g g e a r f r o n t a x l e CONTENTS S U B J E C T P A G E D escription....................................4C 2- 1 Disassembly of A x le .................................. 4 C 2 - 2 Inspection....................................4 C 2 - 2 D isassem bly.....................................
Page 256: Disassembly Of Axle
4C2-2 93/4-INCH RING GEAR FRONT AXLE DISASSEMBLY OF AXLE • Mark the bearings as left and right, and place INSPECTION them with the proper bearing caps and cups. 9. Differential shims (21). Perform the following checks before disassembling the • Mark the shims as left or right. axle.
Page 257 /4-INCH RING GEAR FRONT AXLE 4C2-3 1. A xle H o u s in g 11. W a sh er 22. D iffe re n tia l Case 2. R ing G ear and P in io n Set 12. P in io n N u t 23.
Page 258 4C2-4 93/4-INCH RING GEAR FRONT AXLE F-04756 Figure 7 — R em oving the Ring G ear Figure 4 — S preading th e D ifferen tial Case...
Page 259 /4-INCH RING GEAR FRONT AXLE 4C2-5 Figure 10— R em oving th e Pinion Gears Figure 13— Pinion Flange R em oval...
Page 260 4C2-6 93/4-INCH RING GEAR FRONT AXLE Figure 16— R em oving th e Pinion Inner Bearing...
Page 261: Cleaning And Inspection
93/4-INCH RING GEAR FRONT AXLE 4C2-7 CLEANING AND INSPECTION CLEANING PINION AND RING GEAR L ® Inspect Do not steam clean drive parts having ground and Pinion and ring gear teeth for cracking, chipping, polished surfaces such as gears, bearings, and shafts. scoring, or excessive wear.
Page 262: Assembly Of Axle
4C2-8 93/4-INCH RING GEAR FRONT AXLE ASSEMBLY OF AXLE Figure 19— In sta lling th e L ock Pin 4. Pinion gears (24) to the differential without the thrust Im portant washers (26). Lubricate all seal lips, bearings, gears, and bearing •...
Page 263: Determining Total Differential Shim Pack Size
/4-INCH RING GEAR FRONT AXLE 4C2-9 Figure 20— Installing the Ring Gear Bolts Figure 22— Determining Differential Shim Pack • Refer to “ Determining Total Shim Pack Size” in this 6. Force the differential assem bly in the opposite section. direction as far as it will go.
Page 264 4C2-10 9 /4-INCH RING GEAR FRONT AXLE Figure 26—Scooter Gage on the Height Block • This reading indicates the amount of shims needed for a nom inal pinion setting. The pinion marking may change the pinion depth by adding or deleting shims from the nominal pinion setting.
Page 265: Pinion Installation
/4-INCH RING GEAR FRONT AXLE 4C2-11 Measure each shim separately with a micrometer and add them together to obtain the total shim pack thickness. If a baffle (5) or slinger is used, these must also be measured and included in the shim pack (figure 28).
Page 266 4C2-12 9 /4-INCH RING GEAR FRONT AXLE specifications, change the shim pack by the torque of 1.13 N-m (10 in. lbs.) to rotate the amount the indicator needle is from the pinion pinion (figure 32). Rotate the pinion several marking. times to seat the bearings and assure a more Remove the pinion nut (12), washer (11), pinion accurate reading pinion depth setting.
Page 267 /4-INCH RING GEAR FRONT AXLE 4C2-13 Figure 38— Installing the Differential Bearings • Add shims to increase the preload. 5. With the force still applied to the differential case, set the dial indicator to zero. 6. Force the differential case away from the pinion ASSEMBLING THE gear to obtain an indicator reading.
Page 268: Checking Backlash
4C2-14 9 /4-INCH RING GEAR FRONT AXLE 4. High backlash is corrected by moving the ring gear • Use a rawhide hammer to seat the differential assembly in the axle housing (figure 40). closer to the pinion. 5. Low backlash is corrected by moving the ring gear 18.
Page 269: Specifications
/4-INCH RING GEAR FRONT AXLE 4C2-15 SPECIFICATIONS TORQUE SPECIFICATIONS F astener Ft. Lbs. Ring Gear Bolts............................Bearing Cap B olts............................ Axle Cover B o lts ............................AVAILABLE SHIM SIZES Differential Bearing Adjusting S h im ..........................0.003-inch 0.005- nch 0.010- nch 0.030- nch Outer Pinion Bearing S h im ................
Page 270: Special Tools
4C2-16 93/4-INCH RING GEAR FRONT AXLE SPECIAL TOOLS D-116-2 D-115-3 J-8092 D-116-1 J-5590 D-115 J-8614-01 J-23690 D-117 J-29721 D-120 J-24385-01 D-111 P - x / r ^ J-29721-70 C-4171 J-8107-03 J-7818 9. Differential Side Bearing Removal Plug 10. Rear Pinion Bearing Cup Installer 1.
Page 271 T TRUCK FRONT AXLE 4C3-1 SECTION 4C3 T TRUCK FRONT AXLE CONTENTS S U B J E C T P A G E D escription....................................4 C 3 - 1 Disassembly of A x le ..................................4 C 3 - 2 Inspection....................................4 C 3 - 2 D isassem bly.....................................
Page 272: Disassembly Of Axle
4C3-2 T TRUCK FRONT AXLE DISASSEMBLY OF AXLE Bearing cups (33) and sleeves (32) from the case. INSPECTION • Turn the sleeves (32) using J 33792 until the cups are pushed out of the case (figure 8). Perform the following checks before disassembling the Bearings (30) from the sleeves (32).
Page 273 T TRUCK FRONT AXLE 4C3-3 F-05785 Figure 1— A xle C om po n ents...
Page 274 4C3-4 T TRUCK FRONT AXLE 1. S h a ft 16. S p rin g 31. In se rt 46. N ut 2. D e fle c to r 17. S h ift S h a ft and F ork 47.
Page 275 T TRUCK FRONT AXLE 4C3-5 30. B earing 32. Sleeve J-21551 / - — F-01782 Figure 6—Separating the Carrier Case Halves Figure 9— Remove the Sleeve Bearing 18. B o lt 29. C a rrie r Case 19. L ock Tab 32.
Page 276 4C3-6 T TRUCK FRONT AXLE R E M O V A L -33791-2 F-04696 Figure 12— Removing the Pinion Bearing IN S T A L L A T IO N J-33791-1 J-33791-3 J-33791-2 Figure 13 — R em oving th e In n er Pinion Bearing Cup 95.
Page 277: Cleaning And Inspection
T TRUCK FRONT AXLE 4C3-7 CLEANING AND INSPECTION CLEANING BEARINGS Inspect Do not steam clean drive parts having ground and polished surfaces such as gears, bearings, and shafts. • Bearings visually and by feel. The bearings should feel smooth when oiled and rotated while applying These parts should be cleaned in a suitable solvent.
Page 278: Assembly Of Axle
4C3-8 T TRUCK FRONT AXLE ASSEMBLY OF AXLE Im portant Lubricant all the seal lips, bearings, gears, and bearing surfaces with axle lubricant prior to assem bly. J 337 9 0 DIFFERENTIAL CASE ASSEMBLY Install or C onnect (Figures 1, 2 and 16) Tool Required: J 33790 Side Bearing Installer 1.
Page 279: Pinion Depth Adjustment
T TRUCK FRONT AXLE 4C3-9 PINION DEPTH ADJUSTMENT 1. Rotate the pinion with the torque w rench and observe the reading. 2. If the pre lo a d to rq u e is b elow s p e c ific a tio n s , Tools Required: c o n tin u e to rq u in g...
Page 280 4C3-10 T TRUCK FRONT AXLE A. B u tto n L o ca te d in B e aring Bore B. B u tto n M oved O u t o f B e aring Bore F-05791 Figure 19— M easuring Pinion D epth...
Page 281 T TRUCK FRONT AXLE 4C3-11 J 3 3 7 8 8 F-01791 Figure 23— Installing the Sleeve Bearing 6. Turn the left adjusting sleeve IN one notch using F-01781 J 33792. 7. Rotate the pinion several times to seat the bearings. Figure 24—...
Page 282 4C3-12 T TRUCK FRONT AXLE A. Mark Location on the Case F-01830 Figure 26— Marking Sleeve Location 10. Check and record the backlash at three or four points around the ring gear. • The pinion must be held stationary when checking backlash.
Page 283: Gear Tooth Contact Pattern C H E C
T TRUCK FRONT AXLE 4C3-13 ADJUSTMENTS AFFECTING TOOTH CONTACT Two adjustments can be made which will affect the tooth contact pattern. These are backlash and the position of the drive pinion (pinion depth) in the carrier. The effects of bearing preloads are not easily seen on hand loaded teeth pattern tests.
Page 284 4C3-14 T TRUCK FRONT AXLE L O W F L A N K C O N T A C T D E C R E A S E P IN IO N S H IM T O E C O N T A C T IN C R E A S E B A C K L A S H H E E L C O N T A C T D E C R E A S E B A C K L A S H...
Page 285 T TRUCK FRONT AXLE 4C3-15 J 3 3 8 4 2 F-05789 Figure 33— Installing the Differential Pilot Bearing Inspect (Figure 35) Tool Required: J 33798 Engagement Tool Operation of the shift mechanism. Insert J 33798 into the shift fork. Turn the axle shaft while engaging and disengaging the shift mechanism with the tool.
Page 286 4C3-16 T TRUCK FRONT AXLE S h ift C ab le H o u s in g F-01668 Figure 35—Checking the Shift Mechanism SPECIFICATIONS Fastener Ft. Lbs. Ft. Lbs. In. Lbs. Cable Housing and Tube Attaching B o lts ..............Left Hand Output Shaft Cover B o lts ................
