ST 333 71 1971 Chevrolet Chassis Overhaul Manual Passenger Cars and 10 To 30 Truck PDF

SECTIO N IN D EX
1971
SECTION NAME
CHASSIS OVERHAUL MANUAL

covering 1 AIR CONDITIONING
COMPRESSOR
CHEVROLET, CHEVELLE 4-WHEEL DRIVE

MONTE CARLO, NOVA, 3 FRONT AXLE DIFFERENTIAL
\
CAMARO, CORVETTE REAR AXLE

and 4 DIFFERENTIAL CARRIER
SERIES 10-30
POWER BRAKE
CHEVROLET TRUCKS 5 CYLINDER
FOREW O RD
This manual includes procedures involved in disassem b ly
6 ENGINE
and assem b ly of major components of 1971 Chevrolet,
C hevelle, Monte Carlo, Nova, Camaro, Corvette and S eries
10 -3 0 Trucks. Information on maintenance and adjustm ents,
m inor se rv ic e operations, and rem oval and installation for
these components is contained in either the 1971 P assen ger
Car or Truck C hassis Service Manual. 6M CARBURETORS
The Section Index on this page enables the u ser to quickly
locate any d esired section. At the beginning of each section
containing more than one major subject is a Table of Con
tents, which g ives the page number on which each major STARTING MOTOR
subject begins. An index is placed at the beginning of each
major subject within the section.
6Y SOLENOID AND
DELC0TR0N
Sum m aries of Special T ools, when required, are found at
the end of major section s, while Specifications covering
veh icle components are presented at the rear of the manual. TRANSMISSION
T his manual should be kept in a handy place for ready AND CLUTCH,
referen ce. If properly used, it will enable the technician to
better se rv ic e the ow ners of Chevrolet built v eh icles.
7 4-WHEEL DRIVE
All information, illustration s and sp ecification s contained TRANSFER CASE
in this literature are based on the latest product information
available at the tim e of publication approval. The right is STEERING GEAR,
reserv ed to make changes at any tim e without notice.
POWER STEERING
9 PUMP AND CONTROL
VALVE
CH EVRO LET M O TO R D IV ISIO N

G eneral M otors C orporation SPECIFICATIONS
DETROIT, M IC H IG AN
© 1970 General Motors Corporation Printed in U.S.A.

SECTION 1
AIR CONDITIONING
COMPRESSOR
INDEX
M inor R epair P ro ced u res................................. ............. 1-1 Compressor R ear Head and Internal Mechanism 1-7
H ub and Drive P late...................................... ............. 1-1 Pressure Relief Valve ................................................. 1-7
Pulley and Bearing Assembly...................... ............. 1-2 R ear Head, Oil Pum p and Valve A ssem blies...... 1-7
Coil Housing Assembly ............................... ............. 1-3 M ajor Internal M echanism ........................................ 1-8
M ajor Repair P ro ced u res................................. ............. 1-4 Leak Testing the Com pressor................................... 1-13
Shaft Seal A ssem b ly ...................................... ............ 1-5 Special T o o ls..................................................................... 1-15
For all practical purposes all vehicles make use of the same excessive heat, the hub and drive plate and the pulley should
air conditioning compressor. A ctual differences between be replaced. Check further for the underlying cause of the
com pressors are found in their m ounting brackets, pulleys, damage, i.e. low coil voltage or binding of the compressor
connector assemblies and com pressor capacities, none of internal mechanism.
which affect the following O verhaul Procedures.
Installation
MINOR REPA IR P R O C ED U R ES
NOTE: When hub and drive plate assembly is ready
The following operations to the H ub and Drive Plate, for installation, clean its frictional face with a suita
Pulley and Bearing, and Coil Housing are covered as "M i ble cleaner.
nor" because they m ay be perform ed w ithout first purging
the system or removing the com pressor from the vehicle. The 1. Insert the square hub and drive plate key into the key
shaft seal assembly may also be serviced w ithout removing way in the drive shaft allowing it to project approxi
the com pressor from the vehicle but this operation is covered mately 3/16" out of the end of the keyway (fig. 4).
later in this section as a "M ajor R epair Procedure" because 2. Line up the key in the shaft with the keyway in the hub.
the system m ust first be purged of refrigerant.
Illustrations used in describing these operations show the 3. Using Tool J-9480 and W asher J-9480 2 (fig. 5), install
com pressor removed from the vehicle to more clearly illus the hub - and drive plate assembly. Pull the assembly
trate the various operations. onto the shaft until there is approxim ately 3/32" space
between the frictional surfaces of the drive plate and
Hub and Drive Plate pulley. (A ZER O thrust race is approximately 3/32"
thick and may be used to roughly gauge this operation.)
Removal
1. If disassembly is being perform ed on a bench, m ount NOTE: Use Tool J-9403 to hold hub and drive plate
Holding Fixture J-9396 in a vise and attach the com if necessary.
pressor to the fixture.
2. Using C lutch H ub Holding Tool J-9403 and Socket 4. Install the hub spacer washer and, using Snap Ring
J-9399, remove the locknut from the shaft (fig. 2). Dis Pliers J-5403, install the retainer ring (Item 37, fig. 1),
card locknut. convex side of ring facing washer.
3. Tool J-9401 may now be used to remove the hub and 5. Use Tools J-9399 and J-9403 to install a new locknut.
drive plate assembly (fig. 3). Tighten the nut to 14-26 ft. lbs. torque. A ir gap between
the frictional faces should now be .022" to .057".
NOTE: Carefully snug tool into place with wrench
to insure engagement with threads. NOTE: The shoulder or circular projection on the
locknut must face towards retainer ring.
4. Use Snap Ring Pliers J-5403 to remove the retainer ring
(Item 37, fig. 1). T hen remove the hub spacer. 6. The pulley should now rotate freely.
Inspection CAUTION: Never pound or drive the hub and drive

plate into position. Always use the proper tools
If the frictional surface shows signs of damage due to when removing or replacing clutch parts. Failure to
CHEVROLET OVERHAUL MANUAL

AIR CONDITIONING COMPRESSOR 1-2
Fig. 1-S ix C ylinder Com pressor-C ross Sectional V iew
1. Rear Head 15. Pulley and Bearing Assem bly 26. T hrust Bearing
2. Rear Head to Shell ” 0 " Ring 16. Pulley Bearing 27. T hrust Race
3. Rear Discharge Valve Plate 17. Pulley Bearing Retainer Ring 28. Com pressor Shell
4. Rear S uction Reed Plate 18. Pulley and Bearing Retainer 29. C ylinder Assem bly
5. Piston Ring Ring 30. S haft Seal
6. Piston Drive Ball 19. Clutch Hub and Drive Plate 31. S haft Seal Seat " 0 " Ring
7. Ball Seat Assem bly 32. S haft Seal Seat
8. Piston 20. Oil Pump Gears 33. Shaft Seal Seat Retainer Ring
9. Front Suction Reed Plate 21. M ainshaft Bearing (Rear) 34. A bso rbe nt Sleeve
10. Front Discharge Valve Plate 22. Oil Inlet Tube " 0 " Ring 35. A bsorbent Sleeve Retainer
11. Front Head to Shell " 0 " Ring 23. Oil Inlet Tube 36. Spacer
12. Front Head 24. W obb le Plate and M ainshaft 37. Clutch Hub Retainer Ring
13. Coil and Housing Assem bly Assem bly 38. S haft Nut
14. Coil H ousing Retainer Ring 25. T hrust Race
do so may result in serious internal compressor dam 3. Remove shaft key.

age and seal leakage due to shift of crankshaft. 4. Place Puller Pilot J-9395 over the compressor shaft and
pull off the pulley assembly using J-8433 pulley puller
7. O perate the refrigeration system and rapidly cycle the (fig- 7).
clutch (by turning the air conditioning off and on at
least 20 times at approxim ately one second intervals) to
seat the m ating parts of the clutch. Inspection
Check the appearance of the pulley and bearing assembly.
Pulley and Bearing Assembly If the frictional surface of the pulley shows signs of excessive
grooving due to slippage, both the pulley and the clutch hub
1. Remove the hub and drive plate assembly. and drive plate assembly should be replaced. The frictional
2. Using Snap Ring Pliers J-6435, remove the pulley and surfaces of the pulley and bearing assembly should be cleaned
bearing retainer ring (fig. 6). with a suitable solvent before reinstallation.

Fig. 4-D rive Plate Key Installed in Keyway

3. Install the wire bearing retainer ring.
4. Replace the hub and drive plate assembly. Use proper
tools. D O N O T drive or pound on the hub assembly.
Coil Housing Assembly

Fig. 2--Removing Shaft Locknut Removal
Bearing Replacem ent 1. Remove the hub and drive plate assembly, the pulley
and bearing assembly, and electrical connector.
1. W ith the pulley and bearing assembly removed from
2. Scribe the location of the coil housing to the compressor
the compressor, use a sharp pointed instrum ent to
body. This operation is to insure th at the electrical
remove the wire retainer ring.
term inals will be reassembled in the same position.
3. Using Snap Ring Pliers J-6435, remove the coil housing
CAUTION: If the bearing is to be reused be careful
retainer ring (fig. 8).
not to slip and damage the seal.
4. Remove the coil housing assembly.
2. F rom the rear of the pulley, press or drive bearing out Inspection
of pulley using Tool J-9398 and H andle J-8092.
3. F rom the front o f the pulley and using Tool J-9481 with Check coil for loose connectors or cracked insulation.
H andle J-8092, press or drive the new bearing into the Amperage should not be m ore than 3.2 amps at 12 volts D.C.
pulley. at room tem perature.
Installation
1. Using Tool J-9481, press or drive the pulley and bearing
assembly onto the com pressor neck. The pulley should
now rotate freely.
2. Install retainer ring using Snap Ring Pliers J-6435.
Fig. 3-R em oving Hub and Drive Plate Assem bly Fig. 5— Installing Hub and Drive Plate Assem bly

Fig. 6-R em oving Pulley and Bearing Assem bly Retainer Ring
Installation
1. R otate the coil housing to the correct position as in
Fig. 8-R em oving Coil Housing Retainer Ring
dicated by the scribe m arks and the location of the
electrical term inals and fit into place (fig. 9). ing disassembled and serviced. A clean workbench, prefera
2. Use Snap Ring Pliers J-6435 to install retainer ring. bly covered with a sheet of clean paper, orderliness in the
NOTE: Install flat surface of the retainer ring facing

the coil housing.
3. Replace the pulley and bearing assembly and the hub

and drive plate assembly. D O N O T drive or pound on
the hub assembly.
4. If the com pressor is installed in the vehicle, connect the
electrical connections.
M A JO R REPA IR P R O C ED U R ES
The following service procedures are considered major
since the refrigeration system m ust be completely purged of
refrigerant before proceeding a n d /o r because m ajor internal
operating and sealing com ponents of the compressor are be-
Fig. 7-R em oving Pulley Fig. 9 -ln s ta llin g Coil Housing

work area and a place for all parts being removed and re and the shaft itself of any dirt or foreign m aterial before
placed is of great im portance as is the use of the proper, clean removing the seal seat. (This is absolutely necessary to
service tools. A ny attem pt to use make-shift or inadequate prevent any m aterial from getting into the compressor.)
equipm ent m ay result in dam age a n d /o r im proper com pres
sor operation. 4. Place Tool J-22974 over the end of the shaft to prevent
These procedures are based on the use of the proper service chipping the Ceramic seat. Fully engage the knurled
tools and the condition th at an adequate stock of service tangs of Tool J-23128 into the recessed portion of the
parts is available. Service parts stock should include the fol seal seat by turning the handle clockwise. Lift the seat
lowing: from the compressor with a rotary m otion (fig. 11).
1. M ajor interior m echanism assem bly-ready for installa
tion in shell as is. CAUTION: DO NOT tighten the handle with a
2. Service cylinder assem bly-front and rear halves with wrench or pliers; however, the handle must be hand
m ain bearings in place and halves dowel pinned tightened securely to remove the seat.
together.
3. Piston drive balls. 5. W ith Tool J-22974 still over the end of the shaft, engage
4. Ball seats—total of 10 sizes, including the Z ER O seat. the tabs on the seal assembly with the tangs on Tool
5. T hrust ra c e s-to ta l of 14 sizes, including the ZERO J-9392 by twisting the tool clockwise while pressing the
race. tool down. Then lift the seal assembly out.
6. Pistons—low and high compression. 6. Remove the seal seat ”0 ” ring from the compressor
7. Piston rings. neck using Tool J-9553 (fig. 11).
8. M ain shaft bearings. 7. Recheck the shaft and inside of the com pressor neck for
9. T hrust bearings. dirt or foreign m aterial and be sure these areas are
10. C om pressor shaft and wobble plate. perfectly clean before installing new parts.
11. Suction reed valves.
12. D ischarge valve p la te -fro n t and rear. Inspection
13. C om pressor front head.
Seals should not be reused. Always use a new seal kit on
14. C om pressor rear head.
rebuild. Be extremely careful that the face of the seal to be
15. Pulley and pulley bearing.
installed is not scratched or damaged in any way. M ake sure
16. C lutch hub and drive plate assembly.
that the seal seat and seal are free of lint and dirt that could
17. Seal k it-serv ice-co n tain s all seals and "O" rings.(a)
damage the seal surface.
18. Shaft seal kit.(a)
19. N u ts-h e a d to shell, and shaft.(a) A pparent seal leaks are sometimes the result of misposi-
tioning of the wobble plate on the com pressor shaft caused
20. R etainer rin g s-all necessary sizes.
21. Cylinder locator (dowel) pins. by im proper procedures during pulley removal, pounding or
22. Valve and head locator (dowel) pins. dropping on the com pressor shaft or collision impact. Check
23. Service discharge crossover tube kit. as shown in Figure 12. If m easurem ent is greater than shown,
replace the shaft and wobble plate assembly.
(a)To be used each time a compressor is rebuilt.
All parts required for servicing are protected by a preser
vation process and packaged in a m anner which will elimi Installation
nate the necessity o f cleaning, washing or flushing of the 1. Coat the new shaft seal seat ”0 ” ring with clean Frigi-
parts. The parts can be used in the m echanism assembly just
daire 525 viscosity refrigeration oil (or equivalent) and
as they are rem oved from the service package.
install in the com pressor neck groove using Tool J-
I iston ball seats and shaft th ru st races will be identified on 21508 (fig. 13).
the parts themselves to denote their size and dimension.
Shaft Seal Assembly NOTE: Refrigerant oil has been specifically dehydrated
and therefore has a great affinity for the moisture in
W hen replacing the shaft seal assembly, even if the com
the atmosphere. NEVER leave the refrigeration oil bottle
pressor remains on the vehicle during the operation, it will
uncapped for more than a few moments or oil contam
be necessary to purge the system of refrigerant as outlined in
the Chassis Service M anual. ination will result.
2. Coat the ”0 ” ring and seal face of the new shaft seal
Removal assembly with clean refrigeration oil and carefully en
gage the seal assembly onto the locking tangs of Tool
1. A fter first purging the system of refrigerant, remove the J-9392 (fig. 13). Place shaft Seal Protector J-22974 over
clutch hub and drive plate, and the shaft key. the end of the shaft and slide the seal down the shaft,
2. Pry out the sleeve retainer and remove the absorbent turning the tool clockwise and applying light pressure
sleeve. Remove the seal seat retaining ring using Snap until the seal assembly engages the flats on the shaft and
Ring Pliers J-5403. is seated in place. R otate the tool counter-clockwise
3. Thoroughly clean the area of the compressor neck sur slightly (to release it from the seal) and remove Tool
rounding the shaft, the exposed portion of the seal seat, J-9392.

Fig. 1 0 -S ix C ylinder C om pressor-Exploded V iew
1. S haft Nut 16. S haft Seal Seat 29. Drive Key 43. M ainsha ft Rear
2. Clutch Hub Retainer Retainer Ring 30. Discharge Crossover Bearing
Ring 17. Shaft Seal Seat Tube 44. Discharge Crossover
3. Spacer 18. S haft Seal 31. Piston Ring Tube Rear " 0 " Ring
4. Clutch Hub and Drive 19. S haft Seal Seat " 0 " 32. Piston Front Drive and Spacer
Plate Assem bly Ring Ball 45. Rear Suction Reed
5. Pulley and Bearing 20. Com pressor Front 33. Piston Front Ball Plate
Retainer Ring Head Seat 46. Rear Discharge Valve
6. Pulley Bearing 21. Front Discharge 34. Piston Plate
Retainer Ring Valve Plate 35. Piston Rear Ball Seat 47. Oil Pump Drive Gear
7. Pulley Bearing 22. Front Suction Reed 36. Piston Rear Drive 48. Oil Pump Driven Gear
8. Pulley Valve Ball 49. Rear Head-to-Shell
9. Coil Housing Retainer 23. Discharge Crossover 37. Piston Ring " 0 " Ring
Ring Tube Front " 0 " Ring 38. Drive S haft and 50. S trainer Screen
10. Coil Housing and Spacer W obb le Plate 51. C om pressor Rear
11. Com pressor Shell 24. M ainsha ft Front A ssem bly Head
12. A bso rbe nt Sleeve Bearing 39. Rear T hrust Race and 52. High Pressure Relief
13. A bso rbe nt Sleeve 25. Head Locating Pins Bearing Pack Valve and " 0 " Ring
Retainer 26. Front C ylinder Half 40. Rear C ylinder Half 53. Rear Head-to-Shell
14. Oil Drain Plug and 27. Front T hrust Race 41. Oil Inlet Tube " 0 " Retaining Nuts
Gasket and Bearing Pack Ring 54. C om pressor-to-
15. Front Head-to-Shell 28. Suction Crossover 42. Oil Inlet Tube C o n n e cto r “ 0 ” Rings
" 0 " Ring Cover
3. Coat the seal face of the new seal seat with clean refrig into a cylinder, overlapping the ends, and slipping the
eration oil. G rip the seal seat w ith Tool J-23128 and sleeve into the com pressor neck with the overlap to
push into place with a rotary motion, so as not to dis ward the top of the compressor. W ith a small screw
turb the ”0 ” ring and to also effect a seal with this ”0 ” driver or similar instrum ent, carefully spread the sleeve
ring. Remove Tool J-23128. until the ends of the sleeve b u tt at the top vertical
4. Install the new seal seat retainer ring with Tool J-5403, centerline.
with the flat face against the seal seat. Press on the 7. Position the new metal sleeve retainer so that its flange
retainer ring until it snaps into place. Remove Tool face will be against the front end of the sleeve. Tool
J-22974 from the end of the shaft. J-9395 may be used to install the retainer. Press and tap
5. Leak test the com pressor as described under ’’Leak with a mallet, setting the retainer and sleeve into place
Testing the Com pressor” in this section. C orrect any (retainer recessed approxim ately 1/32” from the face of
leaks found. the com pressor neck).
6. Install the new absorbent sleeve by rolling the material 8. Reinstall the clutch hub and drive plate assembly.

Fig. 1 1-R em oving Seal Seat and O- Ring
Compressor Rear Head and Internal

Mechanism
Service operations to the rear head or internal mechanism Fig. 13--Replacing Seal and 0-Ring
of the com pressor should be perform ed with the compressor
removed from the vehicle to insure th at the necessary degree head casting, is encountered, the valve assembly should be
of cleanliness may be m aintained. Clean hands, clean tools removed after purging the system and a new valve and gasket
and a clean bench, preferably covered w ith clean paper, are installed. The entire system should then be evacuated and
of extreme importance. recharged.
Rear Head, Oil Pump and Valve
Pressure Relief Valve
Assemblies
W hen a faulty pressure relief valve, located in the rear
Removal
1. Remove the com pressor from the vehicle, drain com
pressor oil into a clean container, clean the exterior of
the com pressor case and rear head casting with a suita
ble solvent and m ount the compressor, rear head up, in
Vti" (APPROX.)
holding Fixture J-9396 which should then be m ounted
securely in a vise.
STRAIGHT EDGE 2. Remove the four nuts from the shell studs.
3. Remove the rear head. Examine the sealing surface on
WIRE GAUGE
.029" SHOULD "G O " the casting webs. If this surface is damaged by nicks or
.072" SHOULD "NOT GO" scratches, the head should be replaced.
OR SHOULD "JUST GO" 4. Examine the suction screen in the rear head for any
ABSORBENT SLEEVE damage or contam ination. Clean or replace the screen
RETAINER as necessary.
SEAL SEAT
5. Remove and examine the oil pum p gears. If either of the
RETAINER RING gears shows any wear or damage, replace both gears.
SEAL SEAT
NOTE: Keep the ends of the two oil pump gears
"O " RING matched and replace the same end toward the dis
charge plate upon reassembly.
SEAL ASSEMBLY
6. Remove the rear head-to-shell ” 0 ” ring and discard.
7. W ith two screw drivers, carefully pry up on the rear
discharge valve plate assembly (fig. 14). Check for
broken reeds or damaged seats and replace entire as
sembly if such is found.
CAUTION: Excessive force during this operation

Fig. 12~Checking fo r W o b b le Plate Position on Shaft may loosen valve reed retainer rivets.