Page 287 T TRUCK FRONT AXLE 4C3-17 SPECIAL TOOLS J-21551 J -3 3837 J -2 9 7 6 3 J-3 3 8 3 8 J -3 3 7 8 2 J -3 3 8 4 2 J-3 3 7 8 5 J -3 3844 J -3 3 7 8 8 J -3 3 8 9 3 J-3 3 7 9 0...
Page 288 4C3-18 T TRUCK FRONT AXLE SPECIAL TOOLS J 29307 J 8001 J 33791 J 34037 J 33798 1. S lid e H a m m e r 2. Bushing Rem over 3. Dial In d ic a to r Set 4.
Page 289 K TRUCK FRONT AXLE 4C4-1 SECTION 4C4 K TRUCK FRONT AXLE CONTENTS S U B J E C T P A G E D e s crip tio n ....................................... 4C4- Disassembly of A x le ..................................4C4- In s p e c tio n ..................................... 4C4- D is a s s e m b ly ....................................
Page 290: Description
4C4-2 K TRUCK FRONT AXLE DESCRIPTION transm it the driving force. This prevents tire scuffing when The front axle on K model vehicles has a center discon going around corners and prevents prem ature wear on nect feature which, under most conditions, allows shifting internal axle parts.
Page 291 K TRUCK FRONT AXLE 4C4-3 Figure 1— F ront A xle C om po n ents (K -15-25 M odels)
Page 292 4C4-4 K TRUCK FRONT AXLE 22. Sleeve(s) (32) and side bearing (33) cups (right side only on K35). • Turn the sleeve(s) to push the bearing cup(s) out of the bore(s). Use J 36599 (figure 9). Shaft 32. Sleeve 23. Adjuster plug (61) with side bearing cup (33) and C D - 33.
Page 293 K TRUCK FRONT AXLE 4C4-5 Figure 3 — F ro n t A xle C om po n ents (K 35 M odels)
Page 294 4C4-6 K TRUCK FRONT AXLE 37. Ring and Pinion 1. Shaft Gears 2. D eflector 3. Seal 38. Shim 39. Bearing 4. Bearing 40. Spacer 5. Tube 41. Bearing 6. Bolt 7. T hrust W asher 42. Seal 43. D eflector 10.
Page 295 K TRUCK FRONT AXLE 4C4-7 T~ — 61. A d ju s te r Plug 63. B o lt 64. Lock F-5858 Figure 7— Removing the Pilot Bearing Figure 10—Turning the Adjuster Plug (K35 Models) Figure 8— Removing the Left Shaft J 3 65 9 9 F-5788 Figure 11 —...
Page 296 4C4-8 K TRUCK FRONT AXLE J 365 9 8-6 F-5861 F-5859 Figure 12— Removing the Pinion Flange Figure 15— Removing the Outer Pinion Bearing and Seal 39. B e aring C up F-5864 F-4696 Figure 17 — R em oving th e S ide B earings Figure 14 —...
Page 297: Cleaning And Inspection
K TRUCK FRONT AXLE 4C4-9 R E M O V A L J 3 6 6 1 6 IN S T A L L A T IO N J 3 6 6 1 6 F-5285 Figure 18— Removing the Pin (K15-25 Models) Figure 19—...
Page 298: Assembly Of Axle
4C4-10 K TRUCK FRONT AXLE SHIMS, THRUST WASHERS AND Sealing surface of the pinion flange for nicks, burrs, ADJUSTER SLEEVES or rough tool marks which would cause damage to the seals’ inside diameter and result in an oil leak. Inspect Replace all worn or broken parts.
Page 299: Pinion Depth Adjustment
K TRUCK FRONT AXLE 4C4-11 PINION INSTALLATION J 3 65 9 8-3 (K 1 5 -2 5 ) Install or C onnect (Figures 1 through 4 and 11, 23 and 24) Tools Required: J 35512 Bearing Installer (K15-25 Models) J 36614 Bearing Installer (K35 Models) J 8614-01 Pinion Flange Remover J 36333 Seal Installer 1.
Page 300 4C4-12 K TRUCK FRONT AXLE J 3 66 0 1 -4 (K 1 5-25 ) J 3 66 0 1 -3 (K 3 5) B u tto n L o ca te d In Bore B e aring S w u n g O u t o f Bore N ut W a sh er P ilo t...
Page 301 K TRUCK FRONT AXLE 4C4-13 Figure 25— Measuring Pinion Preload J 8 0 9 2 J 22761 (K 1 5 -2 5 ) J 2 9 7 1 0 (K 3 5 ) install them on the same side from which they were removed.
Page 302: Adjusting Backlash
4C4-14 K TRUCK FRONT AXLE J 365 9 9 F-5873 Figure 30— Installing the Side Bearing Cups 2. New O-ring (62) to the adjuster plug (61) (K35 models). 3. Sleeves (32) and/or adjuster plug (61) to the carrier case (29). F-5857 •...
Page 303 K TRUCK FRONT AXLE 4C4-15 J 8001-1 F-5874 F-5875 Figure 32— Measuring Backlash at the Pinion Flange Figure 31— Measuring Backlash at the Ring Gear 1. Refer to figures 1 through s p e c ific a tio n 0.13-0.18 2.
Page 304: Gear Tooth Contact Pattern Check
4C4-16 K TRUCK FRONT AXLE A test made without loading the gears will not give a satisfactory pattern. Turn the companion flange with a wrench so that the ring gear rotates one full revolution then reverse the rotation so that the ring gear rotates one revolution in the opposite direction.
Page 305: Axle Tube Assembly
K TRUCK FRONT AXLE 4C4-17 L O W F L A N K C O N T A C T D E C R E A S E P IN IO N S H IM T O E C O N T A C T IN C R E A S E B A C K L A S H H E E L C O N T A C T D E C R E A S E B A C K L A S H...
Page 306: Final Assembly
4C4-18 K TRUCK FRONT AXLE • If the figure obtained in step 5 was 3.53 mm, use a 3.30 mm shim. • If the figure obtained in step 5 was 3.30 mm, use a 2.70 mm shim (K15-25 models) or 2.80 mm shim (K35 models).
Page 307 K TRUCK FRONT AXLE 4C4-19 C. M easure w ith A xle S h a ft F orced O u tb o a rd 1. S h a ft 5. Tube 9. C a rrie r C o n n e c to r 23.
Page 308 4C4-20 K TRUCK FRONT AXLE MEASURING DIMENSION “ B” MEASURING DIMENSION “ A ” (K15-25 SHOWN) F-5878 Figure 38— Measuring to Calculate Shim Size Tighten Bolts ( ) to 40 N m (30 ft. lbs.). Inspect (Figure 40) • Shift mechanism operation. Insert a drift into the actuator hole in the axle tube.
Page 309: Drive Axle Assembly
K TRUCK FRONT AXLE 4C4-21 Figure 40— Checking the Shift Mechanism DRIVE AXLE ASSEMBLY OUTER DEFLECTING RING Tools Required: J 8059 Snap Ring Pliers REPLACEMENT J 35910 Seal Clamp Tool J 36652 Swage Clamp Tool Remove or Disconnect (Figures 41, 42 and 43) .
Page 310 4C4-22 K TRUCK FRONT AXLE Tri-pot H ousing A ssem bly Shaft Retaining Ring Tri-pot Joint S pider Needle R etainer Ring Needle Retainer Tri-pot Joint Ball Needle Roller Spacer Ring Swage, Ring . Tri-pot Joint Seal 15. Ball . Seal Retaining C lam p 16. C/V Joint Inner Race 17.
Page 311 K TRUCK FRONT AXLE 4C4-23 Install or Connect Small seal-retaining clam p ( ) on the neck of the new seal (13). Do not crimp. Slide the seal (13) onto the axle shaft ( 2) and position the neck of the seal in the seal groove on the axle shaft.
Page 312: Outer Joint Assembly Replacement
4C4-24 K TRUCK FRONT AXLE MAKE SURE SWAGE RING AND SWAGE SWAGE CLAMP SIZE CHART RING CLAMP ARE IN PROPER ALIGNMENT APPLICATION DESCRIPTION TOOL NO. K 10/20 Split Plate Swage Clamp J 36652-1 K 30 (Outboard) Split Plate Swage Clamp J 36652-2 K 30 (Inboard) Split Plate Swage Clamp...
Page 313: Inner Tri-Pot Seal Replacement
K TRUCK FRONT AXLE 4C4-25 Important Be sure that the retaining ring side of the inner race (16) face the axle shaft ( HAMMER Perforin steps 1 th rough 3 in “ O u te r J o in t Seal Replacem ent”...
Page 314 4C4-26 K TRUCK FRONT AXLE Shaft retaining ring (2) in the groove of the axle shaft SPIDER ASSEMBLY (12) with J 8059. Slide the tri-pot spider (3) towards the end of the shaft ) and reseat the spacer ring ( ) in the groove on the axle.
Page 315: Specifications
K TRUCK FRONT AXLE 4C4-27 Important Make sure that the seal (10), housing ( and swage ring (9) all remain in alignm ent (figure 47). — Continue to tighten each bolt 180° at a time, alternating until both sides are bottomed. •...
Page 316 4C4-28 K TRUCK FRONT AXLE & J 29307 J 36616 J 36612 J 22761 J 36613 J 29710 J 22888 J 8092 J 36609 J 8107-2 J 36597 J 29369-1 J3612-B J 29369-2 J 36606 J 33842 J 8614-01 J 34011 .
Page 317 K TRUCK FRONT AXLE 4C4-29 J 34037 J 35512 J 36614 J 34672 J 36366 J 36600 J 22833 J 36615 J 36598 J 34047-3 J 8001 J-36599 J 36601 ' ’ i U ) J 29763 J 35910 J 36603 19.
Page 318 «C4-30 K TRUCK FBOHT AXLE —...
Page 319 SECTION 5 BRAKES The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology NOTICE: See ‘Notice’ on page 5-1 of this section. NOTICE: This fastener is an important attaching part in that it could affect the performance of vital components and systems, and/or could result in major repair expense, It must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 320 5-2 BRAKES 16. Cover 17. Bracket 18. Nut 6. O-Ring 19. Boot 7. Spring 20. Pedal Rod 8. Housing 21. Pin 9. Bolt 22. Piston Assembly 10. Seal 23. Seal 27 26 24. Retainer 1. Retainer 11. Accumulator Valve 2. Accumulator 25.
Page 321 BRAKES 5-3 8. Housing B. 3.0 mm (0.125-inch) 11. Accum ulator Valve 57 mm (2.25*inches) A. W ire Hook F-00768 Figure 4— Removing the Accumulator Valve Figure 7— Installing the Piston Assembly & Tighten • Bolts to 30 N-m (22 ft. lbs.). 9.
Page 322: Master Cylinders
5 -4 BRAKES MASTER CYLINDERS Inspect COMPOSITE MASTER CYLINDER • Diaphragm for cuts, cracks, or a swollen condition. The Delco-Moraine Composite Master Cylinder has • Cylinder bore for scoring or corrosion. If corrosion is identifying information stamped into the front outlet tube. present, replace the cylinder.
Page 323 BRAKES 5-5 1. C over 2. D iap hrag m 3. R ese rvo ir 4. G ro m m e t 5. Q u ic k Take-Up Valve . S p rin g 7. S p rin g R e ta in e r .
Page 324: Bendix Master Cylinder
5-6 BRAKES Cover Diaphragm R e se rvo ir G rom m et Q uick Take-Up Valve Spring Spring R etainer Primary Seal Secondary Piston Secondary Seal Snap Ring Primary Piston A ssem bly 9. Tube seats (if removed). Body •...
Page 325 BRAKES 5-7 21. Bail 22. C over 23. D iap hrag m 24. B ody 25. S p rin g 26. S p rin g R e ta in e r 27. P rim a ry Seal 28. S e co n d a ry P isto n 29.
Page 326 BRAKES 5 - 8 4. Primary piston assembly (51) and snap ring (52). • The prim ary piston m ust be depressed to 24. Body install the snap ring. 25. Spring 28. Secondary Piston 5. O-ring (55) and springs (47). 30.
Page 327: Vacuum Boosters
BRAKES 5-9 Cover Diaphragm Filter Reservoir Compensating Valve Seal Valve Poppet Spring Secondary Spring Secondary Piston Piston Return Spring Primary Piston Snap Ring Body Bolts O-Ring F-00775 Figure 19— Bendix Master Cylinder Components VACUUM BOOSTERS Delco-Moraine Vacuum Boosters have a build date on a means 1986).
Page 328 5-10 BRAKES 1. B o o t 2. S i l e n c e r 3. V a c u u m c h e c k Valve 4. G r o m m e t F r o n t H o u s i n g S e a l .
Page 329: Tandem Diaphragm Vacuum Booster
BRAKES 5-11 F-05891 Figure 24— G aging th e P iston Rod 11. Front housing seal (5). 12. Silencer (2) and boot (1). • Gage the piston rod using J 22647 (figure 24). If not within limits, obtain a service adjustable piston rod. Lubricate the inside and outside diameters of the grommet and front housing seal with a thin layer of silicone.
Page 330 5-12 BRAKES B o ot S ile n c e r V acuum C h e ck Valve G ro m m e t F ro n t H o u s in g Seal P rim ary P isto n B earing Rear H o u s in g F ro n t H o u s in g R eturn S p rin g...
Page 331 BRAKES 5-13 P rim ary P isto n B earing Rear H o u s in g F ro n t H o u sin g R eturn S p rin g Pow er P iston G rou p P is to n Rod (Gaged) R e a c tio n R e ta in e r...
Page 332: Specifications
5-14 BRAKES A. D iap hrag m Lip 18. S e co n d a ry P isto n B earing 20. S e co n d a ry D iap hrag m 19. H o u s in g D ivid er 21.
Page 333: Special Tools
BRAKES 5-15 SPECIAL TOOLS J 2 2 6 4 7 J 2 3 4 5 6 J 2 4 5 5 1 -A J 2 6 8 8 9 J 2 5 0 8 3 J 6 2 1 7 1.
Page 335: General Engine Mechanical
SECTION 6 ENGINE CONTENTS S U B J E C T P A G E General Engine M e c h a n ic a l.................................6A- 1 2.5 Liter L 4 .....................................6A1- 1 2.8 Liter V 6 .....................................6A2- 1 4.3 Liter V 6 .....................................6A3- 1 4.8 Liter L 6 .....................................6A4- 1 V8 E n g in e .......................................
Page 336: General Information
6A-2 GENERAL ENGINE MECHANICAL GENERAL INFORMATION USING RTV SEALER STATEMENT ON 1. Do not use RTV when extreme temperatures are CLEANLINESS AND CARE expected, such as exhaust manifold, head gasket or where gasket eliminator is specified. • An engine is a combination of many machined, 2.
Page 337: M Easuring C Ylinder Bore T Ap Er And O Ut-Of-R Ound (All M O D E Ls )
GENERAL ENGINE MECHANICAL 6A-3 CYLINDER BORES, PISTONS, RINGS, AND CONNECTING RODS MEASURING CYLINDER BORE TAPER AND OUT-OF-ROUND (ALL MODELS) Tool Required: J 8087 Cylinder Bore Gage (or equivalent) • If one or more cylinder bores are rough, scored or worn beyond limits, it will be necessary to smooth or true up such bores to fit new pistons.
Page 338: Cylinder Bore Reconditioning (2.8 L Engines)
6A-4 GENERAL ENGINE MECHANICAL 6. If honing is not required, the cylinder bores should be cleaned with a hot water and detergent wash. Apply clean engine oil to the bore after cleaning. CYLINDER BORE RECONDITIONING (ALL EXCEPT L AND 2.8 L ENGINES) 1.
Page 339: Honing
GENERAL ENGINE MECHANICAL 6A-5 boring bar may be tilted which would result in the 6. By measuring the piston to be installed at the sizing rebored cylinder wall not being at right angles to the point specified in the proper section, and adding the crankshaft.
Page 340 6A-6 GENERAL ENGINE MECHANICAL 2. Connecting rod bearing inserts. If the inserts are to be reused, place them in a rack so they can be installed in their original connecting rod and cap. 3. Snap rings. Use snap ring pliers. 4.
Page 341 GENERAL ENGINE MECHANICAL 6A-7 CLEANING AND INSPECTION * 31 Clean Piston. — Remove all varnish and carbon deposits. DO NOT USE A WIRE BRUSH. M easure (Figures 8 and 10) — Remove the carbon from the ring grooves. Use Piston pin d ia m e te r (figu re 8). C heck a ga in st a ring groove cleaning tool.
Page 342: Piston Selection (2.5 L And 2.8 L Engines)
6A-8 GENERAL ENGINE MECHANICAL • R efer to “ S p e c ific a tio n s ” in the p ro p e r section. Determine if the piston clearance is in the acceptable range. 2. If the used piston is not acceptable, determine if a new piston can fit the cylinder bore.
Page 343 GENERAL ENGINE MECHANICAL 6A-9 • The piston must be installed with the piston crow n in d e n t on th e sam e side as th e connecting rod bearing tang slots (figure 14). 2. Piston pin. Apply engine oil to the pin and push into place.
Page 344 6A-10 GENERAL ENGINE MECHANICAL B-04979 Figure 16— Measuring Ring End Gap Inspect (Figures 17) Ring fit as follows: 1. Fit each compression ring to the piston on which it is going to be used. 2. Slip the outer surface of the top and second compression ring into the respective piston ring groove (figure 17), to make sure that the ring is free.
Page 345 GENERAL ENGINE MECHANICAL 6A-11 The top compression ring is a keystone type. The oil ring is a two-piece type, consisting of an expander and a scraper ring. 1^, M easure (Figures 7 and 16) Ring end gap as follows: 1. Select rings comparable in size to the piston being used.
Page 346: Camshaft Bearings
6A-12 GENERAL ENGINE MECHANICAL CAMSHAFT BEARINGS £3 )innm iiinnnnm >iinnm ini'ni| | ]u>m A. Bearing Tool A. Bearing Tool C. N ut B.05277 B. Driver H andle B. P ilo t D. P u lle r S crew B-05276 Figure 19— Removing or Installing the Inner Figure 20—...
Page 347: Hydraulic Lifter O V Erh A U
GENERAL ENGINE MECHANICAL 6A-13 1. Outer camshaft bearings. Drive the bearings into Holding the puller screw with a wrench, turn place using J 6098-01 (figure 20). the nut with a second wrench to pull the camshaft bearing into place. Im portant Remove the puller screw, pilot, and bearing tool.
Page 348 6A-14 GENERAL ENGINE MECHANICAL 2 2 3 2 2 5 2 2 7 2 30 221 djit ( — fL B dj • — ^ 2 24 2 2 6 2 28 221. L ifte r B ody 226. P lu n g e r 222.
Page 349: Valve Lifter Leak-Down Rate Test (Flat Type Lifters O N
GENERAL ENGINE MECHANICAL 6A-15 A. Screwdriver Figure 26— Removing the Check Ball Retainer (Typical) clean, lint-free shop rags. Work with clean hands, on a clean work surface. 1. Check ball (225) to the small hole in the bottom of the plunger (226). A.