Fig. 14--Removing Rear Discharge Valve Plate
8. Carefully lift off the rear suction reed valve. Valve m ust
be replaced if any dam age is evident.
Installation
1. Carefully replace the suction reed valve and the rear
discharge plate over th e dowel pins and ports in the
cylinder assembly. Proper positioning of the reed plate
may be determ ined by lining up the proper opening in
the plate with the discharge crossover tube opening.
2. Position the rear head casting to align with the dowel
pins. The two lower m ounting pads will be in alignment
w ith the oil sum p in the shell. R otate the cylinder as
sembly back and forth by hand, if necessary, to permit
this alignm ent. Remove the rear head from this trial Fig. 15-P rop er Oil Pump Gear P ositioning
assembly.
3. Install the inner oil pum p gear over the ” D ” flat on the Major Internal Mechanism
shaft and place the outer oil pum p gear over the inner
gear. Position the outer gear as follows: The clutch hub and drive plate assembly, drive key, pul
a. Observe the position of the oil sum p in the shell. ley, and coil housing and shaft seal should be removed before
b. Locate the approxim ate centerline of this sump. proceeding with the following com pressor disassembly.
c. Facing the centerline of the sump and viewing from
the sum p side (bottom ) of the compressor, move the Removal from Shell
O U T E R gear tow ard the right (side having the oil
drain fitting) until it is at approxim ately 90 degrees 1. Remove the rear head, discharge plate and suction reed
(3 o’clock position) from the centerline of the oil valve from the compressor as outlined under ’’Rear
sum p (fig. 15). H ead and Reed Valve Assemblies.”
4. Coat the head-to-shell ”0 ” ring with clean refrigeration 2. Remove the oil inlet tube and ”0 ” ring with Tool J-
oil and generously lubricate the area around the outer 5139 as shown in Figure 16.
edge of the valve plate where the ”0 ” ring will be 3. Carefully lay the compressor shell on its side and slide
placed. Oil also the oil pum p gears, valve reeds and the out interior mechanism and front head assembly. DO
area where the head casting web sealing surface will N O T ham m er or use undue force to remove the mech
contact the valve plate. anism; however, gentle taps on the head casting may aid
5. Install the head-to-shell ” 0 ” ring. in removing the assembly.
6. Be sure th at the suction screen is properly positioned in
the rear head, then assemble the rear head to the com CAUTION: DO NOT hammer or tap on the compres
pressor shell being careful not to damage the sealing sor shaft.
surface on head casting webs.
4. Remove front head casting, front discharge valve plate
CAUTION: Be sure head does not bind against oil and suction reed valve from the mechanism. Examine
pump gears when being installed. parts for damage and replace if necessary. Check p ar
ticularly for damage to the sealing surfaces on the front
7. Install new nuts to the threaded shell studs and tighten head casting webs.
to 19-25 ft. lbs. torque. 5. Examine the mechanism for any obvious damage.
8. Leak test the com pressor as outlined under ’’Leak Test 6. Remove the suction crossover cover (fig. 17).
ing the C om pressor” in this section. 7. If desired, the mechanism may be assembled in Check
9. Install com pressor in the vehicle. ing Cage J 9397 and operated on a m otor test stand, or

Fig. 16— R em oving O il In le t T ube and " O ” Ring
by some other suitable means, to observe sound level

and general operation. Tighten cage nuts evenly to
14-16 ft. lbs. torque.
8. Rem ove mechanism from the cage.
Disassem bly
Fig. 18 -U n seatin g Discharge Crossover Tube
If the m echanism has sustained m ajor damage, due possi
bly to loss of refrigerant a n d /o r oil, it may be necessary to NOTE: Before driving cylinder apart, position wob
replace it w ith a complete service interior mechanism assem ble plate toward front of compressor in area of
bly rath er than to replace individual parts. If further disas crossover tube.
sembly is considered worthwhile, proceed as follows:
1. Before disassembling the cylinder and mechanism, 4. Carefully remove the rear half of the cylinder from the
num ber the pistons and cylinder locations so that all pistons and set the front cylinder half, with the piston,
parts may be replaced in their original location. Pistons shaft and wobble plate, in Compressing Fixture J-9397.
and cylinder bores m ay be identified by numbering
them 1, 2 and 3 w ith a pencil. 5. Push up on the shaft and, one assembly at a time,
2. Use an old discharge tube to drive discharge tube out remove pistons, rings, seats and balls placing all parts
of cylinder (fig. 18). (D rive from R E A R of cylinder). in Tray J-9402 in the com partm ent associated with the
3. Drive the cylinder halves apart and free from the dowel proper end of the piston. D iscard all piston ball seats.
pins and discharge crossover tube using a fiber block
and m allet (fig. 19). D iscard the discharge crossover NOTE: The front of the piston may be identified by
tube.
Fig. 17— Rem oving S u ctio n Crossover Cover Fig. 19 -S e p a ra tin g C ylinder Halves

a notch in the casting web (fig. 20). The piston com Proper selection of thrust races and ball seats is of extreme
partments in Tray J-9402 have a boss at this notch importance.
location to indicate the front. 1. Secure from service parts stock:
Four-ZER O thrust races
6. Remove and inspect all piston rings. Replace all broken Three-ZER O ball seats
or dam aged rings. D am aged pistons m ust also be re Two-New thrust bearings
placed. 2. Assemble a ZER O thrust race, a new needle thrust
7. Examine piston balls. Replace if they show burning or bearing and another Z E R O thrust race, in that order,
excessive wear. to the front end of the shaft. (A dab of clean petroleum
8. Remove the rear com bination of thrust races and bear jelly will hold the bearing-race pack together and in
ing from the shaft and discard all three pieces. place on the shaft.) Lubricate front and rear faces of the
9. Remove the shaft and wobble plate assembly from the wobble plate with clean refrigeration oil.
front half of the cylinder. 3. W ith the front half of the cylinder assembly resting on
10. Remove the front com bination of thrust washers and Tool J- 9397, insert the shaft threaded end through the
bearing and discard all three pieces. front main bearing until the thrust race assembly rests
11. Exam ine all surfaces of the wobble plate and, if satisfac on the front cylinder hub.
tory, reuse. If it shows signs of wear, replace the shaft 4. Assemble a ZER O thrust race, a new needle bearing
and wobble plate as an assembly. Use care not to move and a second ZER O thrust race in that order, to the
wobble plate on the shaft. This is factory set. rear of the shaft.
12. Examine the front and rear cylinder halves and replace 5. Apply a light smear of clean petroleum jelly to the ball
if cylinder bores are deeply scored or damaged. pockets of each of the three pistons.
13. W ash all parts to be reused in a suitable cleaner. Blow 6. Place the balls in the piston pockets. The petroleum
dry all parts. jelly will hold the balls in place.
14. If cylinder main bearings are to be replaced they may 7. Apply a light smear of petroleum jelly to the cavity of
be removed and reinstalled at this time using Tool J- three new ZER O ball seats and place one seat over each
9432. Drive against the lettered end of the bearings and front piston ball. There should now be a ball and seat
from the outside of the cylinder. Bearing m ust be not in the front ball pocket of each piston and a ball only
m ore than 1 /8 ” below surface. in the rear ball pocket.
Gauging Procedure NOTE: Do not assemble any of the piston rings at

this time.
The gauging operations which follow have been worked
out on a simple basis to establish and provide necessary 8. R otate the shaft and wobble plate until the high point
running clearances. Two gauging procedures are necessary. of the wobble plate is directly over the cylinder bore
The first gauging operation is m ade to choose the proper previously designated as No. 1. Lift up slightly on the
size ball seats to provide, at each piston, a .0005” to .0010” shaft and wobble plate assembly, insert the front
total preload between the seats and the wobble plate at the (notched) end of the No. 1 piston into the cylinder bore,
tightest place through the 360 degree rotation of the wobble and at the same time, place the front ball and seat and
plate. The bronze ball seats are provided in .0005” variations the rear ball only over the wobble plate (fig. 21). Hold
including a basic ZER O seat.
The second gauging operation, perform ed at the rear shaft
W obble Plate
thrust bearing and race pack, is designed to obtain .0005” to
.0015” preload between the hub surfaces of the wobble plate
and the front and rear hubs o f the cylinder. A total of 14 steel
th ru st races, including a basic Z ER O race, are provided in
increm ents of .0005” thickness to provide the required fit.
Front
Cylinder
NOTCH BOSS! Half ^
Front Thrust Races
S j and Bearing * B
H o ld in g F ix tu re l
H I J-9396
| Compressing |
Fixture J-9397
Fig. 2 0 -N o tc h Id e n tifyin g Front End of Piston Fig. 2 1 — Installing Piston, Front Ball and Seat and Rear Ball

front thru st bearing pack tight against wobble plate hub

while lifting shaft.
9. R epeat this operation with pistons No. 2 and No. 3.
10. A lign the rear head casting with bores, suction passage,
discharge crossover holes, and dowel pins. Tap into
place, using a plastic block and mallet (fig. 22). R ear Ball
W o b b le Plate
11. Place the cylinder assembly in the checking cage with
the front o f the com pressor shaft pointing up, position F eeler G a g e s
ing the discharge tube opening between the cage bolts.
This will provide access for the feeler gauge. Assemble
the cage and tighten all nuts evenly to 14- 16 ft. lbs.
torque.
12. Use a leaf type feeler gauge and a suitable spring scale
to check clearance between the R E A R ball and the S p rin g Scale
wobble plate (fig. 23) of the No. 1 piston. Use a suitable (Pull Scale
com bination o f feeler gauge leaves until 4 to 8 oz. of p a ra lle l to
Z' slo pe o f
force is required to pull gauge from between the ball and
W o b b le Plate)
the plate.
NOTE: Use undamaged feeler gauges generously

lubricated with clean refrigeration oil. Support the
spring scale so that only the actual force required to Fig. 2 3 -C h e ckin g Clearance Between Rear Ball and W obb le
pull the feeler gauge free is measured. Plate
race to correspond to this feeler gauge reading and place

R otate the shaft approxim ately 120 degrees and again
this race in parts tray in the rear thrust race com part
check with a feeler gauge between the parts. R otate the
ment.
shaft another 120 degrees and m ake a third check.
15. Loosen the nuts and ring from the checking cage.
F rom this total of three feeler gauge checks, use the
16. Drive the cylinder halves apart, using a fiber block and
M IN IM U M reading to select a num bered seat to corre
mallet.
spond to the feeler gauge reading (i.e.-if m inimum read
17. Carefully remove the rear half of the cylinder and set
ing was .019, use a No. 19 seat. If reading was .0195,
the front half (including the pistons and shaft and wob
use a No. 19-1/2 seat). Place this seat in the parts tray
ble plate assembly) on Fixture J-9397.
in the com partm ent corresponding to the rear ball posi
18. Carefully remove one piston at a time from the wobble
tion of the No. 1 piston.
plate and the front half of the cylinder. Transfer each
13. R epeat the operation described in Step 12 for pistons
piston, ball and seat to its proper place in the parts tray
No. 2 and No. 3.
14. The next gauging operation is to determ ine the space
between the R E A R th ru st bearing and the upper
(outer) rear thru st race. Use a suitable combination of
feeler gauge leaves so th at 4 to 8 oz. of force is required
to pull gauge free (fig. 24). Select a num bered thrust Rear Thrust Race
F eeler G a g e s
S pring Scale
Thrust B ea ring
f
"Ot; * ' •*-.
Fig. 24--Checking Clearance Between Rear T hrust Bearing and

Fig. 22--Assem bling C ylinder Halves O uter T hrust Race

along with the num bered rear seat chosen in Steps 12 faces the inside of the compressor to allow for wob
and 13 above. ble plate clearance.
CAUTION: When the balls and seat are removed 10. W hen all parts are in proper alignment, tap with a fiber
from the piston, be sure that they are placed in the block and mallet to seat the rear half of the cylinder
proper parts tray pocket so as not to lose the rela over the locating dowel pins. If necessary, clamp the
tionship of the balls and seats to the proper end of cylinder in Fixture J-9397 to complete drawing the cyl
the piston. inder halves together.
11. Generously lubricate all moving parts with clean refrig
19. Remove the rear outer (upper) Z E R O thru st race from eration oil and check for free rotation of the parts.
the com pressor shaft and replace it with the num bered
thrust race (determ ined in Step 14 above) from parts NOTE: It may be desirable to clamp the cylinder
tray. assembly in compressing Fixture J-9397 and check
on the motor test stand for proper operation before
NOTE: This ZERO thrust race may be put aside for proceeding further. If any improper operation is ob
reuse in future gauging and/or rebuild operations. served, the mechanism should be regauged to insure
proper operation. Complete the assembly procedure
20. The gauging operations are now complete. when correct operation is obtained.
Assem bly 12. Replace the suction crossover cover as shown in Figure
25. Compress the cover as shown to start it into the slot
After properly perform ing the gauging procedure and and then press it in until flush on both ends.
choosing the correct ball seats and thrust races as outlined
under ’’G auging Procedures,” the cylinder assembly may be Installation Into Shell
reassembled. Be sure to install all new seals and ” 0 ” rings.
All are included in the com pressor seal service kit. 1. Support the cylinder on Fixture J-21352 with the
Assembly procedure is as follows: threaded end of the shaft up.
1. Support the front half o f the cylinder assembly on Fix 2. Assemble the two dowel pins in the front cylinder if
ture J-9397 and install the shaft and wobble plate, they are not already in place.
threaded end down, w ith its front bearing race pack
(ZE R O race, bearing and Z E R O race) and its rear bear NOTE: A rod drilled 1/4 in. deep to the O.D. of the
ing race pack (ZERO race, bearing, num bered race) if dowel pins will aid in installing.
this was not already done at the end of the ’’Gauging
Procedure.”
2. Assemble a piston ring, scraper groove tow ard the cen
ter of the piston, to each end of the three pistons.
3. Apply a light sm ear of petroleum jelly to the num bered
ball seats chosen in the gauging procedure and install
all balls and seats (if rem oved in Step 18 of the gauging
procedure) in their proper place in the piston.
4. R otate the wobble plate so th at the high point is above
cylinder bore No. 1. Carefully assemble piston No. 1,
complete with ball and Z E R O seat on the front and ball
and num bered seat on the rear, over the wobble plate.
H old front thrust bearing pack tight against wobble
plate hub while lifting hub. Compress and enter the
piston ring into the front cylinder half.
5. Repeat this operation for pistons No. 2 and No. 3.
6. Assemble one end of a service discharge crossover tube
into the hole in the front cylinder half.
7. R otate the shaft to position the pistons in a stair-step
arrangem ent, then carefully place the rear cylinder half
over the shaft and start the pistons into the cylinder
bores.
8. Compress the piston ring on each piston to perm it its
entrance into the cylinder.
9. W hen all three pistons and rings are in their respective
cylinders, align the end of the discharge crossover tube
with the hole in the rear half of the cylinder.
NOTE: Be sure the flattened portion of this tube Fig. 2 5 —Installing Suction Crossover Cover

3. Install the discharge crossover tube front ”0 ” ring and

spacer (fig. 26).
4. Aligning the dowel pin holes, discharge crossover and
oil return slot, assemble the suction reed valve to the
front end of the cylinder.
5. Assemble the front discharge valve plate, aligning the
holes w ith the dowel pins and proper opening in the
head.
NOTE: The front discharge plate has a larger diame

ter hole in the center than the rear discharge plate.
6. Check the sealing surface on the compressor front head
casting webs and replace the entire casting if there is
any evidence of damage. D iscard the ” 0 ” ring.
7. Coat the valve plate with clean refrigeration oil. R otate
the front head casting until it is properly positioned
over the discharge reed retainers and dowel pins, then
set it in place (being careful not to damage the sealing
surfaces) and seat it over dowels with light m allet taps.
NOTE: Dowel pin and hole location can be marked

with pencil to aid in locating proper position.
8. A pply clean refrigeration oil to a new ”0 ” ring and ”0 ”

ring groove at the lower edge of the front head casting
and carefully assemble the ” 0 ” ring in the groove.
9. C oat the inside m achined surfaces of the compressor
shell with refrigeration oil.
10. Locate the oil intake tube hole in the rear discharge
plate. Line up the oil sum p with this hole location and
slide the shell down over the mechanism while support
ing the mechanism on Fixture J-2 1352 (Fig. 27).
NOTE: Raise the front head slightly to facilitate

shell installation and to reduce the possibility of da Fig. 2 7 —Installing Shell Over Internal Mechanism
maging the O-ring.
12. Place a new ” 0 ” ring in the oil intake tube hole apply
11. Place Com pressor Support Bracket J-9396 in a vise and, ing clean refrigeration oil to the oil intake tube hole and
carefully inverting the com pressor shell with the m ech the ”0 ” ring. Rotating the compressor mechanism to
anism inside, m ount the front com pressor flange on the line up with the hole in the compressor oil sump baffle,
support bracket. install the pickup tube. Be sure that the ” 0 ” ring and
intake tube are properly seated.
13. Assemble the dowel pins into the rear cylinder.
14. Install the discharge crossover tube rear ”0 ” ring and
spacer.
15. Replace the rear suction reed valve, rear discharge
valve plate, oil pum p gears, rear head and head nuts as
outlined previously under ’’R ear H ead and Reed
A ssem blies-Installation. ’’
16. Install a new shaft seal assembly kit as outlined under
’’Shaft Seal A ssem bly-Installation.”
17. Reinstall the coil housing, pulley and bearing assembly
and hub and drive plate assembly as outlined earlier in
this section.
Leak Testing The Compressor

W henever service operations are performed on the com
pressor shaft seal assembly or on the interior mechanism, use
the following procedure to leak test the reassembled com
Fig. 26— In sta llin g Discharge Crossover T ube F ro n t pressor.
“ O ” Ring and Spacer

1. Install ” 0 ” rings and Cover Plate J-9527 over the suc 4. H ook up a R efrigerant-12 container and charging line
tion and discharge ports o f the com pressor head. (using A dapter J-5420) to cover plate fitting over the
2. Check and add oil to the com pressor as outlined under suction port, charge the com pressor up to can pressure,
’’Checking Com pressor Oil Charge” in the Chassis Ser and leak test com pressor with a leak detector.
vice M anual. 5. T urn off the refrigerant container valve. Transfer gauge
3. Tem porarily install the shaft nut. W ith the compressor line and adapter to cover plate fitting over the discharge
in the horizontal operating position (oil sum p down), port and repeat the procedure outlined in Step 4.
rotate the com pressor shaft several times in the normal 6. C orrect any leaks present.
direction of rotation.

SPECIAL TOOLS
Fig. 28--Air C onditioning Special Tools
1. J -8 3 9 3 C harging Station 17. J-9401 Hub and Drive Plate Assem bly
2. J-5 4 5 3 Goggles Remover
3. J-9 4 5 9 9 0 Degree Gauge Line A da pter 18. J-9 4 8 0 Hub and Drive Plate Assem bly
4. J-5 4 2 0 Gauge Line A da pter Installer
5. J-6 0 8 4 Leak Detector 19. J-9 3 9 2 Seal Remover
6. J-8 4 3 3 Puller 20. J-2 3 1 2 8 Seal Seat Remover
7. J-93 95 Puller Pilot 21. J-93 98 Pulley Bearing Remover
8. J -2 3 5 9 5 R efrigerant Can Valve (Side 22. J-9481 Pulley and Bearing Installer
Tap) 23. J-8 0 9 2 Handle
9. J-6271 R efrigerant Can Valve (Top 24. J -2 1 3 5 2 Internal Assembly Support
Tap) Block
10. J-5421 Pocket Therm om eters (2) 25. J-51 39 Oil Pickup Tube Remover
11. J-5403 N o. 21 Snap Ring Pliers 26. J-9 4 3 2 Needle Bearing Installer
12. J-6 4 3 5 No. 26 Snap Ring Pliers 27. J-9 5 5 3 Seal Seat " 0 " Ring Remover
13. J-9 3 9 6 Com pressor Holding Fixture 28. J -2 1 5 0 8 Seal Seat " 0 " Ring Installer
14. J-9 3 9 7 Com pressing Fixture 29. J -2 2 9 7 4 Shaft Seal Protector
15. J-9 4 0 3 Clutch Hub Holding Tool 30. J-9 5 2 7 Pressure Test Connector
16. J-9 3 9 9 9 / 1 6 ” Thin W all Socket 31. J-9 4 0 2 Parts Tray

SECTION 3
FRONT AXLE DIFFERENTIAL
(4-W HEEL DRIVE)
INDEX
SU BJECT PA G E
Front Axle D ifferential................................................... ........ 3-1 Pinion and B e arin g s........................................................ 3-3
R em oval.................................................................................. 3-1 Removal and Disassembly ........................................ 3-3
D isassem bly................................................................... ........ 3-1 Assembly and Installation ........................................ 3-3
A ssem b ly ................................................................................ 3-1 Axle Shaft G uide and Oil Seal Replacement .......... 3-4
Installatio n ..................................................................... ........3-1 Special T o o ls ..................................................................... 3-5
FRONT A X LE D IFFER EN TIA L Assem bly

1. Position the side gears, thrust washers and pinions in
Removal
differential cases.
1. If front axle assembly is removed from vehicle, m ount 2. Install pinion cross shaft into case and pions, align hole
assembly in suitable holding fixture and remove axle in shaft with hole in case and install lock pin. Peen edge
shafts as outlined in Axle Shaft Removal, Section 3, of hole to retain pin.
T ruck Service M anual. 3. Position ring gear on case and install bolts. Tighten
2. Remove cover attaching bolts and lock washers and the bolts alternately and evenly to 45-65 ft. lbs. torque. Do
m etal tag secured by one o f the attaching bolts. Remove not install differential bearing cones or shims until pin
cover and gasket. ion depth and pinion bearing preload have been
checked as outlined under "Pinion and Bearings-
NOTE: The tag shows the number of teeth on pinion -Assembly and Installation" in later paragraphs.
and drive gear.
3. Remove differential side bearing caps, making sure they Installation

are m arked for reassembly in the same position.
W ith pinion installed and pinion depth and bearing pre
4. Position Spreader Tool J-5231 so the two dowels on tool
load adjustm ents within limits as outlined under "Pinion and
fit into recesses in carrier, install two hold down bolts
bearings- Assembly and Installation" in later paragraphs,
and install a dial indicator at one end of opening in
determine differential bearing preload, install differential and
carrier to indicate w idth of opening.
adjust backlash as follows:
5. Expand spreader tool to spread carrier a m aximum of
.020 ".
Differential Bearing Preload
CAUTION: Do not attempt to remove differential 1. Install differential side bearing cones on case tight
without using the spreader tool. Do not expand car against shoulder on case with special Tool J-22175. Do
rier more than .020 in. or it may be damaged and not install shims at this time.
take a permanent set. 2. Install bearing cups, matching with cones as marked at
disassembly.
6. Remove dial indicator and, using a pry bar, lift out
differential assembly. Remove and tag bearing cups so
they may be reinstalled in their original positions. Re NOTE: If completely disassembled unit, assemble
lieve pressure on spreader tool. pinion before continuing procedure (page 3-3),
spread the carrier housing before placing the differ
Disassem bly ential assembly in the carrier with spreader J
5231-01 (not over .020 in.).
1. Remove bearing cups from differential case and identify
for reassembly.
2. Remove bearing cones from case, using suitable puller 3. Place differential assembly in carrier and install bearing
and remove shims from case. Identify all parts so they caps, tightening bolts just enough to keep caps in place.
may be reassembled in their original location.
3. Drive the pinion shaft lock pin out of case. 4. Install dial indicator at carrier with indicator button
4. Remove ring gear bolts from case and separate gear contacting back of ring gear. Rotate gear and check the
from case. runout.
5. Remove pinion shaft, pinions, side gears and thrust 5. If runout is more than .002".
washers from case. a. Remove differential and remove ring gear.

FRONT AXLE DIFFERENTIAL 3-2
Fig. 1~Front Axle D ifferential Assem bly
1. Nut 12. D ifferential Bearing Cup 21. D ifferential Bearing A djusting 30. T hrust W asher
2. W asher 13. Bearing Cap Shims 3 1. Ring Gear Bolt
3. Pinion Flange 14. D ifferential Bearing A djusting 22. D ifferential Bearing Cap 32. Oil S linger
4. O uter Bearing Shims Shims 23. D ifferential Bearing Cone 33. D ifferential Carrier
5. Drive Pinion 1 5. D ifferential Pinion 24. D ifferential Bearing Cup 34. Inner Bearing Cone
6. Inner Bearing Shims 1 6. T hrust W asher 25. Cover B olt 35. Inner Bearing Cup
7. Lock Pin 1 7. Cover 26. Gasket 36. O uter Bearing Cup
8. D ifferential Side Gear 1 8. Pinion Cross Shaft 27. Axle Shaft 37. O uter Bearing Cone
9. T hrust W asher 19. Ring Gear 28. Axle Shaft Guide 38. Oil S linger
10. Axle Shaft 20. D ifferential Case 29. Oil Seal 39. Oil Seal
11. D ifferential Bearing Cone

b.Install differential w ithout ring gear and check run not vary more than .002" between positions checked. If
out of differential case flange. If runout is more than backlash is not within these limits, change the differen
.002", the defect is probably due to bearings or dif tial bearing shim pack at both bearings to correct. Total
ferential case. If flange runout is less than .002" the of both shim packs must remain the same.
ring gear was probably at fault. Correct the defect 6. Check ring and pinion tooth contact pattern, using red
before proceeding further. lead and oil as outlined in Section 4.
6. If runout is saftisfactory (less than .002"), remove in 7. Install new gasket on carrier and install cover. Install
dicator and determ ine shim thickness necessary for dif metal ratio tag under one of the cover bolts. Tighten
ferential side bearing preload as follows: bolts evenly and alternately.
a. Insert a pry bar between carrier and bearing on end 8. Install axle shafts as outlined previously. (Refer to
housing half of case to move carrier as far as it will Truck Chassis Service Manual, Section 3).
go-
b. M easure clearance between carrier and bearing at
end housing half of case by inserting long feeler
gauges all the way across outer face of bearing. PINION AND BEA RIN G S
W rite down total feeler gauge thickness (For exam
ple: .054"). Remove feeler gauge.
Removal and Disassem bly
c. Insert pry bar between carrier and bearing on ring
gear flange half of case to move carrier until no 1. Remove pinion flange, oil seal, gasket, and oil slinger.
backlash can be detected between ring gear and pin Use Tool J-8614 to hold flange.
ion. 2. Remove differential as outlined in preceding pages.
d. M easure clearance between carrier and bearing at 3. Tap drive pinion and inner bearing cone out of carrier,
ring gear flange half of case by inserting long feeler using a soft hammer. Tag and save shim pack on splined
gauge all the way across outer face o f bearing. W rite end of pinion (outer bearing shim) for reference during
down feeler gauge thickness. (F or example: .036"). assembly. If ring gear and pinion are to be replaced,
e. Remove differential assembly from carrier and write down the m arkings plus, minus or (0) on face of
remove differential side bearings. pinion for reference during assembly.
f. Install shim packs as follows: 4. Remove pinion outer bearing cone from carrier.
5. If pinion bearings are to be replaced:
NOTE: If old shims are to be reinstalled make sure a. Remove inner bearing cup, using suitable drift, and
nicks in shims caused by bearing puller are placed to driver or slide ham m er to take cup out of carrier.
line up with notches in the case. Tag and save shim pack for inner bearing cup for
reference during assembly.
1. A t ring gear flange end of case, install shim pack b. Remove outer bearing cup from carrier, using a
equal to am ount gauged in Step d, above (example: suitable drift or punch.
.036"). Install bearing tight against shim. c. Press pinion inner bearing cone off pinion using
2. Subtract the am ount of shims installed (example: J-8553 and remove oil slinger from pinion.
.036") from the am ount gauged in Step b, above
(example: .054:). To the result (example: .054"
Assem bly and Installation
.036" .018") add .015" to .020" shims to provide
bearing preload. 1. Install oil slinger and new bearing cone on drive pinion,
3. Install the shim pack determ ined in Step (2) above using J-5590 to seat outer bearing against shoulder.
(example: .018" .015" .033") at end housing half of 2. Install outer bearing cup in carrier, using Tool J-6368
case and install bearing tight against shim. with driver handle J-8092 to seat cup in counterbore.
3. If a new ring gear and pinion are to be installed, note
the "plus" or "minus" markings on the rear face of the
Installing Differential
original pinion. These markings represent the variation
1. Using dial indicator and Tool J-5231-01 again, as when from the nominal pinion depth dimension to obtain the
removing and installing differential, spread carrier not proper tooth contact for individual gear sets.
more than .020". The approxim ate depth setting of the new pinion may be
2. Install differential bearing cups and set differential in made by increasing or decreasing the shim pack next to the
carrier. R otate differential and tap ring gear with a soft pinion inner bearing cup to correspond with the difference in
ham m er to assure bearing seating. markings on old and new pinions.
3. Install differential bearing caps in their correct loca To maintain proper pinion bearing preload, shims must be
tions as indicated by m arks m ade at time of removal. added to or subtracted from the pinion outer bearing shim
Tighten bolt slinger tight. pack to correspond with changes made to the inner bearing
4. Release pressure on spreader tool and remove; tighten shim pack.
bearing cap bolts to 80 ft. lbs. torque. If the difference in the markings on the old and new pin
5. Install dial indicator and check ring gear to pinion ions is in the "plus" direction, shims must be removed from
backlash at four equally spaced points around ring gear. both pinion bearing shim packs. If the difference is in the
Backlash must be between .003" and .006" and must "minus" direction, shims must be added.

3-4 FRONT AXLE DIFFERENTIAL
Examples of shim selection- than minus .001" to plus .003", the pinion depth is
satisfactory. If not, change pinion bearing shim packs
Markings on to make the two figures correspond within the specified
Pinions D ifference Amount limits.
New Old Between To Change 8. Using a troque wrench calibrated in inch pound and a
Pinion Pinion Markings Each Shim Pack suitable socket, check pinion bearing preload. The
rotating torque of the pinion shaft should be 10 to 20
+8 +5 +3 D ecrease .003" inch pounds. A dd or remove shims behind the outer
+5 +8 -3 Increase .003" bearing cone to bring preload within limits.
-5 -3 -2 Increase .002” 9. W hen pion depth and bearing preload are within limits,
-3 -5 +2 D ecrease .002”
install differential in carrier, adjust differential bearing
+5 -3 +8 D ecrease .008"
-4 +2 -6 Increase .006"
preload and ring gear backlash and complete the axle
assembly as outlined under "D ifferential-Installation."
4. W hen the approxim ate shim packs have been sleeted, 10. Remove flange and install slinger, new oil seal, flange
install inner bearing shim pack in carrier and install and propeller shaft.
cup, using Tool J 9276-2 to seat cup tight against shims.
NOTE: If not completely assembled, refer back to
5. Insert pinion and inner bearing cone in carrier and Step 3, page 3-1 to install differential into carrier
housing.
install outer bearing shim pack on end of pinion. Install
outer bearing cone, using Tool J-5590 to seat bearing
11. Fill unit with recommended lubricant, lower vehicle on
tight against shim pack. D o not install oil seal at this
time. hoist, and road test vehicle.
6. Install pinion flange, w asher and nut, using Tool J-8614
to hold flange while tightening nut to 210 ft. lbs. torque. AXLE SHAFT GUIDE AND OIL SEAL
REPLACEMENT
7. D eterm ine proper pinion depth using Pinion D epth
Gauge, Tool J- 5341, with Tool J-7892 (SE-1065-1, The axle shaft guides and oil seals, located just outboard
(2)-5, (2)-6, (2)-9SS, (1)-10, (l)-58 with 1" microme of the differential bearings, can be replaced only after re
ters). W hen using the m icrom eter gauge, the actual moval of the differential.
pinion depth setting can be determ ined by adding the 1. Remove differential as outlined previously.
m icrom eter gauge reading to the thickness of the step 2. Drive the guides and seals inboard out of carrier.
plate and com paring the result with the nominal dimen 3. Install new guides in tube.
sion of 2.625" plus or m inus the m arking on the face of 4. Lubricate new oil seals and install in tube, with lip of
the pinion. If the difference in the two figures is less seal inboard, with J-8 107-4.

SPECIAL TOOLS
Fig. 2--Four-Wheel Drive D ifferential Special Tools
1. J-52 3 1-01 Spreader - Axle Carrier. 9. J-86 14 Holder and Remover -

2. J -2 2 8 8 8 Puller - D ifferential side Com panion Flange.
bearing. 10. J -2 3 4 7 6 Installer - Companion Flange
3. J-81 07 -4 A da pter - D ifferential side (use w ith J-8459-5 adapter)
bearing. (not shown).
4. J-2 2 1 7 5 Installer - D ifferential side 11. J-5341 Gauge - Pinion depth Consists
bearing. of parts:
5. J-5 5 9 0 Installer - Pinion inner and (1) SE 1065-1, (2)-5, (2)-6,
outer bearing cone. (2)-9SS, (1)-10,
6. J-6 3 6 8 Installer - Carrier pinion outer (1 )-58 w ith 1" m icrometer.
bearing cup (use w ith J-8092). 12. J-8001 Dial in d ica to r set.
7. J-8 0 9 2 Driver Handle - Carrier pinion 13. J-2 2 8 7 2 Remover - Pinion bearing inner
outer bearing cup (use w ith cup.
J-63 68 ) 14. J -2 3 4 9 4 Installer - Pinion oil seal.
8. J-92 76 -2 Installer - Pinion inner bearing
cup (set against shims).

SECTION 4
REAR AXLE DIFFERENTIAL CARRIER
CONTENTS OF THIS SECTION
Chevelle, M onte Carlo, 116" W.B. Station Series 20 5500 Lb. Differential (D a n a ) ........................ 4-30
W agons, N ova and 10 Series Trucks ............... 4-1 Positraction Differentials ................................................. 4-35
Chevrolet (Except 116"W.B. Station W agons) and Series 20-30 T ruck 5200-7200-11,000 lb.
C a m a ro ..................................................................... 4-11 D ifferentials................................................................441
C o rv ette............................................................................... 4-20 S pecialT oo ls..................................................................... ...4-51
CHEVELLE, MONTE CARLO, 1 16" W .B. STATION

W AGONS, NOVA AND SERIES 10 TRUCK
INDEX
Differential C a s e ................................................................ ....4-1 Inspection.................................................. ......................4-4

R em o v al................................................................................4-1 Pinion a n d /o r Bearing R e p la c e m e n t.................. ....4-4
In sp e c tio n ........................................................................ ....4-1 In stallation .................................................................. ....4-7
Differential Bearing R eplacem ent..................................4-1 Drive Pinion and B earin g ...........................................4-7
Ring G ear or Differential Case Differential Bearing Preload and Ring
R eplacem ent.........................................................................4-3 G ear A d ju stm e n t...................................................... ....4-8
D rive Pinion.........................................................................4-4 Ring G ear and Pinion Contact P attern .................. 4-10
R em o v al................ ........................................................... ....4-4
5. Place left and right bearing cups with bearing caps so

Differential Case that they may be reinstalled in original positions. Place
shims with appropriate cups.
Removal
Inspection
1. Remove axle shafts as outlined in the applicable chassis
Service M anual. 1. Clean all parts in cleaning solvent; inspect all bearing
2. Roll out the differential pinions and thrust washers, cups, races and rollers for scoring, chipping or evidence
then remove side gears and thrust washers. M ark pin of excessive wear.
ions and side gears so th at they can be reassembled in 2. Inspect pinion splines and flange splines for evidence of
original position. excessive wear.
3. M ark one bearing cap and housing for reassembly in 3. Inspect ring gear and pinion teeth for possible scoring,
same position. Remove bearing cap bolts and bearing cracking or chipping.
caps, tap surface of bearing caps to loosen. 4. Inspect differential case for cracks or scores on side
gears, thrust washers, and pinion thrust faces.
CAUTION: Do not attempt to pry caps off as this 5. Check fit of differential side gears in case.
may damage machined face of caps. 6. Check fit of side gear and axle shaft splines.
7. Inspect differential pinion shaft for scoring or evidence
4. Using a pry bar as shown in Figure 2A, pry differential of excessive wear.
case out of carrier. Exercise caution in prying on carrier
so th at gasket sealing surface is not damaged. If the
bearings are preloaded, the case will suddenly fall free
Differential Bearing Replacement
when it is pried past a certain point; therefore, make 1. Install Tool J-22888 and A dapter Plug J-8 107-4, assur
sure case is properly supported to prevent damage. The ing puller legs are fitted securely in notches in case and
bearing caps may be loosely installed, as shown in Fig against bearing cone.
u re 2A , to p re v e n t case fro m falling. 2. Tighten puller screw to remove bearing (fig. 3A).

REAR AXLE DIFFERENTIAL CARRIER 4-2
r y ----------- 1 4
15
Fig. 1A-R ear Axle Cross-Section
1. C om panion Flange 13. Cover

2. D eflector 14. Pinion Shaft
3. Pinion Oil Seal 15. Ring Gear
4. Pinion Front Bearing 16. Side Gear
5. Pinion Bearing 17. Bearing Cap
Spacer 18. Axle Shaft
6. D iffere ntial Carrier 19. T hrust W asher
7. D iffere ntial Case 20. D ifferential Pinion
8. Shim 21. Shim
9. G asket 22. Pinion Rear Bearing
10. D iffere ntial Bearing 23. Drive Pinion
11. "C " Lock
12. Pinion S haft Lock
Bolt

Fig. 2A --D ifferential Case Removal
3. Place new bearing on hub w ith thick side of inner race

tow ard case and drive into place, using Tool J-9537 for
light-duty axle and Tool J-8359 for heavy-duty axle.
4. Before bearing installation on opposite hub, support
differential case on A dapter Plug J-8107-4. This allows
differential case to rest on adapter instead of bearing
cage (fig. 4A). Install rem aining bearing as instructed in
Step 3.
Ring Gear or Differential Case

Replacement
Fig. 4 A -D iffe re n tia l Bearing Installation
1. Remove the ring gear screws and lock washers and,
using a soft faced ham m er, tap ring gear off the case.
3. Position ring gear over pilot diam eter of the case. Install
NOTE: Do not attempt to pry ring gear from case, to every other ring gear bolt and lock washer, then draw
do so may damage machined surfaces. them up evenly and snugly so that gear face is flush with
face of case.
2. Install guide pins, m ade from 3/8"-24 x 1-1/2" long cap 4. Remove guide pins and install remaining bolts - torque
screws with heads cut off and ends slotted, to ring gear all bolts to specifications.
(fig. 5A). 5. Install thrust washers and side gears in case. If same
parts are used, replace in original sides. Position pinions
and thrust washers through loading hole in case 180
J 2 2 88 8
Fig. 3A ~ D iffere ntial Bearing Removal Fig. 5A -R in g Gear Guide Pins Installed

degrees apart so th at they engage side gears. R otate

gears until pinion shaft holes are aligned. Install pinion
shaft and lock screw. It is not necessary to torque lock
screw until axle shafts are installed.
Drive Pinion
Removal
1. Remove differential as previously outlined.
2. Remove propeller shaft.
3. Install Tool J-8614-1 on pinion flange and remove pin
ion flange nut and w asher (fig. 6A). (Position J-8614-1
on flange so th at the four notches are tow ard flange.)
Discard nut and use a new one upon reassembly.
4. Thread end of Tool J-8614-3 into small O.D. end of
J-8614- 2. Then with J-8614-1 installed as in Step 6,
Fig. 7A~Drive Pinion Flange Removal
insert J-8614-2 into J-8614-1 and turn it 45 degrees to
locked position. Remove flange by turning J-8614-3 chipping or evidence of excessive wear. On pinion bear
while holding J-8614-1 (fig. 7A). ing rollers, inspect large end of rollers for wear. This is
5. Pry old seal out of bore, using a screw driver or a where wear is most evident on tapered roller bearings.
ham m er and chisel.
If deflector requires replacement, remove by tapping
from flange. Clean up stake points. Install new deflec NOTE: The pinion bearings are of the tapered type,
tor, and stake deflector at three new equally spaced and the natural wear pattern is a frosted condition
positions. with occasional slight scratches on races or rollers.
This does not indicate a defective bearing.
NOTE: Staking operation must be performed in
such a manner that the seal operating surface is not 2. Inspect pinion splines and flange splines for evidence of
damaged. excessive wear.
3. Inspect ring gear and pinion teeth for possible scoring,
6. Remove drive pinion by tapping on front end w ith a soft cracking or chipping.
faced ham m er. T hen remove pinion front bearing cone
from carrier bore. D iscard pinion bearing spacer and
use a new one upon reassembly. Pinion and/or Bearing Replacement
1. If necessary to replace pinion bearings, tap old cups out
NOTE: Care must be taken not to damage pinion of carrier using a brass drift. Tap alternately on oppo
bearings while removing pinion from carrier. Inspect site sides of cup to prevent cups from cocking in carrier.
bearings and cups for damage and replace if needed. Inspect cup seats and bore for any nicks or burrs and
Inspection remove as necessary.
2. Position new bearing cup in carrier, thick edge of cup
1. Clean all gears and bearings in cleaning solvent and
inspect all bearing cups, races and rollers for scoring,
Fig. 6A -D rive Pinion Nut Removal Fig. 8A -D rive Pinion Rear Bearing Cup Installation

Fig. 9 A -D rive Pinion Front Bearing Cup Installation
tow ard shoulder in carrier, then using Cup Installer