Page 350: C Ylinder H E A
6A-16 GENERAL ENGINE MECHANICAL Adjust the ram (with the weight arm clear of the ram) so that the point is positioned on the set line (marked “ S” ). Tighten the jam nut to maintain the setting. Operate the lifter through full travel of the plunger by pumping the weight arm to fill the lifter with test fluid and force out air.
Page 351 GENERAL ENGINE MECHANICAL 6A-17 B-04519 Figure 30—Cleaning the Combustion Chambers Figure 32— Measuring Stem to Bore Clearance (Typical) (Typical) • Move the stem of the valve from side to side REPAIR using light pressure to obtain a clearance reading. If clearance exceeds specifications, it will be necessary to ream valve guide bores VALVE GRINDING for oversize valves as outlined later in this...
Page 352 6A-18 GENERAL ENGINE MECHANICAL Regardless of what type of equipm ent is used, however, it is essential that valve guide bores be free from carbon or dirt to ensure proper centering of the pilot in the guide. Refer to “’Specifications” in the proper section for valve seat angle specifications.
Page 353: Measuring Main Bearing C Le A Ra N C
GENERAL ENGINE MECHANICAL 6A-19 Figure 36— Reaming the Valve Guides (Typical) MEASURING MAIN BEARING CLEARANCE Main bearings are of the precision insert type and do not use shims for adjustment. If clearances are found to be excessive, new upper and lower inserts will be re quired.
Page 354: M Easuring Connecting Rod Bearing C Le A R A N C
6A-20 GENERAL ENGINE MECHANICAL 2. On the edge of the gaging plastic envelope there is a graduated scale. W ithout removing the gaging plastic, measure its compressed width (at the widest point) with the graduations on the gaging plastic en velope (figure 38).
Page 355 GENERAL ENGINE MECHANICAL 6A-21 A. Measure W idest Point of Gaging Plastic w ith Graduated Scale B-04997 Figure 39— Placing the Gaging Plastic on the Figure 40— Measuring the Gaging Plastic Connecting Rod Journal § M easure (Figure 40) sively out-of-round, interference between the •...
Page 356 6A-22 GENERAL ENGINE MECHANICAL SPECIAL TOOLS J 808 7 J 5 790 J 2 5 2 2 0 J 8 089 J 2 4 0 8 6 J 8101 J 2 9 1 3 4 -A J 8001 J 8 0 5 6 J 6098-01 J 2 9 6 6 4 1.
Page 357 6A1-1 SECTION 6A1 2.5 LITER L4 ENGINE CONTENTS SUBJECT PAGE D escription....................................6 A 1 - 2 Engine Lubrication.................................. 6 A 1 - 2 Disassembly of the E ngine..............................6 A 1 - 4 Tools and Shop Equipm ent..............................6 A 1 - 4 Accessory R em o val................................6 A 1 - 4 C le a n in g ....................................
Page 358: Subject Page
6A1-2 2.5 LITER L4 ENGINE CONTENTS (CONT.) SUBJECT PAGE Assembly of Engine Cont. Oil Pan Installation................................. 6A 1 -2 7 Oil Pump Driveshaft Installation............................6 A 1 -2 7 Cylinder Head Installation..............................6 A 1 -2 7 Valve Train Component Installation..........................6A 1-29 W ater Pump In s ta lla tio n ..............................
Page 359 2.5 LITER L4 ENGINE 6A1-3 A. O il P um p Drive G ear O ilin g B. O il P ressure S e n d in g U n it B-07950 Figure 1— Engine Lubrication Diagram...
Page 360: Disassembly Of The Engine
6A1-4 2.5 LITER L4 ENGINE DISASSEMBLY OF THE ENGINE 17. Cylinder Head Gasket 34. Valve Stem Oil Shield 1. Outer Engine Heat Stove 18. Intake Valve 35. Valve Spring 2. Bolt 19. Exhaust Valve 36. Intake Valve Stem Seal 3. Stud 37.
Page 361 2.5 LITER L4 ENGINE 6A1-5 Figure 3 — C ylinder H ead, M anifolds, and C om po n ents...
Page 362: Intake Manifold Removal
6A1-6 2.5 LITER L4 ENGINE 102. F ro n t C over 50. Push Rod Cover 77. O il P um p 103. S crew 51. Piston and Pin 78. N u t 104. C a m s h a ft G ear 52.
Page 363 2.5 LITER L4 ENGINE 6A1-7 F-05715 Figure 5 — Block and C om ponents...
Page 364 6A1-8 2.5 LITER L4 ENGINE 37. W a sh er 38. B o lt 42. S tud 43. In ta ke M a n ifo ld 44. G a sket F-01984 Figure 6— Intake Manifold Components 2. B o lt 3.
Page 365: Valve Train Component R Em Oval
2.5 LITER L4 ENGINE 6A1-9 A. 22 mm (7/s") B. 55 mm (21 /s") C. 4 0 m m ( 1 1 /2") D. 10 mm (3/a") 25 mm (1") Deep Holes for Pushrods E. 22 mm (7/s") Drill 25 mm (1") Deep Holes for Valve Lifters VALVE TRAIN COMPONENT...
Page 366: Cylinder Head Removal
6A1-10 LITER L4 ENGINE 2 .5 31. Bolt 32. Rocker Arm Ball 17. Head Gasket 33. Rocker Arm 24. Cylinder Head 45. Push Rod Guide 25. Head Bolt (Stud) 47. Push Rod 27. Head Bolt F-01989 F-01991 Figure 13— Cylinder Head Components Figure 11—...
Page 367: Oil Pan Removal
2.5 LITER L4 ENGINE 1 - 1 1 89. Key 94. Bolt 95. Crankshaft 96. Bolt 97. Crankshaft 98. Bolt 99. Washer 100. Crankshaft F-01992 Figure 14— Timing Gear Cover and Components OIL PAN REMOVAL PISTON AND CONNECTING ROD REMOVAL R em ove or D isconnect (Figure 5) Rem ove or D isconnect (Figures 5, 16 and 17) 1.
Page 368: Flywheel R E M O V A
2.5 LITER L4 ENGINE 1 - 1 2 markings, to insure proper reassembly. Use a silver pencil to mark the parts if necessary. • To avoid mismatching the connecting rods and c o n n e c tin g rod ca p s, rem ove o n ly one connecting rod cap at a time.
Page 369: Crankshaft Rear Oil Seal Removal (Without Removing Crankshaft)
2.5 LITER L4 ENGINE 6A1-13 CRANKSHAFT REAR OIL SEAL REMOVAL (WITHOUT REMOVING CRANKSHAFT) ■ ' R em ove or D isconnect (Figure 5) NOTICE: Care m u st be taken n o t to d am ag e the crankshaft outsid e d ia m e te r surface w ith the pry tool.
Page 370: Cleaning, Inspection, And Repair
6A1-14 2.5 LITER L4 ENGINE T im in g M arks C ra n k s h a ft G ear T h ru s t Plate B o lts C a m s h a ft G ear T h ru s t Plate C a m sh a ft F-05719 Figure 21 —...
Page 371: Cylinder Bores
2.5 LITER L4 ENGINE 6A1-15 Figure 22—Checking the Block Gasket Surface must be flat within 0.10 mm (0.004-inch) to assure that the gasket will provide a tight seal between the cylinder head and the block. A. Bore G a g in g P oint CYLINDER BORES B.
Page 372: Intake And Exhaust Manifold
6A1-16 2.5 LITER L4 ENGINE 108. C a m s h a ft F-01998 Figure 25— Measuring Camshaft Journal Runout Figure 27— Measuring Camshaft Thrust Plate Clearance (Camshaft End Play) INTAKE AND EXHAUST journals. If runout exceeds 0.020-inch, the camshaft MANIFOLDS is excessively bent and should be replaced, along with the camshaft bearings.
Page 373: Camshaft Bearings
2.5 LITER L4 ENGINE 6A1-17 A. A rb o r Press B. Press Tool 104. C a m s h a ft G ear 105. T h ru s t Plate 108. C a m s h a ft F-02027 Figure 29—...
Page 374: Water P U M
6A1-18 2.5 LITER L4 ENGINE 77. P um p B o dy 79. S p rin g R e ta in in g 80. S p rin g 81. C over S cre w s 82. C over 83. C over G a sket 85.
Page 375: Valve Train Components
2.5 LITER L4 ENGINE 6A1-19 Drive gear and shaft (128) for looseness in the pump VALVE TRAIN COMPONENTS body (77). Inside of the cover (82) for wear that would permit oil PUSHRODS, PUSHROD GUIDES, to leak past the ends of the gears. ROCKER ARMS AND BALLS T he pum p g e a rs and b od y are not s e rv ic e d separately.
Page 376 6A1-20 2.5 LITER L4 ENGINE 18. In ta ke Valve 19. E xh a u st Valve 28. Valve S p rin g Cap 29. Valve S tem O il Seal 30. Valve K eepers 34. Valve S tem O il S h ield 35.
Page 377: Thermostat And Housing
2.5 LITER L4 ENGINE 6A1-21 Make sure that the keepers seat properly in the groove. Repeat the preceding steps on the remaining valves. Check each valve seal using J 22330. Wet the suction cup portion of the tool lightly with engine oil.
Page 378: Assembly Of Engine
6A1-22 2.5 LITER L4 ENGINE • Mount the crankshaft in V-blocks or between centers. • Use a dial indicator as shown. • If the main bearing journals are misaligned, the crankshaft is bent and must be replaced along with the main bearings. B-02792 Figure 38—...
Page 379 2.5 LITER L4 ENGINE 6A1-23 A lig n m e n t H o le in C ra n k s h a ft D u st Lip D ow el Pin C o lla r M andrel S cre w s C ra n k s h a ft Rear O il Seal F-02029 71.