J-7137 for heavy-duty axle and J-7817 for light-duty
Fig. 1 1 A -ln sta lle d V ie w of Pinion Depth Gauge (Light-Duty
axle to install front cup and J-0270- 14 for light-duty
Axle)
axle and J-8608 for heavy-duty axle to install rear cup,
press cup into carrier until it seats against shoulder
6. For Passenger Cars: Light-D uty Axles--J-6266-52-
(figs. 8A and 9A). Check installation to make certain
-position gauge plate with lower surface (x stamped
th at cup is not cocked and that it is fully seated against
near low side) tow ard top of carrier (fig. 11 A).
shoulder.
Heavy-Duty A xles--J-6266-53-position gauge plate
3. Remove pinion rear bearing cone and roller assembly, with higher surface (x stamped near high side) toward
using Press Plate Tool J-22912 (fig. 10A). Record thick top of carrier (fig. 12A).
ness of shim removed from between bearing cone and a.Insert clamp screw through gauge plate and both of
pinion head. the pinion bearings.
4. If the original ring gear and pinion and the pinion rear b. Position J-6266-25 (light-duty axle) or J-8360-2
bearing assembly are to be reinstalled, the original shim (heavy-duty axle) on threaded end of clam p screw
or one o f the same thickness may be used. If the ring and index it in front bearing. Install hex nut and
gear and pinion or the pinion rear bearing assembly are rotate bearings several times to make sure that they
replaced, the correct shim thickness may be determined are seated.
as follows. 7. For Truck: Position J-6266-52 Pinion D epth Setting
5. Lubricate pinion bearing cone and roller assemblies and G auge Plate in pinion rear bearing (fig. 13A). Gauge
position them in proper cups. plate has two gauging surfaces.
Fig. 10 A -D rive Pinion Cone and Roller Assem bly Removal Axle)

i. Position Tool J-6266-28 in carrier as shown in Fig

ure 15A. Swing tool body so that plunger does not
J-6266-31
DIAL INDICATOR (HEAVY DUTY
touch gauge plate, and set indicator dial at zero.
ONLY)
NOTE: Barrel Adapters Tool J-6266-31 must be

used when gauging heavy- duty axle. Make sure
adapters are seated in differential bearing bores of
carrier before measuring depth.
PLUNGER
j. Slowly swing inner end of tool plunger across gauge
plate until highest indicator reading is obtained. Re
cord this m easurem ent and recheck to see th at it is
correct.
k. All service pinion gears are stam ped with a code
num ber on the threaded end of the pinion. The
num erical difference between the code num ber and
the gauge reading obtained in Step i determines the
required thickness of the pinion locating shim.
EX A M PLE:
Pinion Code N u m b er................................... 45
Fig. 13A --lnstalled V ie w of Pinion Depth Gauge
D ial Indicator R e a d in g ............................... 16
D ifference........................................................ 29
Light-duty axle-position gauge plate with lower surface Proper Shim T h ic k n e ss................................... 029”
(x stam ped near low side) tow ard top of carrier.
Heavy-duty axle-position gauge plate with higher sur
face tow ard top of carrier. NOTE: Shims are available in .001" increments from
d. Insert clam p screw through gauge plate and both of .021" to .037". Each shim has the thickness etched on
the pinion bearings. flat surface for easy identification.
e. Position J-6266-25 on threaded end of clam p screw
and index it in front bearing, install hex nut and
rotate bearings several times to m ake sure th at they 9. Remove Tool J-6266 and pinion bearing cone and roller
are seated. assemblies from carrier.
8. Continue with the following steps for both passenger and 10. Position shim selected in above procedure on pinion
truck. shaft and against pinion head.
f. Tighten hex nut until 20 in lbs. of torque is required 11. Install new cone and roller assembly, using Tool J-5590
to rotate bearings (fig. 14A). for lightduty axle (fig. 16A) or Tool J-9772 for heavy-
g. A fter torque has been established check position of duty axle (fig. 17A). Press cone against shim and rear
gauge plate in carrier (See Steps b and c). face of pinion.
h. Position dial indicator (Tool J-8001-3) on gauge
post of Tool J- 6266-28 so th at indicator button rests
on top of tool plunger.
Fig. 14 A -M e a su rin g Drive Pinion Bearing Rotating Torque Fig. 15 A -M e a su rin g Drive Pinion Shim Requirem ent

J-22804-2
J-9458
Fig. 1 8 A -D rive Pinion Flange Oil Seal Installation (Light Duty)
pinion shaft and install pinion front bearing cone and

roller assembly.
2. Pack the cavity between the seal lips of the pinion flange
oil seal, with a lithium-base extreme pressure lubricant,
position seal in bore and place gauge plate J-22804-2
(light-duty axle or J-22804- 1 (heavy-duty axle) over
seal and against seal flange. Gauge plate insures proper
seating of seal in carrier bore.
Fig. 16A~Drive Pinion Cone and Roller Assem bly Installation 3. Using Tools J-21468 and J-9458 for light-duty axle (fig.
(L ig h t D u ty ) 18A) or Tool J-21057 for heavy-duty axle (fig. 19A),
press seal into carrier bore until gauge plate is flush with
the carrier shoulder and seal flange. T urn gauge plate
Drive Pinion and Bearing 180 degrees from installer position; seal m ust be square
in carrier bore to seal properly against pinion flange.
Installation
4. Position and align pinion flange on pinion shaft, using
1. Position pinion and rear bearing cone and roller assem Tools J-9458 and J-8614-1. Tool J-9458-1 is threaded
bly in carrier, install a new pinion bearing spacer on onto pinion shaft and nut tightened against J-9458-2 to
Fig. 17 A -D rive Pinion Cone and Roller Assem bly Installation Fig. 19A~Drive Pinion Flange Oil Seal Installation
(Heavy Duty) (Heavy Duty)

3. Service spacers are available in one thickness only:

.170" ± .001" for light an d h eav y -d u ty axles. Steel
service shim s are used w ith th e service sp acer. See
s h im c h a r t b e lo w fo r s h im a v a ila b ility a n d
id en tificatio n .
NOTE: Production preloading of the differential

bearings is accomplished by the use of cast iron pre
load shim. These shims cannot be used when re
building the carrier as they may break when tapped
into place.
Fig. 20A~D rive Pinion Flange Installation 4. Install strap J-22779-6 on left bearing by tightening
bearing bolts alternately and evenly to snug fit.
5. W ith the ring gear tight against the pinion gear (.000"
pull flange on shaft (fig. 20A). Remove J-9458 after to .001" backlash) insert gauging Tool J-22779 between
flange is seated. the left bearing cup and carrier housing (fig. 22A).
5. Pack the cavity between end of pinion splines and pin W hile oscillating tool, turn adjusting nut clockwise un
ion flange w ith a nonhardening sealer (such as Per- til a noticeable drag is produced.
m atex Type A or equivalent) prior to installing washer
and nut on pinion.
DIFFERENTIAL BEARING SHIM IDENTIFICATION
6. Install new self-locking nut on pinion shaft. Tighten nut
to remove end p lay -co n tin u e alternately tightening, in
Identification Notches
small increm ents, and checking preload with Torque Shim
W rench J-5853 and A dapter J-5810 until torque re Heavy Duty Light Duty
Thickness
quired to rotate pinion is 20-25 in. lbs. for new bearings I.D. O.D. I.D. O.D.
and seal, or 5-10 in. lbs. when used parts are reinstalled
.040 0 0 3 4
(fig. 21 A). .042 4 1 4 0
.044 4 2 4 1
NOTE: Rotate torque wrench slowly as torque in .046 4 3 4 2
creases relatively fast. If, however, it happens that .048 4 4 4 3
the torque specification is exceeded back off nut .050 5 0 5 0
and readjust to specifications. .052 5 1 5 1
.054 5 2 5 2
Differential Bearing Preload and Ring Gear .056 5 3 5 3
Adjustment .058 5 4 5 4
1. Check condition of bearing cups, cup seat in carrier and .060 6 0 6 0
carrier caps to m ake sure they are free from nicks, burrs .062 6 1 6 1
and foreign m aterial. .064 0 2 0 0
.066 0 3 0 1
2. Lubricate bearings w ith axle lubricant, position cups on
.068 0 4 0 2
proper bearings then install differential assembly in car .070 1 0 0 3
rier. Install right bearing cap, tightening the bolts to a .072 1 1 1 0
snug fit. .074 1 2 1 1
.076 1 3 1 2
.078 1 4 1 3
.080 2 0 2 0
.082 2 1 2 1
.084 2 2 2 2
.086 2 3 2 3
.088 2 4 3 0
.090 3 0 3 1
.092 3 1 3 2
.094 3 2 3 3
.096 3 3 0 4
.098 3 4 1 4
.100 4 0 2 4
* Additional shims are available for the light-duty axle; these shims,
with a thickness of .052' through .062', are identified by a number
Fig. 21 A--M easuring Drive Pinion Bearing Preload stamped on the shim. This number indicates the shim thickness.

12. T urn adjusting nut clockwise while oscillating tool until

a noticeable drag is produced (bearing outer race ro
tates with tool). Remove tool and measure the thickness
of the gauging plate in a minimum of three places (fig.
23A). Average these readings and record results.
13. T urn ring gear 90 degrees and repeat Steps 11 and 12.
14. The thickness of the service shim is determined as in

Step 9, however, an additional .008" must be added to
obtain proper side bearing preload.
EXAM PLE:
G au ge thickness
(h ig h er re a d in g ) .................................................. 226"
Service sp acer used
D iffe re n c e ......................................................... 056"
P r e lo a d .......................................................... plu s .008"
Service shim size
(righ t s id e )........................................................ 064"
Fig. 2 2 A -D e te rm in in g Service Shim Size
NOTE: Service shims are available in increments of
6. Tighten lock bolt on side of the tool then remove tool. .002” -if the shim measurement falls between the
available shims, select a shim thinner by .001".
7. Using a m icrom eter, m easure the thickness of the gaug
ing plates in a m inim um o f three places (fig. 2 3A). 15. Install the selected shim between the service spacer
Average these readings and record result. and bearing, using a soft-face ham m er (fig. 24).
8. T urn ring gear 90 degrees and repeat Steps 5, 6 and 7. 16. Install right bearing cap and torque both bearing caps
to specifications. M ount a dial indicator on the carrier
9. T h e th ic k n e ss o f the service shim is d e te rm in e d by and check backlash between ring gear and pinion (fig.
su b tra c tin g th e th ick n ess o f th e service sp acer from 25A). Backlash should be within the range of .003" to
th e h ig h e r o f th e tw o a v e ra g e d re a d in g s o b ta in e d .010" with a reading of .005" to .008" preferred. Check
in ste p s 7 a n d 8. reading at four equally spaced positions around the ring
EXAM PLE: gear. Variation in reading should not exceed .002".
G a u g e thickness (h ig h er re a d in g ) ...................... 254"
Service sp a c e r used NOTE: Position the dial indicator so that indicator
button is perpendicular to tooth angle and in line
Service shim size (left s id e ).................................. 084"
with gear rotation.
10. Install the selected shim between the service spacer and
bearing. Remove strap J-22779-6 and install left bearing If variation in backlash exceeds .002" measure ring gear
cap. Torque bearing cap bolts to specifications. and case runout as shown in Figure 26A. G ear runout should
11. Remove right-hand bearing cap and install Tool J- not exceed .002"; should runout exceed this limit, check ring
22779 between right bearing cup and carrier housing.
Fig. 2 3 A -M e a su rin g Gauge Plate Thickness Fig. 2 4 A -ln s ta llin g D ifferential Shim

Fig. 2 5 A -C h e ckin g Ring Gear Backlash Fig. 2 7 A -G e a r Tooth Nom enclature
gear and case for deform ation a n d /o r foreign m atter between 5. Inspect the contact pattern produced by the above
case and gear. procedure. (Figure 27A shows the terminology used in
If gear lash is not w ithin limits, correct by decreasing shim analyzing contact patterns). M ake adjustm ents as in
thickness on one side and increasing thickness of the other dicated by the contact pattern (fig. 28A).
shim the same amount. T otal shim thickness m ust be m ain The large end of the tooth is called the "heel" and the
tained to m aintain proper preload. small end the "toe". Also, the top of the tooth, which
EX A M PL E : By decreasing shim on the right side is the part above the pitch line, is called the "face,"
.002" and increasing shim thickness of the left side by while the part below the pitch line is called the "flank".
.002" backlash will decrease by .001". The space between the adjacent meshing teeth is re
ferred to as "backlash".
Figure 28A shows correct and incorrect contact pat
Ring Gear and Pinion Contact Pattern terns. Contact pattern "A" provides the ideal bearing
for quietness and long life. If the pattern shows a toe
1. Thoroughly clean the ring and pinion gear teeth.
contact "B", it indicates not enough backlash. To cor
2. Paint ring gear teeth lightly and evenly with a mixture
rect, move the ring gear away from the pinion by in
of pow dered red lead and oil of a suitable consistency
creasing the right thickness while decreasing left shim
to produce a contact pattern.
thickness an equal amount.
3. Remove the differential pinion shaft, and install axle
If the pattern shows a heel contact "C," it indicates
shafts and d ru m s-in stall wheel bolts to retain drum s on
too m uch backlash. To correct, move the ring gear
axle shaft. Expand brake shoes until a torque of 60 ft.
tow ard the pinion by increasing left shim thickness
lbs. is obtained at pinion nut.
while decreasing right shim thickness an equal amount.
4. R otate pinion through several revolutions in the for
ward and reverse direction until a definite contact pat
tern is developed on the ring gear.
NOTE: Make adjustment increasing and decreasing
shim thickness by 0.002" at a time, check contact
with red lead mixture and continue adjustment until
tooth contact appears as in "A ". Backlash must re
main within limits.
If the pattern shows a high face contact "D ", it indi

cates th at the pinion is too far out, th at is, too far
tow ard the front of the car.
To correct a pattern such as "D ", it will be necessary
to install a thicker pinion shim as described under "Pin
ion a n d /o r Bearing Replacem ent". A .001" thicker
shim is recommended as a starting point. Continued
changes may be necessary to obtain the correct setting.
If the pattern shows a flank contact "E", it indicates

th at the pinion is in too far. To correct, replace the
pinion shim with a .001" thinner shim and recheck
contact pattern.
In m aking pinion adjustments, be sure backlash is
Fig. 2 6 A -C h e ckin g Ring Gear Runout correct before testing contact pattern. Moving the pin

ion in reduces backlash and moving it out increases NOTE: This wheel to axle flange fastener is an im
backlash. portant attaching part in that it could affect the
A fter satisfactory contact pattern is produced as in performance of vital components and systems, and
"A ," clean ring and pinion gear teeth and pour a liberal /or could result in major repair expense. It must be
q u a n tity o f re a r axle lu b ric a n t o n g ears a n d b e a r replaced with one of the same part number or with
ings. T u rn gears to w o rk lu b ric a n t in to all su rfaces. an equivalent part if replacement becomes neces
sary. Do not use a replacement part of lesser quality
6. Install wheel assembles: fill rear axle with proper lubri or substitute design. Torque values must be used as
cant to specifications. specified during reassembly to assure proper reten
tion of this part.
TOE CONTACT CORRECT HEEL CONTACT

TOOTH
CONTACT
FACE CONTACT FLANK CONTACT
Fig. 28A~G ear Tooth C ontact Patterns
CHEVROLET (EXCEPT 1 1 6 " W .B . STATION WAGONS)

AND CAMARO
INDEX
Service Inform ation.......................................................... .... 4-11 Install Pinion Assembly and Adjust Pinion
Removal and Disassembly of Differential Case P r e lo a d ..................................................................... .. 4-15
A ssem bly................................................................... .... 4-12 Assemble Standard Differential C ase................. .. 4-17
R em oval.......................................................................... 4-12 Install Case and Adjust Side Bearing
Disassembly o f C a s e ................................................... 4-12 P r e lo a d .................................................................4-17
Rem oval of Pinion B earings................................. .... 4-12 A djust Backlash...........................................................4-18
Assembly and Installation o f Differential C ase........ .... 4-13 G ear Tooth Pattern C h eck ................................... ...4-18
Set Pinion D e p th ................................................................... 4-14
SERVICE INFORMATION
O verhaul procedures for P and M type axles used on located on the front of the right axle tube about three (3)
Chevrolet Models differ slightly from other axles. These axles inches outboard from the differential carrier. For example,
will be stam ped "P" or "M " in the axle identification num H K P 218 DW .
ber. Refer to the third letter in the axle identification num ber

Removal and Disassembly of

Differential Case Assembly
Removal of Differential Case Assem bly -

Differential in Car
1. Raise vehicle on hoist.

2. Loosen parking brake cables so th at brake is not applied
when axle assembly is lowered.
3. M ark rear universal jo in t and pinion flange for proper
alignm ent at reassembly. Disconnect rear universal
joint.
4. Lower differential assembly ju st far enough to clear
lower portion of fuel tank.
NOTE: The following steps also apply when making Fig. IB -D iffe re n tia l Case Removal
repairs with differential assembly removed from
car. Disassem ble Standard Differential Case
Assem bly
5. Remove bolts securing cover to housing to drain lubri
cant.
6. W hile lubricant is draining, remove rear wheels and 1. If differential side bearings are to be replaced, install
drum s. Tool J-22888 and A dapter Plug J-8 107-4 for P Type
Axles and A dapter Plug J-8 107-2 for all others. (Fig.
7. Remove rear axle shafts as outlined in Chassis Service
2B)
M anual.
2. Remove screw that retains differential pinion shaft.
Remove differential pinions, side gears and thrust
NOTE: Before proceeding with following steps, it is washers from case.
advisable to check the existing ring gear to pinion 3. If ring gear is to be replaced and it is tight on case after
backlash as described under "Adjust Differential removing bolts, tap it off using a soft hammer; do not
Backlash". This will indicate gear or bearing wear or pry between ring gear and case, to do so may damage
an error in backlash or preload setting which will m achined surfaces.
help in determining cause of axle noise. Backlash
should be recorded so that if same gears are reused, Removal of Pinion and Bearings
they may be reinstalled at original lash to avoid
1. Check Pinion bearing preload as described under "In
changing gear tooth contact.
stall Pinion Assembly and A djust Pinion Preload." If
there is no preload reading, check for looseness of pin-
8. M ark side bearing caps for installation in same position

on reassembly. Remove bolts holding differential side
bearing caps to housing.
CAUTION: Do not attempt to pry caps off as this

may damage machined face of caps.
9. D ifferen tial case assem bly can now be re m o v e d by

p ry in g ag ain st rin g gear b o lt u sing su ita b le p ry b ar.
E xercise c a u tio n in pry in g o n carrier so th a t gasket
sealin g su rface is n o t d a m a g e d . I f th e b e a rin g s are
p re lo a d e d , th e case will su d d e n ly fall free w hen it
is p rie d p a st a c e rta in p o in t; th e re fo re , m ak e sure
case is p ro p erly su p p o rte d to p rev en t dam ag e. T he
b e a rin g caps m ay be loosely in stalled , as sh o w n in
F ig u re IB to p re v e n t case fro m falling.
10. Place right and left bearing outer races and shims in sets
with m arked bearing caps so th at they can be reinstalled
in their original positions. Fig. 2 B -D iffe re n tia l Side Bearing Removal

Fig. 3B--Drive Pinion Nut Removal
ion assembly by shaking. Looseness indicates need for

bearing replacement. If assembly is run long with very Fig. 5B--Removing Drive Pinion Rear Bearing.
loose bearings, ring and pinion will also require replace
ment. bolts when pressure is applied. Record thickness of
2. Install H older J-8614-10 on flange by using two shim removed from between bearing and pinion head.
5/16-18 x 2" bolts with flat washers. Remove pinion
6. Pry pinion oil seal from carrier and remove front pinon
nut and washer. See Figure 3B.
bearing. If this bearing is to be replaced, drive outer
3. Pull pinion flange from pinion using Puller J-8614-2 in race from carrier using a brass drift in slots provided for
H older J-8614-1. To install puller, back out puller this purpose.
screw, insert puller through holder, and rotate 1/8 turn. 7. If rear pinion bearing is to be replaced, drive outer race
See Figure 4B. from carrier using a brass drift in slots provided for this
a. If deflector requires replacem ent, remove by tap purpose.
ping from flange.
4. Remove pinion assembly. If necessary, tap pinion out
Assembly and Installation of Differential
w ith soft ham mer, while being careful to guide pinion
w ith hand to avoid dam age to bearing outer races. Case Assembly
5. If rear pinion bearing is to be replaced, remove rear
pinion bearing from pinion shaft using Press Plate J- Before installation of any parts, examine the wearing
22912 (fig. 5B). Tighten nuts on tool until plates are surfaces of all parts for scoring or unusual wear. M ake cer
under the bearing inner race. Then, set tool on press. tain that the interior of the carrier housing is absolutely clean
M ake sure the plates straddle opening on press. Do not and dry. Also make certain that the parts to be assembled are
position bolts across opening. To do so may bend the absolutely clean and that there are no burred edges. Lubri
cate all parts with the specified rear axle lubricant just before
assembly.
NOTE: If equipped with positraction differential,

only positraction lube should be used.
NOTE: If the ring gear and pinion are changed, only

factory hypoid lubricant should be used for filling
because of its special anti scoring properties. For
this reason the proper lubricant is included in the
carton with the replacement gears as received.
1. If rear pinion bearing is to be replaced, install new outer

race using D river H andle J-8092 and Installer J-9745
on P-Type and J-8608 on all other axles. See Figure 6B.
2. If front pinion bearing is to be replaced, install new

outer race using Installer J-7137 with D river Handle
Fig. 4B -D rive Pinion Flange Removal J-8092. See Figure 6B.

Fig. 6 B -D rive Pinion Front and Rear Bearing Cup Installation
Set Pinion Depth
NOTE: If the original ring gear and pinion and the

pinion rear bearing assembly are to be reinstalled,
the original shim thickness may be used.
Ring and pinion gear sets are m atched in a special test

m achine which perm its adjustm ent of pinion depth in ring
gear until a point is reached where best operation and proper
tooth contact under load is obtained. A t this point, the set
ting of the pinion with reference to the centerline of the ring
gear is indicated by the m achine. This setting may vary
slightly from the design or "nom inal" setting due to allowa
ble variation in m achining the parts. However, most produc
tion pinions and all pinions used for service replacem ent are
zero or nom inal pinions. If during repair, a pinion is found
having a plus or m inus reading recorded in thousandths on
the re?r face of the pinion, this indicates th at the pinion Fig. 7B ~lnstalled V iew of Pinion Depth Gauge
during testing was found to have best tooth contact at a
b. Position J-6266-25 onto front bearing. Install nut
position varying from design or nominal depth.
and rotate bearings several revolutions to make sure
In order to com pensate for all of the allowable machining
they are seated.
variables, a procedure of gaging the carrier and shimming the
pinion has been developed. A fter gaging a carrier, the assem c.Tighten hex nut until 20 in. lb. of torque is required
bler is able to install a shim between the front face of the to rotate bearings (Fig. 8B).
pinion and its bearing so th at pinion depth can be adjusted
to an exact required specification for best tooth contact in
For All Except P-Type Axles:
each axle assembly.
d. Install Tool J-6266-28. Rest plunger of Tool J-6266-
Pinion depth is set with Pinion Setting Gage J-6266.
28 on low gauging surface m arked Y (Fig. 9B).
Set up pinion setting gage as follow s (Fig. 7B):
For P-Type Axles:
1. Be certain th at all parts of pinion setting gage are clean. e. Install adapter rings J-6266-31 onto Tool J-6266-28.
Install onto carrier. Rest Plunger of Tool J-6266-28
2. Lubricate front and rear pinion bearings which will be on high gauging surface m arked Z (Fig. 9B).
used in final reassembly and position them in their
respective races in the carrier. For All Axles:
a. Position Gauge Plate J-6266-54 into carrier and in f. Position dial indicator (Tool J-8001-3) on gauge post
sert bolt through gauge plate and both pinion bear of Tool J-6266-28 so that indicator button rests on
ings. top of tool plunger.