Page 380: Main Bearing Installation (Without Removing The Crankshaft)
6A1-24 2.5 LITER L4 ENGINE T im in g M arks MAIN BEARING INSTALLATION C ra n k s h a ft Gear (WITHOUT REMOVING THE T h ru s t Plate B o lts CRANKSHAFT) C a m s h a ft G ear T h ru s t Plate C a m sh a ft Install or C onnect (Figures 5 and 42)
Page 381: Crankshaft Pulley Hub Installation
2.5 LITER L4 ENGINE 6A1-25 CRANKSHAFT PULLEY HUB INSTALLATION -► <- Install or C onnect (Figures 5 and 47) 1. Crankshaft pulley and hub. Slide the hub on the crankshaft until it bottoms against the crankshaft gear. 2. Bolt (98) and washer (99). T ighten Hub retaining bolt to 220 N-m (160 ft.
Page 382: Oil Pump Installation
6A1-26 2.5 LITER L4 ENGINE 89. Key 94. Bolt 95. Crankshaft 96. Bolt 97. Crankshaft 98. Bolt 99. Washer 100. Crankshaft F-01992 Figure 47—Timing Gear Cover and Components FINAL ASSEMBLY OIL PUMP INSTALLATION Install or C onnect (Figure 5) Install or C onnect (Figure 5) •...
Page 383: Oil Pan Installation
2.5 LITER L4 ENGINE 6A1-27 T ighten • Oil pan bolts to 10.0 N m (90 in. lbs.). OIL PUMP DRIVESHAFT INSTALLATION Install or C onnect (Figures 5 and 52) 1. Shaft and gear assembly (115 and 114). Turn the shaft until it indexes the oil pump shaft pilot properly in the oil pump body.
Page 384 6A1-28 2.5 LITER L4 ENGINE • Cylinder head bolts should be washed in solvent and dry at the time of installation. All residual oil should be wiped from the cylinder head mating surfaces. • C oat the th re a d s of b o lt 9 w ith se a lin g c o m p o u n d (P a rt N u m b e r...
Page 385: Valve Train Component Installation
2.5 LITER L4 ENGINE 6A1-29 A. A p p ly A C o n tin u o u s (5 m m 3/ie -ln ch ) D ia m e te r Bead O f RTV A s S h ow n B-07963 Figure 56—...
Page 386: Thermostat Housing Installation
6A1-30 2.5 LITER L4 ENGINE INTAKE MANIFOLD INSTALLATION “►+ Install or C onnect (Figure 59) 1. Gasket. • Apply sealant to the bolts indicated in figure 59. 2. Intake manifold. 3. Intake manifold bolts and washers. T ighten • Intake manifold bolts to 34 N-m (25 ft. lbs.). 4.
Page 387 2.5 LITER L4 ENGINE 6A1-31 37. W a sh er 38. B o lt 42. S tud 43. In ta ke M a n ifo ld 44. G a sket F-01984 Figure 59— Intake Manifold Installation Tightening Sequence T ig h te n b o lts in n u m b e r s e q u e n c e as sh ow n. Or, “...
Page 388 6A1-32 2.5 LITER L4 ENGINE 5. Listen for improperly adjusted valves or sticking 2. Fill the crankcase with the proper quantity and lifters, or other unusual noises. grade of oil. Refer to the proper Truck Service 6. Check for oil and coolant leaks while the engine is Manual or Ow ner’s and Driver’s Manual for this running.
Page 389: Engine Specifications
2.5 LITER L4 ENGINE 6A1-33 SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherwise noted. GENERAL DATA: Type Displacement 2.5L Bore 4.00 Stroke 3.00 Compression Ratio 8.3:1 Firing Order 1-3-4-2 Oil Pressure 36-41 psi 2000 RPM CYLINDER BORE: Diameter 4.000 Out Of Round 0.001 (Maximum)
Page 390 6A1-34 2.5 LITER L4 ENGINE SPECIFICATIONS (CONT.) ENGINE SPECIFICATIONS (CONT.) All specifications are in INCHES unless otherwise noted. CRANKSHAFT: Diameter 2.300 0.0005 Main Taper 0.0005 Journal Out of Round 0.0005-0.0022 Main Bearing Clearance 0.0035-0.0085 Crankshaft End Play 2.000 Diameter 0.0005 Crankpin Taper 0.0005...
Page 391 2.5 LITER L4 ENGINE 6A1-35 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS In. Lbs. Item Ft. Lbs. Main Bearing Cap B o lt s ........................88 Connecting Rod N u t s ......................... 40 Oil Pan Bolts (A ll)..........................10.0 — Oil Pump to Block B o lt s ........................25 Oil Pickup Tube N u t........................
Page 392 6A1-36 2.5 LITER L4 ENGINE SPECIAL TOOLS J -2 1 882 J-8 0 37 J-3 4 9 9 5 J -3 4 1 4 4 -A J-8 0 8 0 J -3 4 9 2 4 -A J-8 0 6 2 J-2 2 3 3 0 J -3 3 0 4 9 J -3 0 4 9...
Page 393 6A2-1 SECTION 6A2 2.8 LITER V-6 CONTENTS S U B J E C T P A G E D escription....................................6 A 2 - 2 Engine Lubrication.................................. 6 A 2 - 2 Disassem bly....................................6 A 2 - 6 Tools and Shop Equipm ent..............................6 A 2 - 6 Accessory R em o val................................6 A 2 - 6 C le a n in g ....................................
Page 394 6A2-2 2.8 LITER V-6 CONTENTS (CONTINUED) S U B J E C T P A G E Assembly of Engine (Continued) Torsional Damper Installation.............................6A2-21 Piston and Connecting Rod In s ta lla tio n .........................6 A 2-22 Oil Pump Installation ................................6A 2-23 Oil Pan Installation.................................
Page 395 2.8 LITER V-6 6A2-3 Figure 1— Engine Lubrication Diagram...
Page 396 6A2-4 2.8 LITER V-6 Figure 2 — Engine Lubrication Diagram...
Page 397 2.8 LITER V-6 6A2-5 A. L u b ric a tio n B e g in s B. 189° D u ra tio n O f L u b ric a tio n C. End O f L u b ric a tio n D.
Page 398: Disassembly
6A2-6 2.8 LITER V-6 B-09312 Figure 4— Engine Lubrication Diagram DISASSEMBLY ACCESSORY REMOVAL TOOLS AND SHOP EQUIPMENT This manual assumes that the engine accessories have A clean, well lit work area should be available. Other been removed. These accessories may include one or necessary equipm ent includes: A suitable parts cleaning more of the following: tank, compressed air supply, trays to keep parts and...
Page 399: Cleaning
2.8 LITER V-6 6A2-7 Figure 5— Air Injection Tube Figure 6— EGR Valve CLEANING EGR VALVE REMOVAL Remove the engine accessories before cleaning, to Rem ove or D isconnect (Figure 6) provide better access to engine exterior surfaces. After removing the TBI unit, distributor, etc., cover the openings 1.
Page 400: Valve Train Component Removal
6A2-8 2.8 LITER V-6 Figure 7— Exhaust Manifold Installation 1. Nuts (6), balls (8), rocker arms (7), and pushrods (9). VALVE TRAIN COMPONENT • Every effort should be made to insure that REMOVAL these m ating parts are installed in th e ir original locations during assembly.
Page 401: Front Cover And W Ater Pump R Em O Val
2.8 LITER V-6 6A2-9 Figure 11— Removing the Hydraulic Lifter (Typical) FRONT COVER AND WATER PUMP REMOVAL 6. N u ts 7. R o cke r A rm s |+ + | Rem ove or D isconnect 8. B a lls 9.
Page 402: Camshaft Removal
6A2-10 2.8 LITER V-6 A. F ro n t 40. B o lt 41. O il P um p 42. S h a ft F-6523 Figure 12— Oil Pump Installation Figure 13— Replacing the Camshaft (Typical) 3. Connecting rod and piston (figure 15). CAMSHAFT REMOVAL •...
Page 403: Crankshaft Removal
2.8 LITER V-6 6A2-11 Figure 15— Replacing the Piston and Connecting Rod (Typical) A. F ro n t FLYWHEEL REMOVAL 85. B o lt 86. M ain B e aring Cap R em ove or D isconnect 87. B earing In s e rt 88.
Page 404: Cleaning, Inspection, And Repair
6A2-12 2.8 LITER V-6 Figure 17— Removing or Installing the Main Bearing Insert CLEANING, INSPECTION, AND REPAIR — The area where the main bearing inserts A solvent tank, large enough to hold the larger engine parts, will be needed along with various bristle brushes contact the main bearing bore should be and a gasket scraper.
Page 405: Piston And Connecting Rod Assemblies
2.8 LITER V-6 6A2-13 PISTON AND CONNECTING ROD ASSEMBLIES Refer to GENERAL ENGINE MECHANICAL (SEC. 6A) and perform the following: Disassem ble Components as required. |m j| Clean Components as outlined. Inspect Components as outlined. € M easure Piston pin diameter and clearance. Piston to bore clearance, and fit the pistons.
Page 406: Camshaft
6A2-14 2.8 LITER V-6 Figure 19—Checking the Camshaft Journals CAMSHAFT Im portant Whenever the camshaft needs to be replaced, a new set of lifters must also be installed. Inspect Camshaft lobes and journals for scratches, pitting, scoring, and wear. M easure Camshaft journal diameter (figure 19).
Page 407: Water P U M
2.8 LITER V-6 6A2-15 Install or C onnect Tool Required: J 35468, Seal Installer New seal so that the open end of the seal is toward the inside of the cover. — Drive the seal into position with J 35468. —...
Page 408: Valve Train Components
6A2-16 2.8 LITER V-6 Figure 22— Installing the Oil Pump Screen • Pushrods for bending. Roll the pushrod on a flat Tighten surface to dete rm ine if it is bent. R eplace if • Screws to 9.0 N-m (80 in. lbs.). necessary.