Fig. 8 B -M e a su rin g Drive Pinion Bearing Rotating Torque

Fig. 10B--M easuring Drive Pinion Shim Requirem ent
g. Slowly swing end of tool plunger across gauge plate
until highest indicator rearing is obtained (Fig. 5. Position shim selected in above procedure on pinion
10B). A t this highest reading, zero dial indicator. shaft and against pinion head.
Recheck to assure zero reading. 6. Examine the ring gear for nicks, burrs or scoring. Any
h. Swing rod off gauge plate and read dial indicator. of these conditions will require replacem ent of the gear
This reading is the proper shim. set.
7. Select the correct pinion shim to be used during pinion
NOTE: Read indicator direct. Do not read indicator reassembly on the following basis:
travel. a. If the production pinion is being reused and the
pinion is m arked plus, subtract the am ount specified
3. For P-Type axles, shims are available from .020" to on the pinion from the shim thickness as determ ined
.039" in increm ents of .001". in Step 3.
For all other axles, shims are available from .020" to b. If the production pinion is being reused and the
.038" in increm ents of .002". (If odd num ber shim is pinion is m arked minus, add the am ount specified
required, use next highest num ber shim). on the pinion to the shim thickness as determined
If necessary to install shim greater than mentioned in Step 3.
above use two shims whose thickness equals required c. I f a service p in io n is b ein g used (n o m a rk in g )
num ber. Each shim has the thickness etched on the flat th ic k n e ss d irectly as d eterm in e d in S tep 3.
surface for easy identification.
4. Remove Tool J-6266 and pinion bearing cone and roller
assemblies from carrier. NOTE: Frequently production pinions are nominal or
zero pinions (no marking). When reusing a nominal
production pinion, shim as with service pinion using
shim thickness directly as determined in Step 3.
8. Position correct shim on pinion shaft and install rear

pinion bearing. Use Installer Tool J-6547 for P-Type
axles and J-9772 for all others (Fig. 11B).
Install Pinion Assem bly and Adjust Pinion
Preload
1. Place front bearing into bore.

2. Coat O.D. of pinion seal with sealing compound. Install
seal by using Installer J-22388. See Figure 12B. Note
that seal does not install flush but it protrudes about
.150" out from the housing.
3. Coat lips of pinion oil seal and seal surface of pinion
Fig. 9B -G a uge Plate M arking flange with gear lube.

PROTECTIVE
TUBE OR PIPE
J— 9 7 7 2 OR
J— 6 5 4 7 FOR
PO NTIAC BUILT AXLES
Fig. 13B -D rive Pinion Flange Installation
nut and washer installation and preload has been

Fig. 11B -D rive Pinion Rear Bearing Installation checked.
Pack cavity between end of pinion splines and pinion

4. Install a new pinion bearing spacer onto the drive pin
flange with a non-hardening sealer (such as Perm atex
ion.
Type A or equivalent) and install washer and nut on
5. Remove nut and sleeve from Com panion Flange In
pinion snugly.
staller J-9458. Screw J-9458 onto drive pinion and in
Check preload by using an inch pound torque wrench
sert assembly into housing.
such as J-5853 as shown in Figure 14B.
6. Position Com panion Flange, in same position as
removed, onto drive pinion. Install sleeve and nut onto
J-9458. NOTE: After preload has been checked, final tight
7. Install Com panion Flange H olding Tool J-8614-10. See ening should be done very cautiously. For example,
Figure 13B. if when checking, preload was found to be 5 inch
pound, additional tightening of the pinion nut as lit
8. Tighten nut on Tool J-9458 which draw s drive pinion
tle as 1/8 turn can add 5 additional inch pound drag.
through front bearing and companion flange. Tighten
Therefore, the pinion nut should be further tight
only until end play is rem oved from drive pinion then
ened only a little at a time and preload should be
remove Tool J-9458.
checked after each slight amount of tightening. Ex
ceeding preload specifications will compress the
NOTE: When no further end play is detectable, and
collapsible spacer too far and require its replace
when Holder J-8614 will no longer pivot freely as ment.
pinion is rotated, preload specifications are being
neared. Further tightening should be done only after
11. W hile observing the preceding caution, carefully set
preload drag at 20-25 in. lb. on new bearings or 10-15
in. lb. on reused bearings.
J— 22388
Fig. 12B— Installing Drive Pinion Oil Seal Fig. 14B -M e a su rin g Drive Pinion Bearing Preload

12. R otate pinion several times to assure th at bearings have PRESS

been seated. Check preload again. If drag has been
reduced by rotating pinion, re-set preload to specifica
tion.
Assem ble Standard Differential Case Assem bly

Before assembling the differential, examine the wearing
surfaces of all parts for scoring or unusual wear. Also make
certain th at all parts are absolutely clean. Lubricate parts
with rear axle lubricant ju st before assembly.
1. Place side gear thru st washers over side gear hubs and
install side gears in case. If same parts are reused, re
place in original sides.
2. Install the two pinion gears and washers, through the
two big windows in the case, into mesh with the side J - 8 107-4
gears making sure the pinion gear bores are 180 degrees
apart.
3. R otate the side and pinion gears as on assembly until Fig. 16 B -D iffe re n tia l Bearing Installation (P-Type Axle)
the pinion gear bores are in alignm ent with the pinion
shaft bores in the case. amount. By changing the thickness of both shims equally, the
4. In s ta ll p in io n sh a ft a n d lo ck screw . T o rq u e to original backlash will be maintained. All differential side
sp ecificatio n s. bearing preload shims used in production are cast iron. Shims
5. A fter m aking certain th at m ating surfaces of case and used during service repairs of the differential are of a stamped
ring gear are clean and free of burrs, thread two 7/16 steel design and are used along with a production type, .170"
x 20 x 2 (LH ) studs into opposite sides of ring gear, then thick, cast shim. Stamped steel service shims m ust be used
install ring gear on case. See Figure 15B. Install ring when differential repairs are made that require changing side
gear attaching bolts ju st snug. T orque bolts alternately
in progressive stages to specifications.
6. If differential side bearings were removed, install new
bearings using Installer J-22175 for P-Type axles (Fig.
16B) and J- 22761 for all others (Fig. 17B).
differential case on A dapter Plugs J-8107-4 (P-Type) or
J-8107-2. This allows differential case to rest on adapter
plug instead of bearing cage (Fig. 16B-17B). Install
other bearing as done in Step 6.
Install Differential Case and Adjust Side

Bearing Preload
D ifferential side bearing preload is adjusted by changing
the thickness of both the right and left shims by an equal
J-8107-4
Fig. 15B -R ing Gear Guide Pins Installed (Typical) Fig. 1 7 B --D iffe re n tia l Bearing In sta lla tio n (E xce p t P-Type A xles)

bearing preload. Service, steel, adjusting shims are available

in thicknesses ranging from .040" to .100" in increm ents of
.002 ".
1. Before installation of case assembly, make sure th at side
bearing surfaces in carrier are clean and free of burrs.
Side bearings m ust be oiled w ith gear lube and if same
bearings are being reused, they m ust have original outer
races in place.
2. Place differential case and bearing assembly in position
in carrier. Use service type adjusting shim totaling same
thickness as original production type adjusting shims if
either new or reused bearings are to be used. Slip left
shims in position at left bearing with steel shim next to
bearing, then place .170" shim for right side in position
and drive steel shim carefully into position between Fig. 19B~Checking Ring Gear Backlash
bearing and cast shim using a soft ham m er. See Figure
18B. Install side bearing caps, as previously m arked and
2. W ith pinion locked to carrier, check gear lash at 3 or
tighten bolts to 55 lb. ft. before checking side bearing
4 points around ring gear. Lash m ust not vary over
preload or backlash.
.001" around ring gear. If variation is over .001" check
3. R otate differential case assembly several complete turns for burrs, uneven bolting conditions or distorted case
to seat bearings. Check bearing preload using an inch flange and make corrections as necessary.
pound torque w rench connected at pinion nut. Bearing 3. G ear lash at the point of minimum lash should be .006"
preload should read 35-40 lb. in. of rotating torque with to .008" for all new gears. If adjustm ent is necessary,
new bearings or 20-25 lb. in. of rotating torque with adjust to .007". If original gear set having a wear pat
reused bearings. See Figure 14B. If preload is not ac tern is being reinstalled, original gear lash should be
cording to these specifications, increase shim thickness m aintained within plus or minus .001".
on each side .002" for each additional 10 lb. in. preload 4. If gear backlash is not within specifications, correct by
desired, or decrease shim thickness .002" on each side increasing thickness of one differential shim and de
for each 10 lb. in. preload to be subtracted. creasing thickness of other shim the same amount. In
this way, correct differential bearing preload will be
A djust Differential Backlash m aintained.
Shift .002" in shim thickness for each .001" change in
1. R otate differential case several times to seat bearings, backlash desired. If backlash is .002" too much, de
then m ount dial indicator as shown in Figure 19B. Use crease thickness of right shim .004" and increase thick
a small button on indicator stem so th at contact can be ness of left shim .004". If backlash is .002" too little,
made near heel end of tooth. Set dial indicator so that increase thickness of right shim .004" and decrease
stem is as nearly as possible in line with gear rotation thickness of left shim .004".
and perpendicular to tooth angle for accurate backlash 5. Install axle shaft assemblies as outlined in the Chassis
reading. Service Manual.
Gear Tooth Contact Pattern Check
Gear Tooth Nomenclature

The side of the ring gear tooth which curves outward, or
is convex, is referred to as the "drive" side. The concave side
is the "coast" side. The end of the tooth nearest center of ring
gear is referred to as the "toe" end.
The end of the tooth farthest away from center is the
"heel" end. Toe end of tooth is smaller than heel end. It is
very im portant that tooth contact be tested before the differ
ential carrier assembly is disassembled. Variations in the car
rier or pinion rear bearing may cause the pinion to be too far
away from, or close to, the ring gear. Thus, the tooth contact
m ust be tested and corrected if necessary, or the gears may
be noisy.
Test
1. Wipe oil out o
Fig. 1 8B—Installing D ifferential Shim of ring gear.

Effects of Increasing Load on Tooth Contact

Pattern
W hen "load" on ring and pinion gear is increased, such
as when car is accelerated forward from standstill or from
norm al drive, the tooth contact will tend to spread out, and
under very heavy load will extend from near toe to near heel
on the drive side. The entire contact also tends to shift tow ard
heel under increasingly heavier loads and will become some
w hat broader with respect to tops and bottom s of teeth. The
patterns obtained by tooth pattern tests, dependent upon
degree of "loading", approxim ate a norm al light load. For
HEEL HEEL this reason, they will extend only about halfway.
The im portant thing to note is that the contact pattern is
DRIVE SIDE COAST SIDE centrally located up and down on the face of the ring gear
(CONVEX) (CONCAVE) teeth.
A djustm ents A ffecting Tooth Contact
Fig. 20B~G ear Tooth Nom enclature
Two adjustm ents can be made which will affect tooth
contact pattern, backlash, and position of drive pinion in
2. Use gear m arking com pound and apply this m ixture carrier. The effects of bearing preloads are not readily appar
sparingly to all ring gear teeth using a m edium stiff ent on (hand loaded) teeth pattern tests; however, these ad
brush. W hen properly used, the area of pinion tooth justm ents should be within specifications before proceeding
contact will be visible when hand load is applied. with backlash and drive pinion adjustments.
3. Tighten bearing cap bolts to 55 lb. ft. Backlash is adjusted by means of the side bearing adjusting
4. Expand brake shoes until a torque o f 40-50 lb. ft. is shims which moves the entire case and ring gear assembly
required to turn the pinion. closer to, or farther from the drive pinion. (The adjusting
shims are also used to set side bearing preload).
NOTE: A test made without loading the gears will The position of the drive pinion is adjusted by increasing
not give a satisfactory pattern. Turn companion or decreasing the shim thickness between the pinion head and
flange with wrench so that ring gear rotates one full inner race of rear bearing. The shim is used in the differential
revolution then reverse rotation so that ring gear to compensate for m anufacturing tolerances. Increasing shim
rotates one revolution in opposite direction. Exces thickness will move the pinion closer to centerline of the ring
sive turning of ring gear may indicate good tooth gear. Decreasing shim thickness will move pinion farther
pattern because one or two teeth are making proper away from centerline of the ring gear.
contact.
Effects of Pinion Position on Tooth Pattern
5. Observe pattern on ring gear teeth and com pare with W hen the drive pinion is too far away from centerline of
Figures 20B and 2 IB. the ring gear, the pattern will be a high heel contact on drive
HEEL
DRIVE SIDE COAST SIDE

(CONVEX) (CONCAVE)
Fig. 2 2 B -T o o th P attern -P inio n too Far A w ay from Ring Gear

Fig. 21B~Desired Tooth C ontact Under Light Load (Insufficie nt Shim Thickness)


(CONVEX) (CONCAVE)
Fig. 23B ~E ffect on Pattern as Shim Thickness is Increased Fig. 25B ~E ffect on T ooth Pattern as Shim Thickness is
Decreased
side and high toe contact on coast side, provided backlash is
within specifications of .007", .008", .009". See Figure 22B.
Moving the pinion closer to centerline of the ring gear by
increasing shim thickness will cause the high heel contact on
drive side to lower and move tow ard the toe; the high toe
contact on coast side will lower and move tow ard the heel.
See Figure 23B.
W hen the pinion is too close to the centerline of the ring
gear, the pattern will be a low toe contact on drive side, and
a low heel contact on coast, provided backlash is within
specifications. See Figure 24B. Moving the pinion farther
away from the ring gear by decreasing shim thickness will
cause low toe contact on drive side to raise and move toward
HEEL
the heel; the low heel contact on coast side will raise and
move tow ard the toe. See Figure 25B.
(CONVEX) (CONCAVE)
NOTE: Whenever the rear axle is overhauled to the
point of requiring a new ring gear and pinion set the
Fig. 24B~Tooth P a ttern -P inio n too Close to Ring Gear rear axle should be filled ONLY with the lubricant
(Excessive Shim Thickness) included with the gear set.
CORVETTE
INDEX
Differential Case
R em oval.......................................................................... 4-21 Inspection ............................ ........................................ 4-22
Inspection ...................................................................... 4-21 Pinion a n d /o r Bearing R ep lacem en t...................... 4-23
Bearing Replacem ent ................................................. 4-22 Installation..................................................................... 4-26
Ring G ear or Case R ep lacem en t............................ 4-22 Differential Bearing Preload and Ring G ear
Side G ear Yoke Bearing a n d /o r Seal...................... 4-22 A d ju stm en t............................................................... 4-26
Drive Pinion Ring G ear and Pinion Contact P a tte rn .......... ........... 4-28
R em oval.......................................................................... 4-22

Fig. 1C~Carrier A ssem bly-E xploded V iew
1. Cover B olt 11. D ifferential Pinion 19. Side Bearing Cap 26. Side Gear Yoke
2. Carrier Cover Pin Retainer Bolt Bearing Seal
3. Filler Plug 12. Hypoid Ring Gear 20. Side Bearing Cap 27. Side Gear Yoke
4. Cover Gasket 13. Hypoid Drive Pinion 21. D iffere ntial Side 28. Pinion Front Bearing
5. D ifferential Pinion 14. Pinion Bearing Shim Bearing Cup
6. Ring Gear Bolt 15. Pinion Rear Bearing 22. Side Bearing Cup 29. Pinion Front Bearing
7. D iffere ntial Case 16. Pinion Rear Bearing 23. Side Bearing Shim 30. Pinion Oil Seal
8. Pinion Shaft Cup and Spacer 31. Com panion Flange
9. D ifferential Side Gear 17. Pinion Bearing 24. D ifferential Carrier 32. Pinion W asher
10. Side Gear Thrust Spacer 25. Side Gear Yoke 33. Pinion Nut
W asher 18. Side Gear Yoke Snap Bearing
Ring
4. Inspect side gear driveshaft yokes closely for spline
Differential Case wear or yoke cracking. If equipment is available, use
magnetic penetrant m ethod to check for m inute frac
Removal tures in yokes or gears.
1. Clam p carrier in Holding Fixture J-3289.
2. Remove snap rings securing side gear yokes and pull
yokes out of carrier (fig. 1C).
3. M ark differential bearing caps for reassembly in same
relative location and remove caps.
4. Pull differential assembly out of carrier, taking care not
to damage m achined m ounting surface on carrier (fig.
2C). Remove differential bearing shims and m ark for
future reference.
Disassem bly
Follow procedures outlined in "PO SIT R A C TIO N D IF
F E R E N T IA L CASE" Section.
Inspection
1. Clean all gears and bearings in cleaning solvent and
blow dry.
2. Inspect gears for scoring, pitting or cracks.
3. Inspect bearings for spalling, pitting or scoring. Discard
all parts that show excessive wear or failure. Fig. 2C--Removing D ifferential

Fig. 3C~Removing D ifferential Bearing

1. Place Puller J-2 2 8 8 8 over differential bearing using
A dapter Plug J-8 107-4 in side gear bore. Tighten puller
screw to remove bearing (fig. 3C).
2. Install new bearing on hub using Installer J-8359 (fig.
4C).
differential case on A dapter Plug J-8 107-4. This allows
differential case to rest on plug instead of bearing cage
(fig. 4C). Install rem aining bearing.
Ring Gear or Differential Case

Replacement
1. Remove ring gear bolts and tap ring gear off differential Fig. 4C --Differential Bearing Installation
case. 4. W ith com panion flange removed, pinion gear and rear
2. Install guide pins fabricated from 3/8-24 x 1 1/2" bolts bearing assembly can be removed from carrier.
with heads removed and ends slotted (fig. 5C). 5. Pry com panion flange seal out of carrier using screw
3. Clean ring gear m ounting surface and m ounting flange driver and discard seal. Remove pinion front bearing
on case. Place ring gear on pilot case diameter. inner race and roller assembly.
4. Install every other ring gear bolt and draw ring gear up 6. Pry differential side gear yoke seals out of carrier and
evenly until gear is seated against flange. discard seals. Using a piece of 1 3/4" O.D. pipe of
5. Remove guide pins and install remaining ring gear suitable length, tap yoke bearings out of bore.
bolts. T orque bolts to specifications. Inspection
Differental Case Assem bly 1. Clean all gears and bearings in cleaning solvent and
blow dry.
Follow procedures outlined in "P O SIT R A C T IO N D IF
F E R E N T IA L CASE" Section.
Side Gear Yoke Bearing and/or Seal
Replacement
1. Place new yoke bearings on Installer J-9773 and install
bearing into carrier bore using H andle J-7079-2
(fig.6C). Drive bearing until it is fully seated.
2. Place a new seal on Installer J-9774 and install into seal
bore outboard of bearing (fig. 7C).
Drive Pinion
Removal
1. Remove differential case as previously outlined.
2. T urn holding fixture over and remove com panion
flange nut using J-8614-1 H older (fig. 8C).
3. Pull companion flange using J-8614-1 H older with
Puller J- 8614-2 (fig. 9C). Fig. 5C--Ring Gear Guide Pins Installed

J— 8614-2
\
J-8614-1
J-7079-2
Fig. 9C~Removing Companion Flange
NOTE: Do not spin bearings during drying process.

The extremely fast spinning and lack of lubrication
may quickly result in the failure of an otherwise
reusable bearing.
2. Inspect gears for scoring, pitting or cracks.

Fig. 6C ~lnstalling Side Gear Yoke Bearings 3. Inspect bearings for spalling, pitting or scoring. Discard
all parts that show excessive wear or failure.
Pinion and/or Bearing Replacement

1. If necessary to replace pinion bearings tap old cups out
of carrier using a brass drift (fig. IOC). Tap alternately
on opposite sides of cup to prevent cups from cocking
in carrier. Inspect cup seats and bore for any nicks or
burrs and remove as necessary before installing new
J-9774
bearing cups.
2. Select front and rear pinion bearings and drive cups into
carrier using Drive H andle J-8092 and Cup Installers
J-8608 for the rear cup and J-7137 for front cup (fig.
11C). Seat cups securely and squarely against shoulders
in carrier.
Fig. 7C --lnstalling Side Gear Yoke Seal
Fig. 8C--Removing Com panion Flange Nut Fig. 10C~Removing Pinion Bearing Cup

Fig. 1 1C— Installing Pinion Bearing Cups
3. Remove pinion rear bearing inner race and roller as Tighten clamp bolt enough to seat properly and check
sembly using Press Plates J-9771 in H older J-0358-1 gauge plate alignment.
(fig. 12C). Remove and discard shim between bearing 4. Tighten clamp screw until it takes a torque of 20 in. lb.
and gear head. to rotate bearings (fig. 14C).
5. Carefully slide A dapter Rings J-6266-31 over Gauge
Determ ining Pinion Shim Barrel J-6266-28 and place barrel assembly in differen
tial bearing bores (fig. 15C). Plunger on barrel m ust rest
If hypoid gear set, pinion rear bearings or carrier assembly
on lowest step of Gauge Plate J-6266-53.
are to be replaced, thickness of pinion bearing shim will have
6. M ount Dial Indicator J-8001 on gauge post and place
to be determ ined as follows:
pointer on top of plunger (fig. 16C). Swing gauge barrel
1. Lightly lubricate pinion bearings, place in carrier and
aside so plunger does not touch gauge plate and set
rotate several times to seat properly.
indicator at zero.
2. Position Gauge Plate J-6266-53 on rear bearing making
sure it is properly seated and piloted. Loose pilot allows
DIAL INDICATOR
plate to be easily centered in bearing.
3. Insert clam p screw through gauge plate, both bearings
and Clam p Plate J-8 107-4 on front bearing (fig. 13C).
J-6266-31
ADAPTOR
J-6266-53
REAR
P IN IO N
BEARING
FRONT
PINION
BEARING
J -8 107-4
Fig. 12C-Rem oving Pinion Rear Bearing Fig. 13C--Gauge and Clamp Plates Installed

PROTECTIVE
TUBE OR PIPE
Fig. 1 4C--M easuring Drive Pinion Bearing Rotating Torque
Fig. 1 7 C -ln s ta llin g Pinion Rear Bearing
EX A M PLE: #1 #2 #3
J-6266-3 Pinion Code N um ber 40 45 50
Dial Indicator Reading 19 16 14
Difference 21 29 36
Proper Shim Thickness .021” .029” .036’'
NOTE: Shims are available in .001 in. increments

from .021 in. to .037 in.. Each shim has the thick
ness etched on flat surface for easy identification.
9. Remove gauge, gauge plates and clamp screw. Remove

pinion rear bearing inner race and roller assembly from
carrier.
Fig 1 5C— Installing Gauge Barrel
7. Swing gauge plunger back across plate and record high

est indicator reading.
8. All service pinion gears are stam ped with a code num
ber on the threaded end of the pinion. The numerical
difference between the code num ber and the gauge J-210 57
reading obtained in Step 7 determines the required
thickness of the pinion locating shim.
J-22804-1
Fig. 16C -G auging Pinion Depth Fig. 18C —Insta llin g P in ion Seal

Fig 19C—Installing Com panion Flange
Fig. 2 1 C— Installing D ifferential Assem bly

10. Position pinion shim selected in Step 8 on pinion head
and press pinion bearing on pinion using J-9772 Press
7. Pack the cavity between end of pinion splines and pin
Plate (fig. 17C).
ion flange w ith a nonhardening sealer (such as Per-
matex Type A or equivalent) prior to installing washer
Installation and nut on pinion.
8. Install a new nut on pinion shaft. Tighten nut to remove
Drive Pinion and Bearing end play--continue alternately tightening in small incre
1. Lubricate pinion bearings and place pinion gear in car ments, and checking preload with torque wrench J-
rier. 5853 and adapter J-5810 until torque required to rotate
2. Place a new pinion bearing spacer over pinion so it seats pinion is 20-30 in. lbs. For new bearings and seal, or
on inner race of rear bearing. 5-15 in. lbs. when used parts are reinstalled (fig. 20C).
3. Slide pinion front bearing cone and roller assembly over
pinion shaft so it seats against spacer. Differential Bearing Preload and Ring Gear
4. Pack the cavity between the seal lips of the pinion flange Adjustm ent
oil seal with a lithium-base extreme pressure lubricant,
position seal in bore and place gauge plate J-22804-1 1. Check condition of bearing cups, cup seat in carrier and
over seal and against seal flange. Gauge plate insures carrier caps to make sure they are free from nicks, burrs
proper seating of seal in carrier bore. and foreign material.
5. Using tool J-21057 (fig. 18C), press seal into carrier
bore until gauge plate is flush with the carrier shoulder 2. Lubricate bearings with axle lubricant. Position cups on
and seal flange. T u rn gauge plate 180 degrees from proper bearings then install differential assembly in car
installed position; seal m ust be square in carrier bore to rier (fig. 21C). Install right bearing cap, tightening the
seal properly against pinion flange. bolts to a snug fit.
6. Install com panion flange using H older J-8614-1 and
Installer J- 5780 (fig. 19C). 3. Service spacers are available in one thickness only .160"
plus or minus .001". Steel service shims are used with
the service spacer. See following Shim C hart for shim
availability and identification.
NOTE: Production preloading of the differential

bearings is accomplished by the use of cast iron
shims. These shims cannot be used when rebuilding
the carrier as they may break when tapped into
place.
4. Install strap J-22779-6 on left bearing by tightening

bearing bolts alternately and evenly to a snug fit.
5. W ith the ring gear tight against the pinion gear (.000"
to .001" backlash), insert gauging Tool J-22779 be
tween the left bearing cup and carrier housing (fig.
22C). T urn adjusting nut clockwise while oscillating
Fig. 20C--M easuring Drive Pinion Bearing Preload tool until a noticeable drag is produced.

Shim Identification
Shim
Notches
Thickness
I.D. O.D.
.040 0 0
.042 4 1
.044 4 2
.046 4 3
.048 4 4
.050 5 0
.052 5 1
.054 5 2
.056 5 3
.058 5 4
.060 6 0
.062 6 1
.064 0 2
.066 0 3
.068 0 4
.070 1 0 Fig. 23C--M easuring Gauge Plate Thickness
.072 1 1
.074 1 2 higher of the two averaged readings obtained in Steps
.076 1 3 7 a n d 8.
.078 1 4
EX A M PLE:
.080 2 0
.082 2 G a u g e th ick n ess (h ig h er re a d in g ) ................254"
1
.084 2 2 Service s p a c e r...................................................... 170"
.086 2 3 Service shim size (left s id e ) ............................084"
.088 2 4 10. Install the selected shim between the service spacer and
.090 3 0 bearing. Remove strap J-22779-6 and install left bearing
.092 3 1 cap. Torque bearing cap bolts to specifications.
.094 3 2 11. Remove right-hand bearing cap and install Tool J-
.096 3 3 22779 between right bearing cup and carrier housing.
.098 3 4
12. Turn adjusting nut clockwise while oscillating tool until
.100 4 0
a noticeable drag is produced (bearing outer race ro
tates with tool). Remove tool and m easure the thickness
6. Tighten lock bolt on side of the tool then remove tool.
of the gauging plate in a minimurh of three places.
7. Using a microm eter, m easure the thickness of the gaug
Average these readings and record results.
ing plates in a m inim um of three places (fig. 23C).
13. Turn ring gear 90 degrees and repeat Steps 11 and 12.
Average these readings and record result.
8. T urn ring gear 90 degrees and repeat Steps 5, 6 and 7.
14. The thickness of the service shim is determined as in
9. The thickness of the service shim is determ ined by sub
Step 9, however, an additional .008" must be added to
tracting the thickness of the service spacer from the
obtain proper side bearing preload.
EX A M PLE:
G a u g e thick n ess (hig her re a d in g )................226"
Service sp acer u s e d ......................... m in u s .170"
D iffe re n c e .................................................... 056"
P r e lo a d ..................................................... plus .008"
Service shim s iz e ................................................ 064"
NOTE: Service shims are available in increments of
.002 in.-if the shim measurement falls between the
available shims, select a shim thinner by $01 in-
15. Install the selected shim between the service spacer and
bearing using a soft face ham m er (fig. 24C).
16. Install right bearing cap and torque both bearing caps
to specifications.
17. M ount a dial indicator on the carrier and check back
lash between the ring gear and pinion (fig. 25C). Back
lash should be within the range of .003" to .010" with
a reading of .005" to .008" preferred. Check reading at
four equally spaced positions around the ring gear.
Fig. 22C ~M easuring D ifferential Shim Requirem ent Variation in reading should not exceed .002".

Fig. 2 4 C ~ lnstallin g D ifferential Shim Fig. 26C--Checking Ring Gear Runout
NOTE: Position the dial indicator so that indicator 2. Paint ring gear teeth lightly and evenly with a mixture
button is perpendicular to tooth angle and in line of powdered red lead and oil of a suitable consistency
with gear rotation. to produce a contact pattern.
3. G rasp companion flange firmly with a cloth to form a

18. If variation in backlash exceeds .002" measure ring gear
friction brake. Rock the ring gear back and forth, shift
and case runout as shown in Figure 26C. G ear runout
ing bolt heads to develop a contact pattern on ring gear
should not exceed .002"; should runout exceed this
teeth (fig. 27C).
limit, check ring gear and case for deform ation an d /o r
foreign m atter between case and gear. 4. Inspect the contact pattern produced by the above
19. If gear lash is not w ithin limits, correct by decreasing procedure. Figure 28C shows the terminology used in
shim thickness on one side and increasing thickness of analyzing contact patterns.
the other shim the same am ount. Total shim thickness
m ust be m aintained to m aintain proper preload. The large end of the tooth is called the "heel" and
EX A M PL E : By decreasing shim on the right side the small end the "toe". Also, the top of the tooth,
.002" and increasing shim thickness on the left side by which is the part above the pitch line, is called the
.002" backlash will decrease by .001". "face", while the part below the pitch line is called the
"flank". The space between the adjacent meshing teeth
is referred to as "backlash".
Ring Gear and Pinion Contact Pattern
Figure 29C shows correct and incorrect contact
1. T horoughly clean the ring and pinion gear teeth. patterns.
Fig. 25C--Checking Backlash Fig. 27 C -D e velo ping Tooth Pattern

SNAP
RING
Fig. 28C--Gear Tooth N om enclature
C ontact pattern "A" provides the ideal bearing for

quietness and long life. If the pattern shows a toe con Fig. 30C --lnstalling Side Gear Yoke
tact "B", it indicates not enough backlash. To correct,
move the ring gear away from the pinion by increasing "Pinion a n d /o r Bearing Replacem ent". A .001" thicker
right shim thickness while decreasing left shim thick shim is recom m ended as a starting point. Continued
ness an equal amount. changes may be necessary to obtain the correct setting.
If the pattern shows a heel contact "C ", it indicates
too m uch backlash. To correct, move the ring gear If the pattern shows a flank contact "E", it indi
tow ard the pinion by increasing left shim thickness cates that the pinion is in too far. To correct replace the
while decreasing right shim thickness an equal amount. pinion shim with a .001" thinner shim and recheck
contact pattern.
NOTE: Make adjustment increasing and decreasing In m aking pinion adjustments, be sure backlash is
shim thickness by 0.002 in. at a time, check contact correct before testing contact pattern. Moving the pin
with read lead mixture and continue adjustment un ion in reduces backlash and moving it out increases
til tooth contact appears as in (A). Backlash must backlash.
remain within limits. A fter satisfactory contact pattern is produced as in
If pattern shows a high face contact "D ", it indi "A ", clean ring and pinion gear teeth and pour a liberal
cates th at the pinion is too far out, that is, too far quantity of rear axle lubricant on gears and bearings-
tow ard the front of the car. turn gears to work lubricant into all surfaces.
To correct a pattern such as "D ", it will be neces 5. Insert side gear yokes into side gears and install snap
sary to install a thicker pinion shim as described under rings (fig. 30C).
TOE CONTACT CORRECT

TOOTH
CONTACT
FACE CONTACT FLANK CONTACT
Fig. 29 C -G ea r Tooth C ontact Patterns

DIFFERENTIAL CASE AND DRIVE PINION SERIES

2 0 T R U C K -5 5 0 0 LB. CAPACITY DIFFERENTIAL (DANA)
INDEX
G eneral D e sc rip tio n ........................................................ ... 4-30 Differential C a s e .................................................................4-32

Differential case .................................................................. 4-31 Reassembly ................................................................... ..4-32
R em oval.......................................................................... ... 4-31 Drive P in io n ........................................................................4-33
D isassem bly................................................................... ... 4-31 Installation and A djustm ent........................................4-33
Drive Pinion ......................................................................... 4-31 Differential C a s e .................................................................4-34
R em oval.......................................................................... ... 4-31 Preload and A djustm ent............................................ ..4-34
Inspection .......................................................................... ... 4-32 Installation........................................................................4-34
GENERAL DESCRIPTION
The D ana Spicer axle, is sim ilar in design to other Salis differential case the carrier m ust be spread.
bury type axles with the following exceptions: 2. The pinion assembly incorporates an inner and outer
1. The differential side bearing shims are located between bearing shim. The inner shim is used to m aintain proper
the side bearing cone and roller assembly and the differ pinion depth. W hile the outer shim is used to m aintain
ential case (fig. ID ). These bearings are of the tapered proper preload on the pinion bearing.
roller design and are preloaded. In order to remove the
Fig. 1D~Dana Rear Axle Assem bly

1. Nut 11 . Shims (Inner Pinion 18. Lock Pin (Pinion 24. B olt (D ifferential
2. W asher Bearing) Shaft) Bearing Cap)
3. Com panion Flange 12 . Cup (Inner Pinion 19. D ifferential Case 25. Bolt (Ring Gear)
4. Pinion Oil Seal Bearing) 20. Shims (D ifferential 26. Pinion Shaft
5. Gasket 13. Cone and Roller A djusting ) 27. T hrust W asher
7 and 8. Cone and Roller (Inner Pinion) 21. Cone and Roller (Pinion)
(Outer Pinion 14. Ring and Pinion (D ifferential Bearing) 28. Pinion
Bearing) 15. Gasket (Housing 22. Cup (D ifferential 29. Side Gear
9. Shims (Outer Pinion Cover) Bearing) 30. T hrust W asher (Side
Bearing) 16. Screw and W asher 23. Cap (D ifferential Gear)
10 Oil S linger (Cover) Bearing) 31. Spacer (Axle
17. Cover and Plug Shaft)(10 Series only)

D IFFER EN TIA L C A S E 8. Remove dial indicator and with the use of a pry bar
remove differential case from carrier. Remove spreader.
Removal
Disassem bly
1. Place vehicle on hoist with rear axle hanging free.
2. Remove wheel and tire assemblies. 1. Remove differential bearing cups and identify with a
3. Remove axles shafts as follows: tag for reassembly.
a. 10 S eries-T he axle shaft on the 10 Series are the 2. Place differential in vise and drive out pinion shaft lock
semi floating type. O uter end of shaft is supported pin.
by a tapered roller bearing. 3. Remove differential bearing cone and roller using
1. Remove brake drum . Puller J-22888, with Plug J-8 107-3, Figure 3D. Tag
2. Remove four bolts holding wheel bearing flange cone and rollers for assembly.
plate to axle shaft flange.
3. Install Puller J-2 1579 w ith Slide H am m er J- NOTE: If ring gear and pinion are to be reassembled,
2619 and remove axle shafts. note position of shims and replace accordingly.
b. The axle shafts are full-floating type with flanged
outer end of shaft attached to wheel hub by studs 4. Remove spacer, pinion shaft, pinions, side gears and
and nuts. Wheel is supported by tapered roller bear thrust washers from differential case.
ings at outer end of axle housing. 5. Remove screws attaching ring gear to differential case.
1. Remove axle shaft to hub attaching nuts. Remove gear.
2. R ap on axle shaft to loosen shaft from hub and
remove shafts.
4. Remove plug in carrier and drain lubricant.
D RIVE PINION
5. Remove cap screws and lock washers attaching cover
to carrier. Remove cover and gasket.
Removal
6. M ark one side of carrier and m atching cap for reassem 1. Separate rear universal joint, tape trunnion bearings to
bly. Rem ove cap screws attaching bearing caps to car joint, position propeller shaft to one side and tie propel
rier. ler shaft to frame side rail.
7. Using spreader Tool J-5231-01 and dial indicator as 2. Using Holding Bar J-8614-1, attached to pinion shaft
shown in Figure 2D , spread carrier a m aximum of flange, remove self-locking nut and washer from pinion
.020 ". shaft.
3. Install Tool J-8614-2, and 3 into holding bar as shown
NOTE: Do not exceed this dimension as carrier may in Figure 4 D and remove flange from drive pinion.
be permanently damaged. Remove drive pinion from carrier.
4. W ith a long drift, tap on inner race of outer pinion
bearing to remove pinion oil seal, slinger, gasket, outer
pinion cone and roller and shim pack. Tag shim pack
for reassembly.
5. Should inspection indicate necessity, pinion bearing
cups can be removed from carrier using a long drift and
hammer. Remove shims and oil slinger which are
J 22888
Fig. 2D--Spreader J-52 3 1-01 M ounted on Carrier Fig. 3D--Removing D ifferential Side Bearings

3. Inspect ring gear and pinion teeth for possible scoring,

J-8614-1 cracking or chipping.
4. Inspect differential case for cracks or scores or side
gears, thrust washers, and pinion thrust faces.
5. Check fit of differential side gears in case.
6. Check fit of side gears and axle shaft splines.
7. Inspect differential pinion shaft and spacer for scoring
or evidence of excessive wear.
D IFFER EN TIA L C A S E
Reassem bly
1. Position differential side gears and new thrust washers
in differential case.
2. Position differential pinions and new thrust washers in
differential case. Align pinions with holes in differential
case.
Fig. 4D--Removing Pinion Flange 3. Install pinion shaft in differential case. Align hole in
shaft with hole in case, then install lock pin. Peen hole
located behind the inner bearing cup. Tag shims for to prevent pin dropping out of case.
reassembly. 4. Position ring gear to case, then install cap screws.
6. Remove inner pinion cone and roller using Tool J- Tighten cap screws evenly and alternately to specifica
22912, installed as shown in Figure 5D, and press pin tions (See Specification Section).
ion from bearing. 5. W ith an arbor press, press differential side bearings
onto case using Tool J-2 1051. D o not install shims at
IN SPECTIO N OF CO M PO N EN TS this time.
6. Place differential case in carrier and install bearing
1. Clean all gears and bearings in cleaning solvent and caps. Care should be taken to install caps in original
inspect all bearing cups, races and rollers for scoring, position. Use m ark placed on caps and carrier at re
chipping or evidence of excessive wear. On pinion bear moval. Tighten caps just enough to keep bearing caps
ing rollers, inspect large end of rollers for wear. This is in place.
where wear is most evident on tapered roller bearings. 7. Install dial indicator on carrier with indicator button
contacting back of ring gear (Fig. 6D). R otate differen
NOTE: The pinion bearings are of the tapered type, tial case and check for runout. If runout is greater than
and the natural wear pattern is a frosted condition .002", the assembly should be removed and the ring
with occasional slight scratches on races or rollers. gear removed from the case. Again install differential
This does not indicate a defective bearing. case and check runout at differential case flange.
8. Should runout of case flange be greater than .002", the
2. Inspect pinion splines and flange splines for evidence of defect is probably due to bearings or differential case,
excessive wear. and should be corrected before proceeding further.
Fig. 5D--Removing Inner Pinion Bearing Cone and Roller Fig. 6D ~Checking Runout

9. W hen runout is within limits, using a screw driver

blade, between bearing cap and case, move differential
assembly away from dial indicator as far as possible. Set
dial indicator at zero. Shift differential assembly to op
posite side of carrier housing and record reading on dial
indicator. The shim pack thickness to be placed be
tween bearing cone and differential case will be cal
culated later in the procedure.
10. Remove differential assembly for carrier.
D RIVE PINION
In s ta lla tio n an d A d ju s tm e n t
If inspection indicates th at either the drive pinion or ring
gear m ust be replaced, they m ust be installed in pairs, as these
parts are m atched and lapped at tim e of m anufacture, to
obtain the correct gear tooth contact.
1. W henever it is necessary to install a new drive pinion
and ring gear, observe plus or m inus m arks on end of
old pinion, Figure 7D. If m arking on the new pinion is
the same as those on the old pinion, do not change the
shim packs. If m arking is different proceed as follows:
a. M easure the shim pack removed at disassembly.
Fig. 8D— Installing O uter Pinion Bearing Cup
The plus or minus figure on the pinion indicates the
variation from the nom inal distance between the
front of the pinion and the center line of the carrier. this shim pack as was added or removed from the inner
b. If a pinion m arked plus 2 was originally installed shim pack.
w ith a shim pack o f .035" and the new pinion is
m arked m inus 1, the shim pack should be increased 4. Install outer cup in carrier bore. Drive outer bearing
.003" to bring the new pinion to its correct position cup into position using Installer J-7818 with Drive
and the new shim pack would be .038". H andle J-8092 as shown in Figure 8D.
5. Press inner pinion bearing cone and roller onto pinion

NOTE: Shims are available in .003 in., .005 in. and shaft using Installer J-9772 on arbor press as shown in
.010 in. thickness. Figure 9D.
2. Install shim pack and oil slinger in inner cup bore and 6. Install drive pinion and inner bearing cone and roller
drive inner cup into position using Tool J-21059 used assembly in differential carrier.
with J-8092.
7. Install shims and outer pinion cone and roller on pinion
3. M easure shim pack, remove from outer bearing cone
shaft using Tool J-5590 and com panion flange to press
and roller seat. A dd or remove an equal am ount from
bearing onto pinion (Fig. 10D).
Fig. 7D ~M arking From Nom inal on Pinion

New Pinion Marking

O ld Pinion
Marking
- 4 - 3 - 2 - 1 0 +1 +2 +3 +4
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002
+1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003
0 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004
- 1 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005
- 2 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006
- 3 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006 - 0.007
- 4 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006 - 0.007 - 0.008
8. Install flange holding b ar and install washer and nut on 13. Install flange, washer and nut. Torque nut to specifica
pinion shaft. Torque nut to 255 ft. lbs. tions.
9. Remove holding b ar and with an inch pound torque
w rench m easure rotating torque. Rotating torque
should be 10 to 20 in. lbs. with original bearings or 20
D IFFER EN TIA L C A S E
to 40 in.lb. with new bearings.
Preload and Adjustm ent
NOTE: Torque reading to start shaft turning must
be disregarded. 1. Install differential bearing cups and place differential
assembly in carrier.
10. A dd shims to reduce rotating torque. Delete Shims to 2. Install differential bearing caps and secure temporarily
increase preload. with cap screws.
11. Remove nut, washer and flange from pinion shaft. 3. W ith shim pack determined in Step 9 "Differential Case
12. Install oil slinger, gasket and using Tool J-22804 install Reassembly", place shims between cups and carrier.
oil seal. Force shims in on both sides of carrier, use total am ount
of shims in pack, and set ring and pinion with zero
backlash.
4. Remove bearing caps and case from carrier.
5. Remove differential side bearing cone and rollers from
differential case.
6. Install shims as indicated in Step 3, adding .015" addi
tional shims to the ring gear side of case (this will give
the proper am ount of bearing preload and ring gear
backlash) and install side bearing.
Installation
1. Spread differential carrier, using spreader as shown in
Figure 2D.
2. Install differential bearing cups in their correct loca
tions then install differential case into carrier.
3. Install differential bearing caps in the correct location
as indicated by m arks made at disassembly. Install cap
screws finger tight. R otate differential assembly and rap
on case with a soft faced ham m er to ensure proper
seating of case in carrier.
4. Remove spreader and torque cap bolts to specifications.
5. Install dial indicator and check ring gear backlash at
four equally spaced points around the ring gear. Back
lash m ust be held to .004" to .009" and m ust not vary
Fig. 10D— Installing Pinion Flange m ore than .002" between positions checked.