Page 409 2.8 LITER V-6 6A2-17 20. In ta ke Valve 21. E xh a u st Valve 22. Valve K eepers 23. Valve Cap 24. O il S h e d d e r 25. Seal 26. O -R ing B-09551 Figure 23—...
Page 410: Thermostat And Water O U Tle
6A2-18 2.8 LITER V-6 " j | | | | | i ' | | i | | u , | ' i l i | i ' j l | l | | i | | " l | i | i | | r rTTr 3_______ _______ A.
Page 411 2.8 LITER V-6 6A2-19 • Crankshaft run-out. • Mount the crankshaft in V-blocks or between centers. • Use a dial indicator. • If the main journals are misaligned more than 0.025 mm, the crankshaft is bent and must be replaced, along with the main bearing. Figure 28—...
Page 412: Rear Crankshaft Oil Seal Installation
6A2-20 2.8 LITER V-6 A. A lig n m e n t H o le In C ra n k s h a ft 7. Main bearing caps with arrows pointing toward the B. D ust Lip front of the engine. C.
Page 413: Camshaft, Timing Chain And Sprocket Installation
2.8 LITER V-6 6A2-21 be replaced to insure durability of the camshaft lobes and lifter feet. T. Camshaft. Im portant • All camshaft bearing journals are the same d ia m e te r and care m ust be exercised in in s ta llin g th e c a m s h a ft to avoid b e a rin g damage.
Page 414: Piston And Connecting Rod Installation
6A2-22 2.8 LITER V-6 The torsional damper has three timing notches on the inertia ring. The number one cylinder timing reference ENGINE LEFT ENGINE FRONT ENGINE RIGHT mark will be identified by a dab of white paint. If a new dam per assembly is installed, mark the new assembly in the same place for future reference.
Page 415: Oil Pump Installation
2.8 LITER V-6 6A2-23 numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore. If a connecting rod is ever transposed from one block or cylind er to another, new connecting rod bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder number.
Page 416: Valve Train Component Installation
6A2-24 2.8 LITER V-6 Figure 40— Rocker Arms and Pushrods VALVE TRAIN COMPONENT A. Apply Sealer Here INSTALLATION 35. Bolts 36. Bolts If lifter replacement is necessary, use new lifters with a 37. Reinforcements narrow flat along the lower of the body length. This 38.
Page 417: Valve Adjustment
2.8 LITER V-6 6A2-25 INTAKE MANIFOLD INSTALLATION Install o r C onn ect (F igure 42) 1. RTV to the front and rear sealing surfaces on the block. Apply a 5 mm (3/ie-inch) bead of RTV (part number 1052917 or equivalent) to the front and rear of the block as shown.
Page 418: Exhaust Manifold Installation
6A2-26 2.8 LITER V-6 Apply Sealer Here Nuts Reinforcements 4. Gasket Rocker Arm Cover 5. Studs B-09303 Figure 43— Rocker Arm Cover Installation EXHAUST MANIFOLD INSTALLATION Clean Mating surfaces of the manifold and cylinder head. +«- Install or C onnect (Figure 44) 1.
Page 419: Air Injection Tube Installation
2.8 LITER V-6 6A2-27 Figure 44— Exhaust Manifold Installation AIR INJECTION TUBE Im portant INSTALLATION • If a new camshaft or hydraulic lifters were installed, add Engine Oil Supplem ent (GM Part No. 1051396) or equivalent to the engine -► <- Install or C onnect (Figure 5) oil.
Page 420 6A2-28 2.8 LITER V-6 SPECIFICATIONS ENGINE SPECIFICATIONS All S p e c ific a tio n s a re in M ILLIM E TER S un less o th e rw is e n o te d . GENERAL DATA: 6 0 °...
Page 421 2.8 LITER V-6 6A2-29 SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) All specifications are in M IL L IM E T E R S unless otherw ise noted. C R A N K S H A FT D ia m e te r - 3 D ots 67.241-67.249 D ia m e te r - 2 D ots 67.249-67.257...
Page 422 6A2-30 2.8 LITER V-6 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Ft. Lbs. Item Rocker Arm Cover B o lts ..................................Intake Manifold Bolts..............Exhaust Manifold B o lts........................Cylinder Head B o lts ..........................Torsional Damper Bolt........................... Timing Chain D am per................
Page 423: Special Tools
2.8 LITER V-6 6A2-31 SPECIAL TOOLS J-3 0 4 9 J-9290-1 J-5 5 9 0 J -2 3 5 2 3 -E J-5 8 2 5 -A J -2 4 4 2 0 -B J -8 0 6 2 J-2 9 1 1 3 J-8 0 3 7 J-34686 J-8 0 8 0...
Page 424 6A2-32 2.8 LITER V-6...
Page 425 6A3-1 SECTION 6A3 4.3 LITER V-6 ■ j * * * CONTENTS SUBJECT PAGE D escription... * ..................................6 A 3 - 2 Engine Lubrication..................................6 A 3 - 2 Disassem bly....................................6 A 3 - 5 Tools and Shop Equipm ent..............................6 A 3 - 5 Accessory R em o val................................6 A 3 - 5 C le a n in g ....................................
Page 426 6A3-2 4.3 LITER V-6 CONTENTS SUBJECT PAGE Assembly of Engine (Continued) Front Cover Installation................................ 6A 3 -1 8 Torsional Damper Installation.............................6A 3 -1 8 Piston and Connecting Rod In s ta lla tio n .........................6A 3 -2 0 Oil Pump Installation ................................6A3-21 Oil Pan Installation.................................
Page 427 4.3 LITER V-6 6A3-3 ---------------------------------------------------- B-07857 Figure 1— Engine Lubrication Diagram...
Page 428 6A3-4 4.3 LITER V-6 A. Regulator Valve (Shown In Open Position) B. Suction C. Oil Pressure Switch D. Valve Lifter Gallery E. Main Oil Gallery F. Bypass Valve Front View Front View Rear View Showing Path Of Oil To Tinning Chain. Showing Main Gallery, Oil Filter And Crankshaft Oil Feed.
Page 429: Disassembly
4.3 LITER V-6 6A3-5 DISASSEMBLY Cooling Fan Distributor Carburetor TBI Unit It is beyond the scope of this section to detail the many different accessory installations. Refer to the proper Truck Service Manual for this information. Diagrams of emission and vacuum hose routings, wiring harness routing, accessory drive belt layout, etc., should be made before removing accessories.
Page 430: Rocker Arm Cover Removal
6A3-6 4.3 LITER V-6 40. Bolt 41. Retainer 42. Nuts 43. Balls 44. Rocker Arms 45. Pushrods 46. Restrictor 47. Hydraulic Lifter B-07611 Figure 4— Valve Train Components VALVE TRAIN COMPONENT ROCKER ARM COVER REMOVAL REMOVAL 4- + Rem ove or D isconnect (Figure 3) R em ove or D isconnect (Figure 4) 1.
Page 431: Cylinder Head Removal
4.3 LITER V-6 6A3-7 CYLINDER HEAD REMOVAL R em ove or D isconnect 1. Spark plugs. 2. Cylinder head bolts. 3. Cylinder heads. 4. Head gaskets. TORSIONAL DAMPER REMOVAL |<--»| R em ove or D isconnect (Figure 5) Tool Required: 70.
Page 432: Piston And Connecting Rod Removal
6A3-8 4.3 LITER V-6 87. T h ru s t Plate 88. S crew B-07615 Figure 7— Camshaft and Components • Place a cloth on top of the piston. PISTON AND CONNECTING ROD • Perform the cutting operation with a ridge REMOVAL reamer (figure 9).
Page 433: Flywheel Removal
4.3 LITER V-6 6A3-9 CRANKSHAFT REMOVAL Rem ove or D isconnect • Check the main bearing clearance before removing the crankshaft. Refer to “ C rankshaft and Main Bearing Installation” later in this section. • The main bearings and rear oil seal can be replaced Figure 10—...
Page 434: Main Bearing Removal (Without Removing C Ra N K S H A
6A3-10 4.3 LITER V-6 MAIN BEARING REMOVAL (WITHOUT REMOVING CRANKSHAFT) +-► Rem ove or D isconnect Tool Required: J 8080, Main Bearing Remover/Installer 1. Main bearing caps. • Check the main bearing caps for location markings. Mark the caps if necessary. The caps m ust be retu rne d to th e ir o rig in a l locations during assembly.
Page 435: Intake And Exhaust Manifolds
4.3 LITER V-6 6A3-11 M easure Alignm ent of manifold flanges. Use a straight edge and feeler gage. If the flanges do not align, the Piston pin diameter and clearance. manifold is warped and should be replaced. Piston to bore clearance, and fit pistons as outlined. Assem ble CAMSHAFT Components as outlined.
Page 436: Front Cover
6A3-12 4.3 LITER V-6 Install or C onnect Tool Required: J 35468, Seal Installer New seal so that the open end of the seal is toward the inside of the cover. — Drive the seal into position with J 35468. —...
Page 437: Valve Train Components
4.3 LITER V-6 6A3-13 N O TIC E: Be c a re fu l o f tw istin g , sh earin g or collapsing the p ip e w hile installing the p um p. 7. Pickup screen and pipe (if removed) (figure 18). •...
Page 438 6A3-14 4.3 LITER V-6 CLEANING AND INSPECTION OF COMPONENTS 20. Valve K eeper 26. S p rin g Refer to GENERAL ENGINE MECHANICAL (SEC. 6A) 21. Cap 27. In ta ke Valve and perform the following. 22. S h ie ld 28.
Page 439 4.3 LITER V-6 6A3-15 B-03491 Figure 23— Ream ing the R ocker Arm S tud Bore 1. Valves (27 and 29). • Lubricate the valve stems with engine oil. • Insert the valves into the proper seats. 2. Seal (24) (intake valve only). •...
Page 440: Thermostat And Water Outlet
6A3-16 4.3 LITER V-6 • C om press the valve spring using J 8062 (figure 20). Compress the spring enough so the lower valve stem groove can be seen clearly. • Push a new O-ring seal (23) onto the valve stem.
Page 441: Rear Crankshaft Oil Seal Retainer In S Ta Lla Tio
4.3 LITER V-6 6A3-17 ASSEMBLY OF ENGINE PRIOR TO ASSEMBLY The importance of cleanliness during the assembly pro ced ure cannot be overstressed. Dirt w ill cause premature wear of the rebuilt engine. Lubricate all moving parts lightly with engine oil or engine assembly lubricant (unless specified otherwise) during assembly.
Page 442: Rear Crankshaft Oil Seal Installation
6A3-18 4.3 LITER V-6 • T ig h te n th e s c re w s s e c u re ly w ith screwdriver. This will ensure that the seal is A. Rear o f Block installed squarely over the crankshaft. 80.
Page 443 4.3 LITER V-6 6A3-19 87. T h ru s t Plate 88. S crew B-07615 Figure 29— C am shaft and C om ponents N O T IC E : The in e rtia w e ig h t s e c tio n o f th e torsional d a m p e r is assem b led to the hub with ru b b e r type m aterial.
Page 444: Piston And Connecting Rod In S Ta Lla Tio
6A3-20 4.3 LITER V-6 A. Oil Ring Rail Gaps B. 2nd Com pression Ring Gap Notch In Piston D. Oil Ring Spacer Gap (Tang In H ole O r Slot W ith Arc) E. Top Com pression Ring G ap B-07895 Figure 33—...
Page 445: Oil Pump Installation
4.3 LITER V-6 6A3-21 Locate the piston ring end gaps as shown in figure 33. Lubricate the piston and rings with engine oil. W ithout disturbing the ring end gap location, install J 8037 over the piston (figure 34). The piston must be installed so that the notch in the piston faces the front of the engine (figure 33).
Page 446 6A3-22 4.3 LITER V-6 ...... . „ , ......— — A -F orw ard 70. G asket 71. R e in fo rc e m e n t B -Sealant F-04488 Figure 3 7 — Oil Pan Installation...
Page 447: Valve Train Component Installation
4.3 LITER V-6 6A3-23 (Even numbered cylinders are in the right bank; odd num bered cylinders are in the left bank, when viewed from the rear of the engine). 3. Back out the adjusting nut until lash is felt at the pushrod then turn in the adjusting nut until all lash is removed.
Page 448: Egr Valve Installation
6A3-24 4.3 LITER V-6 Bolt Retainer Nuts 43. Balls 44. Rocker Arms 45. Pushrods 46. Restrictor 47. Hydraulic Lifter B-07611 Figure 39— Valve Train C om ponents FLYWHEEL INSTALLATION • Bolts on front and rear exhaust tubes to 28 N m (20 ft. lbs.). -►+ Install or Connect •...
Page 449 4.3 LITER V-6 6A3-25 V IE W A V IE W B C. Port B lo c k in g Plate D. RTV S ealant F-05521 Figure 40— Intake Manifold Installation ENGINE SET-UP AND TESTING 1. After overhaul, the engine should be tested before installation in the vehicle.
Page 450 6A3-26 4.3 LITER V-6 installed, add Engine Oil Supplement (GM part no. 1051396) or equivalent to the engine oil. 3. Fill the cooling system with the proper coolant. 4. With the ignition “ OFF,” or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
Page 451 4.3 LITER V-6 6A3-27 SPECIFICATIONS ENGINE SPECIFICATIONS F-6344...
Page 452 6A3-28 4.3 LITER V-6 SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) All specifications are in INCHES unless otherwise noted. 4.3L DISPLACEMENT: CRANKSHAFT: 2.4484-2.4493 2.4481-2.4490 Diameter #2, #3 2.4479-2.4488 0.0002 (Maximum) Main Production Taper Journal Service Limit 0.001 (Maximum) Production 0.0002 (Maximum) Out Of 0.001 (Maximum) Round Service Limit...
Page 453 4.3 LITER V-6 6A3-29 SPECIFICATIONS (CONTINUED) TORQUE SPECIFICATIONS FT. LBS. IN. LBS. ITEM < • ....10.2 — Rocker Arm Cover Bolts ........... — Intake Manifold B o lts ............Exhaust Manifold Bolts ......— .Center Two B o lts............—...
Page 454 6A3-30 4.3 LITER V-6 SPECIAL TOOLS J-5715 J-6036 J-8062 J-6880 J-35468 . T orsion al D am pe r R em over and In s ta lle r . S tu d R em over . Valve S p rin g C o m p re s s o r 9.
Page 455 6A4-1 SECTION 6A4 4.8 LITER L6 CONTENTS S U B J E C T P A G E Description....................................6 A 4 - 2 Disassembly....................................6 A 4- 4 Tools and Shop Equipm ent..............................6 A 4- 4 Accessory R em oval................................6 A 4 - 4 C le a n in g ....................................
Page 456: Description
6A4-2 4.8 LITER L6 CONTENTS (CONTINUED) S U B J E C T P A G E Assembly of Engine (Cont.) Oil Pan Installation................................. 6 A 4 -2 8 Cylinder Head In stallation..............................6 A 4 -2 9 Valve Train Component Installation..........................6 A 4 -2 9 Valve Adjustm ent..................................6 A 4 -2 9 Checking Valve T im in g ................................
Page 457 4.8 LITER L6 6A4-3 Figure 2 — Lubrication D iagram (F ro n t V iew )
Page 458: Disassembly
6A4-4 4.8 LITER L6 DISASSEMBLY 41. S tud 21. P ushrod . O il Cap 42. In ta ke Valve 22. B o lt . C lip 43. E xh a u st Valve 3. S crew 23. B o lt 44.
Page 459 4.8 LITER L6 6A4-5 13 9 sT/iM-V" le-JsJ 1 1 K ^ V * 7 B-07997 Figure 4 — C ylin d er H ead, M anifolds, and C om po n ents...
Page 460 6A4-6 4.8 LITER L6 112 f K ' 108 «^109 ‘165 1 2 9-^ © ,/ B-05056 Figure 5 — Block and C om ponents...
Page 461 4.8 LITER L6 6A4-7 145. B o lt 93. S crew 146. O il Pan 94. C a m s h a ft G ear 147. F ro n t O il Pan Seal 95. T h ru s t Plate 148.
Page 462: Draining The Engine
6A4-8 4.8 LITER L6 182. Air Manifold 183. Air Injection Tube 184. Valve B-05058 Figure 8— AIR Manifold Installation Figure 7— AIR System Components DRAINING THE ENGINE Rem ove or D isconnect (Figure 5) — Oil pan drain plug (144). Allow the oil to drain. —...
Page 463: Thermostat Housing Removal
4.8 LITER L6 6A4-9 r O r * ------ ► © > o A. 22 mm (7/a”) B. 55 mm (2-1 /a” ) C. 40 mm (1-V2” ) D. 10 mm (3/8” )drill 25 mm (1” )deep Holes for Pushrods E.
Page 464: Cylinder Head Removal
6A4-10 4.8 LITER L6 Figure 15— Removing the Torsional Damper CYLINDER HEAD REMOVAL □ Rem ove or D isconnect (Fig ure 4) 1. Bolts (21). 2. Cylinder head (26). Use care when handling the B-05064 cylinder head to prevent damage to the gasket surfaces.
Page 465: Piston And Connecting Rod Removal
4.8 LITER L6 6A4-11 • Using the m anufacturer’s directions, install a ridge reamer into the top of the cylinder (figure 16). Perform the cutting operation. • After the ridge and/or deposits are removed, remove the ridge reamer. Turn the crankshaft until the piston is at the top of its stroke.
Page 466: Crankshaft Removal
6A4-12 4.8 LITER L6 Figure 18— Flywheel Installed Figure 19— Removing the Lower Seal Half 4. Bolts (122). CRANKSHAFT REAR OIL SEAL REMOVAL (WITHOUT 5. Flywheel (118). REMOVING CRANKSHAFT) CRANKSHAFT REMOVAL 4 -+ Rem ove or D isconnect (Figures 5, 19, and 20) The main bearings and rear oil seal can be replaced 1.
Page 467: Camshaft Removal
4.8 LITER L6 6A4-13 • Use a small brass drift and hammer. Tap on the insert, on the side opposite the bearing tang, until the insert rotates out of position (figure • Use a pair of pliers with the jaws taped to prevent damage to the crankshaft.
Page 468: Cleaning, Inspection, And Repair
6A4-14 4.8 LITER L6 93. Screw 94. Camshaft Gear B-05068 Figure 23— Camshaft Thrust Plate Screws CLEANING, INSPECTION, AND REPAIR The area where the main bearing inserts (130, A solvent tank, large enough to hold the larger engine 133, 136, and 153) contact the main bearing parts, will be needed along with various bristle brushes bore should be smooth.
Page 469: Cylinder Bores
4.8 LITER L6 6A4-15 PISTON AND CONNECTING ROD ASSEMBLIES Refer to GENERAL ENGINE MECHANICAL (SEC. and perform the following: ❖ D isassem ble Components as required. jn jl Clean Components as outlined. Inspect Components as outlined. M easure • Piston pin diameter and pin to piston clearance. •...
Page 470: Camshaft
6A4-16 4.8 LITER L6 A. In d ic a to r B. C h e c k in g F ix tu re B-04578 182. C a m sh a ft Figure 26— Measuring Camshaft Journal Runout A ssem ble (Figure 4) .