6. W henever backlash is not within limits, differential 10. Install axles into carrier and axle flange over hub studs.
bearing shim pack should be corrected to bring back Torque hub stud nuts to specifications.
lash within limits.
7. Check gear tooth contact, using red lead method, as 11. Fill differential with lubricant.
described in "R ear Axle A djustm ent G ear Tooth Con
12. Install wheel and tire assembly.
tact (R ed Lead M ethod)".
8. Using a new gasket, install housing cover and torque
bolts to specifications.
9. Reinstall the rear universal joint, and torque "U" bolt NOTE: This wheel to axle flange fastener is an im
nuts to specifications. portant attaching part in that it could affect the
performance of vital components and systems, and
NOTE: This propeller to pinion flange fastener is an /or could result in major repair expense. It must be
important attaching part in that it could affect the replaced with one of the same part number or with
performance of vital components and systems, and an equivalent part if replacement becomes neces
/or could result in major repair expense. It must be sary. Do not use a replacement part of lesser quality
replaced with one of the same part number or with or substitute design. Torque values must be used as
an equivalent part if replacement becomes neces specified during reassembly to assure proper reten
sary. Do not use a replacement part of lesser quality tion of this part.
or substitute design. Torque values must be used as
specified during reassembly to assure proper reten
tion of this part.
POSITRACTION DIFFERENTIAL CASES

INDEX
G eneral D escription ................................................... ...... 4-35 Power-Lok D ifferential.......................................... .......4-39

P o sitra c tio n s............................................................. ...... 4-35 D isassem bly.......................................................... .......4-39
D isassem bly.......................................................... ...... 4-35 Inspection..................................................................... 4-40
Inspection............................................................... 4-37 A ssem b ly ......................................................................4 4 0
Reassem bly............................................................ 4-37 Testing P ro c e d u re ......................................................441
GENERAL DESCRIPTION
There are three optional Positraction differential units, tial side bearings and must be replaced with an Eaton Posi
namely Eaton, Borg W arner and D ana Power-Lok. The traction differential unit, if service is necessary. (Fig. IE).
D ana Pow er-Lok (Fig. 16E) is used only on T ruck models Overhaul procedures for Positraction equipped axles are
and has its own repair procedure. the same as on a conventional axle except for the operations
The Borg W arner unit is not repairable except for differen- listed herein.
PO SITRA CTIO N (See Fig. 2E)

NOTE
RETAINING
BOLTS Disassem bly
1. Remove ring gear and side bearings following the
procedures established for the conventional differential
unit.
2. a. For all models except Corvette, remove the preload
spring retainer and springs by tapping on the spring
retainer through the observation hole in the case (fig.
3E). Drive the spring retainer from the case sufficiently
to allow insertion of a 1/4 inch bolt in each of the two
front springs. Secure each bolt with a nut (fig. 4E).
2. b. On Corvette vehicles, it will be necessary to raise

NOTE SPLIT the spring retainers slightly to clear the shoulder on the
CASE
side gears. Install Tool J-22311 to clutch pack so that
slotted ends are equally engaged at front and rear of
Fig. 1E--Borg W arner Positraction Ide ntification spring retainer (fig. 5E).

Fig. 2E~Positraction Exploded V iew
1. Ring Gear-to-Case 4. Pinion Lock Screw 7. Clutch Pack Guide 11. Spring Retainer
Bolt and W asher 8. Clutch Disc 12. Pinion T hrust w asher
2. D iffere ntial Case 5. Ring Gear 9. Clutch Plates 13. Pinion Gear
3. Side Bearing 6. Shim 10. Side Gear 14. Pinion Shaft
15. Preload Spring
After installing the retaining bolts in Step 3, continue

to drive spring retainer from the case until enough of
the retainer is exposed to perm it installation of bar
stock and "C" clamp (fig. 6 E). Center the bar stock over
the axle shaft hole in the spring retainer, then compress
"C" clamp sufficiently to perm it w ithdraw al of spring
pack.
4. Position spring pack in vise and remove 1/4 inch bolts.

A lternately relieve "C" clamp pressure and vise pres
sure until spring compression is relieved (fig. 7E).
5. a. For Truck Models roll out the differential pinions

Fig. 3E--Removing Preload Spring Pack (Typical) and thrust washers.

Fig. 7E--Removing Preload Springs from Pack
Fig. 4E--lnstalling Bolts to Retain Springs

5. b. For Passenger models pinion gears can be removed
by rotating them in one direction only. Using Figure 8 E
as a reference, rotate differential case clockwise to
remove the first gear, then rotate case counter-clock
wise to remove the second gear. To remove second gear,
it may be necessary to assist pinion gear upon its seat
by prying on gear through observation holes on case
(Fig. 8E). M ark pinions and side gears for reassembling
in original position.
6. Remove side gear, clutch pack, shims and guides from

case. Tap the assembly from the case, using a brass drift
as shown in Figure 9E. Repeat removal on opposite
gear.
7. Separate clutch pack assembly from side gear. Retain

clutch pack assembly with original side gear.
Inspection
1. Check clutch plates and discs for excessive wear and
Fig. 5E--Removing Preload Spring Pack (Corvette) signs of overheating.
AXLE
SHAFT
Fig. 6E-- C-Clamp and Bar S tock Installed fo r Spring Removal Fig. 8E--Removing D ifferential Pinion Gears

Fig. 9E~Removing Side Gear Fig. 1 1 E--Measuring Pinion Gear Tooth Clearance
NOTE: Clutch plates and discs are not serviced ^

separately, if replacement is required, clutch pack , Lubricate and assemble opposite side gear as above.
Install one side gear, clutch pack assembly and shim(s)
must be replaced as an assembly.
in the differential case.
7 Position pinion gears and thrust washers on side gears.
2. Inspect preload springs for distortion and other defects.
Install pinion shaft through case and gears.
3. Com press springs and determ ine if they are capable of
properly preloading the clutch pack, replace springs Install dial indicator in case so that contact button rests
th at are weak or questionable. against pinion gear (fig. 11E).
4. Exam ine spring retainer for alignm ent between the re Compress clutch pack, using a screw driver as shown
tainer halves and for excessive wear at spring seats. in Figure 11E. Move the pinion gear to obtain tooth
clearance.
Reassem bly 10 Tooth clearance should be .001" to .008", if required,
change shims to obtain proper tooth clearance.
1. Lubricate clutch plates and discs with special positrac- 11 . Remove side gear assembly and repeat tooth clearance
tion lubricant. procedure for other side gear on opposite side of case.
2 . A lternately position clutch plate and clutch disc on side 12. Remove pinion shaft, gears and thrust washers.
gear, beginning and ending with clutch plate, until as- 13. Install remaining side gear, clutch pack assembly and
sembly of clutch pack is complete (fig. 10E). shims in case.
3. Install clutch pack guides on the clutch plate lugs.
M ake sure th at the clutch disc lugs engage with side
gear teeth.
4. Select shims of equal thickness as those removed from
the case, or if old shims are suitable, reinstall them over
the side gear hub.
Fig. 10E--Assembling Clutch Pack Fig. 12E--Spring Pack Compressed fo r Installation

14. Install pinion gears and thrust washers. Installation of

pinion gears can be perform ed by reversing the pinion
gear removal procedure.
15. For all except Corvette assemble springs in spring re

tainer and clamp assembly in vise. Install "C" clamp
and bar stock on spring retainer then install a 1/4 inch
bolt and nut in each front spring (fig. 12E).
16. Position spring pack between side gears and remove bar
stock and "C" clamp.
17. On Corvette vehicles, install Tool J-22311 to compress

clutch pack, secure pack with 1/4" bolts (fig. 13E).
Partially install pack then remove bolts and complete
pack installation-rem ove tool.
18. Drive spring pack into side gears sufficiently to retain

front springs, then remove 1/4 inch bolts from springs.
Drive spring pack into position (fig. 14E).
Fig. 14 E— I n sta 11ing Spring Pack
19. Install the pinion shaft and lock screw to retain side
gears until axle shaft installation. POW ER-LOK D IFFEREN TIA L
20. Check alignment of spring retainer with side gears. The Power-Lok differential (fig. 16E) is a unit which is
Slight movement of the spring pack can be made if installed as optional equipm ent in place of the standard dif
necessary. ferential. The locking differential permits the m ajor driving
force to be transm itted to the wheel with better traction. This
21. Install side bearings and ring gear to case using proce means that the vehicle can be operated on ice, snow, sand or
dure outlined for the conventional differential. under other adverse conditions with a m inim um am ount of
slippage through one wheel.
22. Place differential in carrier and adjust bearings and
backlash as outlined for the conventional differential. Disassem bly
23. Check operation of unit as follows: 1. Remove differential bearing cups and tag for reassem
bly reference.
a. Raise gear of vehicle until rear wheels are off the 2. Remove differential bearing cones, using Puller Tool
ground, and remove one wheel and tire assembly. (J-22888).
3. Tag each bearing cone and shim for reassembly refer
b. A ttach A dapter J-5748 to axle shaft flange and in ence, as they should be replaced in their original loca
stall a 1/2-13 bolt into adapter (fig. 15E). tions.
4. Scribe m ark on both halves of differential so they can
c. W ith Wheel and tire assembly still on vehicle held
be reassembled in their original locations.
firmly to prevent turning, m easure torque required
5. Remove eight bolts attaching two halves of case
to rotate opposite axle shaft with a 0-150 lb. torque
together.
wrench attached to J-5748. T orque required to ro
6. Separate plain half of differential case from flanged
tate axle shaft should be no less than 40 ft-lbs.
half.
7. Remove five plates and discs from side gear ring.
Fig. 13E— Installing Spring Pack Com pression Tool (Corvette) Fig. 15E -M e asu ring P ositraction Rotating Torque

Fig. 16E--Power-Lok D ifferential
1. D ifferential Case Bolt 4. Friction P late-Tabbed 6. Friction P late-Tabbed 8. Side Gear Ring
2. D ifferential (Belleville) (Flat) 9. Side Gear
Case-Plain Half 5. Friction D isc-T oothed 7. Friction D isc-T oothed 10. Pinion Gears
3. D ifferential (Belleville) (Flat) 11. Cross Shafts
Case-Flanged Half
A series of clutch plates and dished (Belleville) friction Assem bly

plates on each side of differential side gears transm it drive
from differential case to axle shafts.
D u rin g assem b ly o p e ratio n s, all p a rts sh o u ld b e k e p t
clean a n d free o f d irt or o th e r foreign m ate ria l. A s each
IMPORTANT: Carefully observe the order in which p a rt is a sse m b le d in its p ro p e r p o sitio n , it is n e c e ssa ry
the plates are used, since they must be replaced in th a t it be lightly c o a ted w ith the correct lu b ric a n t.
the same order. Refer to Figure 16E.
1. Place tabbed Belleville friction plate (4) in flanged dif
8. Remove side gear ring and side gear. ferential case, being extremely careful that convex
9. Remove two cross shafts and pinion gears. (bulged) side is tow ard the side gear (fig. 16E).
10. Remove side gear, side gear ring, and five plates and 2. Assemble remaining plates and discs to splines of side
discs from the opposite side. Observe the order in which gear ring, being sure they are assembled in the same
the plates are used. order of removal. The convex (bulged) side o f the Belle
ville friction disc (5) should be tow ard the side gear and
Inspection it should nest into the Belleville friction plate (4).
3. Place assembled side gear ring w ith plates and discs in
1. Inspect cross shafts and pinions for scoring, wear, pit flanged half of differential case.
ting, etc. If the center lands of either cross shaft show 4. Install side gear and cross shafts w ith pinions.
signs of wear, examine ends of axle shafts to determine 5. In the order listed install the following: (1) side gear, (2)
if the axle shaft is rubbing against cross shaft. This side gear ring, (3) flat plate with tabs, (4) flat disc with
rubbing condition may cause a whine or howl th at is teeth, (5) flat plate with tabs, ( 6 ) Belleville disc with
similar to a pinion bearing noise, at 40 to 50 M PH . This convex (bulged) side up, or tow ard side gear, (7) Belle
condition can be corrected by grinding 1/32" off the ville plate, with convex (bulged) side up, or side tow ard
end of the axle shaft. gear.
2. Inspect clutch discs and plates for wear, cracked, or 6 . Position plain half of differential case over previously
distorted condition. Refer to "Specifications" section. assembled parts with scribe m arkings on both halves of
3. Inspect side gear rings, side gears, and differential cases case in alignment.
for worn, cracked, or distorted condition th at would 7. Install differential case bolts, but do not tighten at this
render these parts unfit for further services. time.

8. Before tightening bolts, use axle shafts and align splines be repeated with the opposite wheels on the dry and slippery
of the side gear and side gear ring, on each side. Tighten surfaces.
bolts evenly and alternately. Remove axle shafts.
The above testing procedure is a rough test that can be
9. Observe if Power-Lok com ponents have been assem made by the owner of the vehicle. However, if it is suspected
bled properly. Each pinion cross shaft can be tight on that the unit is not operating properly, it can be checked by
its ram p or if there is clearance it should be only a few the following procedure.
thousandths, and it should be equal at all four cross
shaft ends. Be sure the transm ission is in neutral. Raise one wheel off
the floor and place a block in the front and rear of the
opposite wheel. Remove the hub cap and install a special tool
Testing Procedure across two wheel studs. Apply a torque wrench to special
tool. D isregard breakaway torque and observe only the
The Pow er-Lok can be effectively tested for correct oper torque required to continously turn the wheel smoothly.
ation by placing one rear wheel on good dry pavement and
the other on ice, snow, mud, gravel, grease, etc. If the torque reading is less than 40 foot-pounds or more
It can easily be determ ined w hether or not the non-slipping than 200 ft. lb., the unit should be disassembled and the
wheel is providing pulling power. The procedure should then necessary repairs made.
SERIES 2 0 -3 0 TRUCK 5 2 0 0 , 7 2 0 0 AND

1 1 ,0 0 0 LB. CAPACITY AXLE DIFFERENTIALS
INDEX
Case and Drive P in io n ................................................... 4 4 4 Differential Reassembly ...........................................4 4 7

R em oval.......................................................................... 4 4 4 Reassembly ..................................................................4 4 7
D isassem bly................................................ .............. .... 4 4 4 Ring G ear and Pinion A djustm ent ................... ...4 4 7
R ep airs............................................................................ .... 4 4 4 Checking Pinion D ep th .......................................... ...4 4 8
Pinion D isassem bly................................................. .... 4 4 4 Ring G ear T hrust Pad A d ju stm e n t................... ...4 4 8
Pinion Inspection.......................................................... 4 4 5 Installation ............................... ................................. ... 4 4 8
Pinion Reassembly ................................................. .... 4 4 5 No-Spin Differential U n it.................................................. 449
Differential D isassem bly............................................ 4-46 D isassem bly.................................................................. 449
Differential Inspection.................................................4 4 6 Inspection................................................................... ... 449
Ring G ear R ep lacem en t............................................4 4 6 Reassembly .................................................................. 449
Differential Bearing R eplacem ent............................4 4 6

Fig. 1 F -5 2 0 0 and 7 2 0 0 lb. C apacity A xle -C ross Section
1. Universal J o in t Yoke 7. Pinion Bearing Shim 12. D ifferential Pinion 16. D iffere ntial Bearing
2. Pinion Bearing and (exc. 11 ,000 lb. axle) (Spider) Gear 17. D iffere ntial Bearing
Oil Seal Retainer 8. Rear Pinion Bearing 13. D iffere ntial Side Gear A d ju stin g Nut
3. Oil Seal 9. Ring Gear T hrust Pad 14. D iffere ntial C ase-Left 18. A d ju stin g Nut Lock
4. Gasket 10. Ring Gear Half 19. D iffere ntial
5. Front Pinion Bearing 11. D ifferential Spider 15. Axle S haft C a se-R ight Half
6. Drive Pinion

Fig. 2F-1 1,000 lb. C apacity A xle-C ross Section
1. Universal J o in t Yoke 8. Ring Gear T hrust Pad 14. Axle Shaft

2. Pinion Bearing Oil 9. Ring Gear 15. D ifferential Bearing
Seal and Retainer 10. D ifferential Spider 16. D ifferential Bearing
3. Oil Seal 1 1. D iffere ntial Pinion A d ju stin g Nut
4. Oil Seal Gasket (Spider) Gear 17. A d ju stin g Nut Lock
5. Front Pinion Bearing 12. D ifferential Side Gear 18. D ifferential
6. Drive Pinion 13. D ifferential C ase-Left C ase-R ight Half
7. Rear Pinion Bearing Half

Case and Drive Pinion (Fig. 1F--2F)
Removal
1. D rain lubricant from differential, remove axle shaft as
outlined in T ruck Service M anual. See "Axle Shaft Re
moval".
2. Remove two trunnion bearing "U " bolts from the rear
yoke and split the rear universal joint.
NOTE: The bearings can be left on the trunnion and

held in place with tape.
3. Swing propeller shaft to one side and tie to the frame

side rail.
4. Remove bolts and lock washers which retain the carrier
assembly to the axle housing. Support the differential
housing w ith a floor jack and roll it from under truck.
Fig. 3F~Pinion Rear Bearing Removal (Except 1 1,000 Lb.)
Disassem bly Repairs

1. M ount carrier assembly in a bench vise or holding fix Pinion Disassem bly
ture.
2. On 11,000 lb. axle, loosen ring gear thru st pad locknut 1. Clamp pinion drive flange in bench vise.
and remove th ru st pad. 2. Remove cotter pin, nut and washer from end of pinion.
3. Remove differential adjusting nut locks and bearing cap 3. Remove drive flange and bearing retainer assembly
bolts and lock washers. from pinion.
4. M ark bearing caps and carrier for reassembly in same 4. Drive oil seal from retainer. D iscard seal as new parts
position. Remove bearing caps and adjusting nuts by should be used at assembly.
tapping on bosses o f caps w ith a soft faced ham m er until 5. On the 11,000 lb. axle, remove pinion rear bearing snap
caps are free from dowels. ring and press bearing from pinion, using Tool J - 1453
(fig. 4F).
CAUTION: Do not attempt to pry cap off as this may 6. On the 5200, and 7200 lb. axles position drive pinion in
damage machined face of cap. an arbor press as shown in figure 5F, and press pinion
from bearing, using appropriate tool as follows.
5. Remove differential and ring gear assembly from the a. J-2224-5200 lb. axle (except P20).
carrier. b. J-2225-7200 lb. axle (seven tooth pinion and P20).
c. J-1439--7200 lb. axle (six tooth pinion).
CAUTION: Exercise care that differential bearing 7. On the 11,000 lb. axles, position drive pinion in an arbor
outer races are not dropped in removing assembly press so that the bearing is supported by two pieces of
from carrier. flat steel stock as shown in Figure 6 F. Place flat stock
parallel to each other and against pinion so as to pick
6. Remove the bolts which attach the pinion bearing re up a large area of bearing outer race. Press pinion from
tainer to the carrier.
7. Remove the pinion and bearing assembly from the car
rier. REAR
P IN IO N BEARING
NOTE: It may be necessary to drive this unit from P IN IO N PRESS

carrier. Use brass drift against pilot end of pinion. PLATE
8. On all axles except the 11,000 lb., remove shims from

carrier m aking note of num ber and total thickness of
shims removed.
9. On all axles except the 11,000 lb., the pinion rear bear
ing outer race and roller assembly is pressed into the
carrier. Remove assembly by driving it from its seat
using a soft drift or punch (fig. 3F). Fig. 4 F -P in ion Rear Bearing Removal (1 1 ,0 0 0 Lb. Axle)

Fig. 5F-R em oval Drive Pinion Front Bearing 5 2 0 0 , 7 2 0 0 lb.