Page 471: Camshaft Bearings
4.8 LITER L6 6A4-17 TIMING GEAR COVER I j j j l Clean Old gasket from the gasket surfaces. • Place the camshaft (182) in a press. Support the camshaft gear. DO NOT support the thrust Inspect plate (95). Timing tab for damage. Timing gear cover for cracks, large dents, etc.
Page 472: Oil Pan And Rocker Arm Cover
6A4-18 4.8 LITER L6 Do not remove the pick-up screen and pipe 201. Pressure Relief Valve unless replacement is required. 202. Spring The pick-up pipe is a press fit in the pump 203. Spring Retaining body (209). Do not try to remove the screen from the pipe. 204.
Page 473: Valve Train Components
4.8 LITER L6 6A4-19 B-09438 Figure 33— Installing the Oil Pump Screen and Pipe VALVE TRAIN COMPONENTS PUSHRODS, ROCKER ARMS, BALLS, AND NUTS | V | Clean • Parts in solvent. Blow dry with compressed air. Make sure the oil passages in the pushrods are clear. Inspect (Figure 4) —...
Page 474 6A4-20 4.8 LITER L6 A. Nut B. Flat Washer B-05245 Figure 36— Removing the Rocker Arm Stud ASSEMBLY 5. Valves (42 and 43). Place them in a rack so they can be returned to their original position at assembly. A ssem ble (Figures 34, 35, and 39) CLEANING AND INSPECTION OF COMPONENTS Tools Required: Refer to GENERAL ENGINE MECHANICAL (SEC.
Page 475: Thermostat And Housing
4.8 LITER L6 6A4-21 i j i i A. G rin d o u t th is p o rtio n . B-05248 Figure 40—Scale for Checking Valve Spring Installed Height tp) M easure (Figures 34, 40, and 41) • Valve spring installed height of each valve spring. 1.
Page 476: Torsional Damper
6A4-22 4.8 LITER L6 D isassem ble (Figure 4) 1. Bolts (55). 2. Water outlet (54). 3. Thermostat (52). 4. Gasket (53). Inspect (Figure 4) Water outlet (54) and housing (50) for cracks or damage. Assem ble (Figure 4) 1. Thermostat (52). 2.
Page 477: Prior To Assembly
4.8 LITER L6 6A4-23 V A L V E R E M O V A L V A L V E IN S T A L L A T IO N B-03497 Figure 45— Replacing the Oil Filter Bypass Valve A ssem ble (Figure 44) Tool Required: J-5590 Gear Installer...
Page 478 6A4-24 4.8 LITER L6 Figure 48—Crankshaft Rear Oil Seal Half in the block. The installation tool must remain in position until the seal half is properly positioned with both ends flush with the block. • Remove the tool, being careful not to withdraw the seal half.
Page 479: Crankshaft And Main Bearing Installation
4.8 LITER L6 6A4-25 MAIN BEARING INSTALLATION (WITH CRANKSHAFT INSTALLED) Refer to “ Crankshaft and Main Bearing Installation,” later in th is section for m ain bearing inse rt sizing information. - ► + Install or C onnect (Figures 5 and 21) Tool Required: J-8080 Main Bearing Remover/Installer 1.
Page 480: Camshaft Installation
6A4-26 4.8 LITER L6 Tig h ten Tig h ten • All bolts (138 and 139) EXCEPT THE REAR • Screws (93) to 9.0 N-m (80 in. lbs.). MAIN BEARING CAP BOLTS to 90 N-m (65 ft. lbs.). TIMING GEAR COVER M easure (Figure 50) INSTALLATION Crankshaft end play.
Page 481: Torsional Damper Installation
4.8 LITER L6 6A4-27 A. Bearing B. W asher C. Stud D. N ut B-05254 Figure 53—Installing the Torsional Damper Figure 54— Piston Ring Gap Location |+"»| R em ove or D isconnect (Figure 5) PISTON AND CONNECTING ROD INSTALLATION •...
Page 482: Oil Pump Installation
6A4-28 4.8 LITER L6 M easure • Connecting rod bearing clearance. Refer to GENERAL ENGINE MECHANICAL (SEC. 6A). Then apply engine oil to the connecting rod bearing. • With the connecting rod cap removed, install J-5329 onto the connecting rod studs (69). 4.
Page 483: Cylinder Head Installation
4.8 LITER L6 6A4-29 CYLINDER HEAD B-05259 INSTALLATION Figure 59— Timing Marks (Typical) JJJ* Clean (Figures 4 and 5) VALVE TRAIN — Gasket surfaces on the block (115) and cylinder COMPONENT INSTALLATION head (26). — Threads for cylinder head bolts in the block (115). Im portant Replace all hydraulic lifters if a new camshaft was Install or C onnect (Figures 4, 5 and 58)
Page 484: Thermostat Housing In S Ta Lla Tio
6A4-30 4.8 LITER L6 5. The following chart shows indicator readings with gears properly indexed for 4.8L engines and the indicator readings resulting from improperly indexed gears. Engine 4.8L Camshaft Part Number 3848000 Valve Lift 0.405" Dial Gears Properly Indexed 0.016"...
Page 485: Intake And Exhaust Manifold Installation
4.8 LITER L6 6A4-31 INTAKE AND EXHAUST ENGINE SET-UP AND TESTING MANIFOLD INSTALLATION 1. After overhaul, the engine should be tested before installing in the vehicle. If a suitable test stand is not Install o r C o nn ect (Figure 4) available, the following procedure can be used after the engine is installed in the vehicle.
Page 486: Specifications
6A4-32 4.8 LITER L6 SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherwise noted. GENERAL DATA: In Line Type 4.8L (292 Cu. In.) Displacement No. Of Cylinders 3.876 Bore 4.12 Stroke 8.0:1 Compression Ratio 1 - 5 - 3 - 6 - 2 - 4 Firing Order 16 psi @ 700 RPM;...
Page 487 4.8 LITER L6 6A4-33 SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) All specifications are in INCHES unless otherwise noted. CRANKSHAFT: Diameter 2.2979-2.2994 Main Production 0.0002 (Maximum) Taper Journal Service Limit 0.001 (Maximum) Out of Production 0.0002 (Maximum) Round Service Limit 0.001 (Maximum) #1-#6: 0.0010-0.0024 Main Production #7: 0.0016-0.0035...
Page 488 6A4-34 4.8 LITER L6 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Ft. Lbs. In. Lbs. Item Flywheel Bolts — Flywheel Housing Bolts — Main Bearing Cap Bolts — Camshaft Thrust Plate Screws — Front Cover Bolts — Torsional Damper Bolt — Connecting Rod Cap Nuts —...
Page 489 4.8 LITER L6 6A4-35 © J -3 0 4 9 J-8 0 62 11 . J-5802-01 J-22912-01 J-3 5 4 6 8 J-5 7 1 5 1 3 . J -6 0 3 6 J-6 8 8 0 J-8 0 8 0 J -2 4 4 2 0 -A J-8 0 3 7 J-5 5 9 0...
Page 490 — — — — — — ■ ■ ■ , ■ Ml-...
Page 491 6A5-1 SECTION 6A5 V8 ENGINE 5.0 LITER (305 Cu. In.) 5.7 LITER (350 Cu. In.) 7.4 LITER (454 Cu. In.) CONTENTS S U B J E C T P A G E Description....................................6 A 5 - 2 Engine Id e n tific atio n ................................6 A 5 - 2 Disassem bly....................................6 A 5 - 6 Tools and Shop Equipm ent..............................6 A 5 - 6 Accessory R em oval................................
Page 492: Description
6A5-2 V8 ENGINE CONTENTS (CONT.) S U B J E C T P A G E Assembly of Engine (Cont.) Rear Crankshaft Oil Seal and Retainer Installation (5.0 L and 5.7 L Engines)............ 6 A 5 -2 9 Camshaft, Timing Chain, and Sprocket Installation....................6 A 5 -3 0 Front Cover Installation...
Page 493 V8 ENGINE 6A5-3 Figure 1— Lubrication D iagram (5.0L and 5.7L Engines)
Page 494 6A5-4 V8 ENGINE Figure 2 — Lubrication Diagram (5 .0 L and 5 .7 L Engines)
Page 495 V8 ENGINE 6A5-5 C y lin d e r w a lls are o ile d by o il th ro w n o ff p re ssure fed c o n n e c tin g rod bearings. CYLINDER WALL AND CAMSHAFT LOBE OILING OIL FILTER AND FUEL PUMP PUSH...
Page 496: Disassembly
6A5-6 V8 ENGINE DISASSEMBLY DRAINING THE ENGINE TOOLS AND SHOP EQUIPMENT A clean, well lit work area should be available. Other + + Rem ove or Disconnect necessary equipm ent includes: A suitable parts cleaning tank, compressed air supply, trays to keep parts and 1.
Page 497: Rocker Arm Cover Removal
V8 ENGINE 6A5-7 C A ST IR O N M A N IF O L D S T A IN L E S S STEEL M A N IF O L D 1. E xh a u st M a n ifo ld 4.
Page 498: Cylinder Head Removal
6A5-8 V8 ENGINE 10. W a te r P um p 11. G a sket 12. B o lt 21. Intake M a n ifo ld 23. Seal (7.4 L Engines) F-05720 Figure 7— Intake Manifold 2. Torsional damper retaining bolt and washer. 3.
Page 499: Timing Chain And Camshaft Sprocket Removal
V8 ENGINE 6A5-9 30. N ut 31. R e in fo rc e m e n t 32. R ocke r A rm C over 33. S tud 34. G a sket 35. C lip 36. B o lt 37. W a sh er TBI ENGINES CARBURETED ENGINES F-04496...

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