Axle (Typical)
Fig. 7F--Pinion Oil Seal Installation (Typical)

bearing making sure pinion is supported to prevent
dam age when removed from bearing.
4. In s ta ll th e 11,000 lb. axle p in io n re a r b e a rin g
assem b ly on p in io n sh a ft m ak in g su re th a t c h a m
Pinion Inspection fe re d side o f in n e r rac e seats a g a in st s h o u ld e r o n
1. W ash all parts in cleaning solvent. p in io n shaft. T h e n in stall p in io n b e a rin g lock rin g
2. Inspect pinion for scored, cracked, chipped or worn using T o o l J-1364 as show n in F igure 8 F.
teeth.
5. Install pinion front bearing as follows:
3. Inspect splines on pinion shaft for excessive wear.
a. 11,000 lb. axles-Position the one-piece double row
4. Inspect pinion bearing assemblies for roughness, defects
ball bearing on pinion shaft, so that extended por
or excessive wear.
tion of inner race is tow ard pinion head. Then, using
a suitable length of 2 inch pipe, press bearing onto
Pinion Reassem bly shaft until it seats against the pinion head.
1. Pack the cavity between the pinion oil seal lips with a
CAUTION: When pressing bearing on pinion, exer
lithium -base EP lubricant to provide initial lubrication
cise care to prevent damage to ground surface of
and to aid in inserting pinion flange.
pilot.
2. Press the oil seal into the retainer-position seal lips
tow ard the pinion bearing-using Tool J-22281 as
b. 5,200, 7,200 lb. axles-Place one cone and roller
shown in Figure 7F.
assembly on pinion shaft so that large end of bearing
3. On the 5200, 7200 lb. axles, lubricate the pinion rear is tow ard pinion then position outer race, spacer and
bearing and carefully press it into carrier. cone and roller assembly on pinion shaft. Position
pinion and bearing assembly in press as shown in
Figure 9F and seat bearing against pinion head.
LOCK RING
DRIVER
Fig. 8F -P in ion Rear Bearing Lock Ring Installation (1 1 ,0 0 0 Lb.

Fig. 6F -D rive Pinion Front Bearing Removal (1 1 ,0 0 0 Lb. Axle) Axle)

Differential Inspection
1. W ash all parts thoroughly in cleaning solvent.
2. Inspect ring gear for chipped, scored or worn teeth.
3. Check radial clearance between differential side gears
and differential case, also fit of differential pinions on
spider.
4. Inspect spider arm s for wear and distortion.
5. Inspect splines and teeth of differential side gears and
pinions for chipping or excessive wear.
6 . Check th ru st washers for wear and replace if even slight
wear is indicated.
7. Check differential side bearings and cups for broken
Fig. 9 F -P in ion Front Bearing Installation races, discoloration or roughness.
8 . Inspect differential case for cracks or distortion.
NOTE: The opposed tapered bearing assembly is
serviced as a unit and consists of one double outer
race, two inner race and roller assemblies and one Ring Gear Replacement
spacer. These parts should always be installed as a
group as the spacer is preselected to give proper 1. Remove ring gear from case by tapping the back of the
pinion bearing adjustment. gear with a soft faced hammer.
2. Inspect ring gear pilot case flange and back of ring gear
6. Slide oil seal retainer on pinion shaft, then tap drive for dirt or burrs.
flange onto pinion splines. 3. Install two guide pins (made from cap screws with
7. Clam p drive flange in a bench vise and install flange heads cut off and ends slotted) to new gear diam etri
washer and nut. Torque nut to specifications and install cally opposite each other.
cotter pin w ithout backing off on nut. 4. Start guide pins through case flange and tap ring gear
on case.
Differential Dissem bly
1. Check differential case to m ake sure th at the two halves
are m arked so they m ay be reassembled in same relation
(fig. 10F). 1. Install Tool J-8107 m aking sure puller legs are fitted
securely in notches in case and tighten retaining yoke
2. Rem ove bolts holding case and cover together. (fig. 11F).
2. Tighten puller screw to remove bearing.
NOTE: Ring gear is mounted on the case. 3. Place new bearing on hub with thick side of inner race
tow ard case and install bearing using appropriate tool
3. Separate cover from case and remove differential side as shown in Figure 12F.
gears and thrust washers, pinion gears w ith thrust a. J-2226-5200 and 7200 lb. axles.
washers and differential spider. b. J-1 4 8 8 -1 1,000 lb. axle.
Fig. 1 0 F -D iffe re n tia l Case Line-Up M arks Fig. 11 F -D iffe re n tia l Bearing Removal

2. Place new pinion bearing retainer gasket on the retainer

and install pinion assembly in carrier.
NOTE: The pinion assembly should be pressed into

the carrier to prevent the possibility of damaging
the shims.
3. Install pinion bearing retainer bolts and lock washers

and torque bolts to specifications.
4. Lubricate differential bearing rollers with engine oil
and place outer races over them.
5. Install differential assembly in carrier and install ad
justing nuts.
CAUTION: Carefully slide adjusting nuts alongside

the bearings so that threads on nuts fit into threads
in carrier.
6. Install differential bearing caps making sure the marks

on the caps line up with the m arks on the carrier.
7. Install bearing cap bolts and lock washers and tighten
until lock washers just flatten out.
Fig. 1 2F--D ifferential Bearing Installation
Ring Gear and Pinion Adjustm ent
NOTE: The side bearing tool is counterbored and 1. W ith differential bearing cap bolts loosened just enough
has pilot to assure proper installation and seating of to perm it turning the bearing adjustm ent nuts with
bearing. Tool J-0972, remove all lash between ring gear and
pinion (fig. 13F).
2. Back off left hand adjusting nut one to two notches to
Differential Reassem bly a locking position.
1. Lubricate differential side gears, pinions and thrust 3. Tighten right hand adjusting nut firmly to force differ
washers. ential in solid contact with left hand adjusting nut.
2. Place differential pinions and thrust washers on spider. 4. Back off right hand adjusting nut until free of bearing;
then retighten snugly against bearing.
3. Assemble side gears and pinions and thrust washers to 5. Tighten right hand nut from one to two additional
left half of differential case. notches to a locking position.
4. Assemble right half of case to left half being sure to line
up m arks on the two halves.
5. Install differential-to-ring gear bolts and lock washers
and tighten evenly until ring gear is flush with case
flange.
6. Remove two guide pins and install rem aining two bolts.
T orque all bolts alternately and evenly to specifications.
Reassem bly
To facilitate adjusting o f pinion depth in the ring gear,
there are five shims available for service use. They are .012",
.015", .018", .021" and .024".
NOTE: Pinion depth adjustment shims are not re

quired for the 11,000 lb. axle.
If the original ring gear and pinion are to be used it is

advisable to replace the same thickness o f shims in the carrier
counter bore th at were removed.
If a new ring gear and pinion are used, one .021" shim
should be used as a standard starting set up.
1. Place shim in bore in carrier or between carrier and
pinion oil seal retainer. Fig. 13F-R ing Gear and Pinion A djustm en t

Ring Gear Thrust Pad Adjustm ent
1. Inspect bronze tip of thrust pad and if worn install a

new one.
2. Install thrust pad and tighten screw until bronze tip
engages back face of ring gear while rotating gear.
3. Back off screw one-twelfth (1/12) tu rn and tighten
locknut to specifications (fig. 15F).
NOTE: Make sure screw does not turn during lock

ing process. This adjustment provides .005 in. to
.007 in. clearance between thrust pad and ring gear
face.
Installation
Fig. 14F-C hecking Ring Gear and Pinion Backlash

1. Clean out axle housing and cover and place new gasket
over axle housing.
2. Assemble differential carrier to axle housing, install
NOTE: This method of adjustment provides for lockwashers and bolts and tighten securely.
proper preload of bearings. 3. Replace axle housing inspection cover, if removed, us
ing new gasket.
6. M ount a dial indicator on the carrier and check the
backlash between ring gear and pinion (fig. 14F). Back
lash should be from .003" to .0 1 2 " (.005" to .008"
NOTE: This propeller shaft to pinion flange fastener
preferred).
is an important attaching part in that it could affect
the performance of vital components and systems,
NOTE: If backlash is more than .012 in. loosen the and/or could result in major repair expense. It must
right hand adjusting nut one notch and tighten left be replaced with one of the same part number or
hand adjusting nut one notch. If backlash is less with an equivalent part if replacement becomes
than .003 in. loosen the left hand adjusting nut one necessary. Do not use a replacement part of lesser
notch and tighten right hand nut one notch. quality or substitute design. Torque values must be
i
used as specified during reassembly to assure
7. Tighten bearing cap bolts to specifications. proper retention of this part.
8. Install side bearing adjusting nut locks and torque to
specifications.
4. Assemble rear universal joint.
C h ecking Pinion Depth 5. Install axle shafts as outlined in applicable axle installa
tion procedure in Service M anual.
1. Coat the ring gear teeth lightly and evenly w ith a mix 6. Fill axle with lubricant to a level even with bottom of
tu re o f powdered red lead and oil of a suitable consist filler hole. See Section 0 in the T ruck Service M anual
ency to produce a contact pattern. Then tu rn the pinion for proper lubricant.
shaft several revolutions in both directions.
2. Exam ine the p attern on the ring gear teeth. If the pinion
depth is correct, the tooth pattern will be centered on
the pitch line and tow ard the toe of the ring gear (fig.
28A).
3. If the pattern is below the pitch line on the ring gear
teeth, the pinion is too deep and it will be necessary to
remove the pinion assembly and increase the shim
thickness between the pinion bearing and the carrier.
4. If the pattern is above the pitch line on the ring gear
teeth, the pinion is too shallow and it will be necessary
to remove the pinion assembly and decrease the shim
thickness between the pinion bearing and the carrier.
5. Changing the pinion depth will m ake some change in
the backlash; therefore, it will be necessary to readjust
the backlash. Fig. 15F-R ing Gear T hrust Pad A djustm en t

NO-SPIN DIFFERENTIAL UNIT
The optionally available N O -SPIN differential unit (fig. 2. Check spider, center cam, holdout ring and driven
1G) is installed in a conventional 5200 or 7200 lb. rear axle clutch teeth for excessive chipping or burring. M inor
housing and the only difference in service procedures are the chips or burrs may be stoned smooth.
Disassembly, Assembly and A djustm ent procedures outlined
below.
Disassem bly (Fig. 1G) NOTE: Replace holdout rings or cams in pairs only.
1. Chisel or punch alignm ent m arks on differential case

(fig. 10F). 3. Check spring retainer seat and splines for fractures.
4. M easure spring height. Free height should be 2 l/8 " -2
CAUTION: The no-spin differential is assembled un 1/4" (fig. 4G).
der spring tension. It is originally supplied with a
retaining bolt, nut and washers used to compress
the until until the differential case bolts are installed Reassem bly
and tightened. If this retainer bolt is not available,
1. Lubricate all clutch teeth and cams before assembly.
use a 1/2-13x6 bolt with nut and washers to com
2. Assemble split holdout rings to center cam and spider
press the unit until the differential case halves are
assembly. Align spider key with slot in holdout ring
opened. If a retainer bolt is not used, hold differen
(fig. 5H).
tial case halves firmly to prevent sudden spring re
3. Assemble driven clutches, spring retainers, springs and
lease.
side gears to spider and center cam assembly.
2. Remove differential case and cover bolts and remove
no-spin (fig. 2G). NOTE: Carefully position spring seats inside re
3. Remove side gears, springs and retainers and driven tainer cups.
clutches.
4. Rem ove split holdout rings with snap ring pliers J-5586 4. Compress no-spin assembly with retainer bolt if availa
(fig. 3G). ble (fig. 6 G). If bolt is not used, install no-spin in differ
ential case, rotate to engage splines, and hold with firm
hand pressure until case and cover bolts are tightened.
NOTE: Spider, center cam and snap ring assembly Torque bolts evenly to specifications.
need not be disassembled as they are not serviced Install no-spin unit in carrier and adjust bearings and
separately. backlash as outlined previously for the conventional
differential unit.
Inspection 6 . Check operation of unit as follows.
a. Raise rear of vehicle until both rear wheels are off
W ash all parts and inspect as follows: the floor.
1. Check side gear and driven clutch splines for excessive b. Shift transm ission into gear.
wear or fracture. c. R otate both rear wheels as far forw ard as possible.
Fig. 1G--No-Spin D ifferentia! U nit-E xplo de d V iew
1. Side Gear 4. Driven Clutch 7. Center Cam

2. Spring 5. H o ldo ut Ring 8. Spider
3. Spring Retainer 6. Snap Ring

SLOT IN HOLD O U T
SPIDER RING
Fig. 5G ~Aligning S pider Key and H o ldo ut Ring
Fig. 2G--Disassem bling Case and Cover
Fig. 6G--Assem bling No-Spin U nit
d. W ith assistant holding left wheel forward, rotate the

Fig. 3G -R em oving H oldout Rings right wheel to the rear, checking for free rotation.
e. R otate both wheels as far to the rear as possible.
f. W hile holding the left wheel rearw ard, rotate the
right wheel forward, again checking for free rota
tion.
g. Repeat Steps c-f, holding the right wheel and rotat
. ing the left wheel for left side forw ard and rearward
operation check.
2 -1 /8 "~ 2 -l/4 "
h. If wheels cannot be rotated freely as described
above, remove and inspect the No-Spin.
Fig. 4 G -M ea surin g Spring Free Height

SPECIAL TOOLS
Fig. 1T--Special T ools— A ll Salisbury T ype A xles (In c lu d in g 1 1 6 ” W.B. S ta tio n Wagons)
E xcep t C h evro let and Cam aro
1. J-62 66 Pinion S etting Gauge Consists o f: 17. J-2 1 4 6 8 Drive Pinion O il Seal In sta lle r— L ig h t
J-62 66 -28 Barrel A d a p te r D u ty A x le (Used w ith J-9 4 5 8 )
J-62 66 -25 Plug 18. J -2 1 0 5 7 Drive P inion O il Seal In s ta lle r -
2. J-62 66 -52 Pinion S etting Gauge Plate Heavy D u ty A xle
Passenger and T ru c k L ig h t D u ty 19. J-83 59 D iffe re n tia l Bearing In sta lle r— Heavy
and T ru c k Heavy D u ty A xles D u ty A x le (Used w ith J-8 0 9 2 )
3. J-6266-53 P inion S etting Gauge Plate— 20. J-5853 0 -5 0 In. Lbs. T orqu e W rench
Passenger Heavy D u ty A xle 21. J-02 70 -14 P inion Rear Bearing Cup I n s ta lle r -
4. J-22 80 4 P inion Seal Gauge Plate L ig h t D u ty A xle (Used w ith J-80 92 )
5. J-6266-31 P inion S e ttin g Gauge 22. J-7 1 3 7 P inion F ro n t Bearing Cup I n s ta lle r -
Sleeves— Heavy D u ty A xle Heavy D u ty A x le (Used w ith J-8 0 9 2 )
6. J-2 2 7 7 9 Side Bearing Shim 23. J-78 17 P inion F ro n t Bearing Cup I n s ta lle r -
Gauge— Includes J-2 2 7 7 9 Strap L ig h t D u ty A x le (Used w ith J-8 0 9 2 )
7. J-9 5 3 7 D iffe re n tia l Bearing In sta lle r— L ig h t 24. J-81 07 -4 D iffe re n tia l Bearing Rem over— Installer
D u ty A x le — (Used w ith J-7079-2) A d a p te r (Used w ith J-95 37 and
8. J-9 4 5 8 C om panion Flange Installer J-22 77 9)
9. J-5 5 9 0 P inion Rear Bearing Cone and R o lle r 25. J-5231-01 Spreader
A ssem bly In sta lle r— L ig h t D u ty A x le 26. J-86 14 C o m panion Flange H o lde r and
10. J-70 79 -2 D river Handle (In se rt T yp e ) Remover
11. J-80 92 D rive r Handle (Threaded T yp e ) 27. J-21051 Seal Installer
12. J-2 2 8 8 8 D iffe re n tia l Bearing Rem over— 28. J-22 91 2 Press Plate
(Used w ith J-81 07 -4 A d a p te r) 29. J -21 57 9 A x le S h a ft Remover
13. J-97 72 Drive Pinion Rear Bearing 30. J-21 05 9 Bearing Cup Installer
In sta lle r— Heavy D u ty A xle 31. J -86 08 Pinion Rear Bearing Cup In s ta lle r -
14. J-8001 Dial In d ic a to r Set Heavy D u ty A x le (Used w ith J-8 0 9 2 )
15. J-5748 P ositra ction T orqu e Measuring 32. J-26 19 Slide Ham m er
A d a p te r
16. J-13 13 0 -1 5 0 F t. Lbs. T o rq u e W rench

t- ' ; . • *® *A
Fig. 2T~Chevrolet and C am aro-S pecial Tools
1. J-2 2 8 8 8 D iffe re n tia l Side Bearing Rem over J-8092 Drive Handle
Use w ith J-81 07 -4 A d a p te r Plug on 10. J-62 66 Pinion D epth S etting Gauge Consists o f:
P&M T ype A xle s and J-81 07 -2 fo r J-6266-31 Ring A dapters (F o r P Type
all others A xle s) J-62 66 -54 Gauge Plate
2 . J-81 07 -4 A d a p te r Plugs— P and M T ype Axles J-62 66 -25 F ro n t Pinion Bearing Bore
3. J-81 07 -2 A d a p te r Plug K ,G ,B ,0 T ype A xles Plug Used w ith J-8001 In d ic a to r
4. J -8 6 1 4 C om panion Flange Remover Consists o f: 11 . J-8001 Dial In d ic a to r
J-86 14 -10 H o lde r 12 . J-65 47 Drive Pinion Rear Pinion Bearing
J-8614-1 N u t (P T ype A x le )
J-8614-2 Screw 13. J-9772 Drive Pinion Bearing In sta lle r K ,G ,B ,0
5. J-2 2 9 1 2 Press Plate T ype A xles
6. J-7 1 3 7 Drive Pinion F ro n t Bearing Cup Installer 14. J-22 38 8 Drive P inion O il Seal Installer
Use w ith J-8 0 9 2 D river Handle 15. J-94 58 C om panion Flange Installer
7. J-9 7 4 5 Drive P inion Rear Bearing Cup Installer 16. J-5853 In. Lb. T orqu e Wrench
K ,G ,B ,0 T ype Axles Use w ith J-80 92 17. J-22 17 5 D iffe re n tia l Side Bearing Installer
D river Handle P T ype A x le
8. J-86 0 Drive Pinion Rear Bearing Cup Installer 18. J-22761 D iffe re n tia l Side Bearing Installer
P T ype A x le Use w ith J-8 0 9 2 D river K ,G ,B ,0 Type Axles
Handle

20
Fig. 3T~Special Tools (Corvette)
1. J-6266 Pinion Setting Gauge-Consists of J-6266- 11. J-22888 Differential Bearing Remover (Used with
28 Barrel Gauge, J-6266-31 Gauge Sleeves and J- J-8107-4)
6266-53 Gauge Plate 12. J-9774 Differential Yoke Bearing Seal Installer
2. J-0358-1 Press Plate Holder 13. J-5780 Companion Flange Installer
3. J-9771 Drive Pinion Bearing Cone and Roller 14. J-8092 Driver Handle (Threaded Type)
Assembly Remover (Used with J-0358-1) 15. J-7079-2 Driver Handle (Insert Type)
4. J-21058 Drive Pinion Oil Seal Installer 16. J-8001 Dial Indicator Set
5. J-9772 Drive Pinion Rear Bearing Cone and 17. J-22779 Side Bearing Shim Gauge-Includes J-
Roller Assembly Installer 22779 Strap
6. J-9773 Differential Yoke Bearing Install (Used 18. J-4880 Snap Ring Pliers
with J-7079-2) 19. J-5810 Torque Wrench Adapter (3 /4 " male to
7. J-8359 Differential Bearing Installer (Used with 3 /8 " female)
J-8092) 20. J-3289 Differential Carrier Holding Fixture
8. J-7137 Drive Pinion Front Bearing Cup Installer 21. J-22311 Positraction Clutch Pack Remover and
(Used with J-8092) Installer
9. J-8608 Drive Pinion Rear Bearing Cup Installer 22. J-1313 0-150 ft. lbs. Torque Wrench
(Used with J-8092) 23. J-5853 0-15 in. lbs. Torque Wrench
10. J-22804-1 Pinion Seal Gauge Plate 24. J-8614 Companion Flange Holder and Remover

Fig. 4T~Special Tools, 5 2 0 0 and 1 1000 Lb. C apacity Axles
1. J-0358 Press Plate Holder 10. J-2225 Pinion Front Bearing Remover Plate
2. J-1453 Pinion Bearing Press Plate 11. J-6203 Pinion Front Bearing Remover Plate
3. J-8107 Differential Bearing Puller Set 12. J-8092 Drive Handle
4. J-1364 Pinion Bearing Ring Drive 13. J-22281 Pinion Flange Oil Seal Installer
5. J-2226 Differential Side Bearing Replacer 14. J-8001 Dial Indicator Set
6. J-22300 Bearing Installer 15. J-0972 Differential Adjusting Nut Wrench
7. J-1488 Differential Side Bearing Replacer Not Illustrated:
8. J-22301 Bearing Installer J-2224 Pinion Front Bearing Remover Plate
9. J-6171 Pinion Front Bearing Remover Plate J-1439 Pinion Front Bearing Remover Plate

SECTION 5
BRAKE COMPONENTS
Power Brake Cylinder Single D iaphragm (Delco Power Brake Cylinder Single Diaphragm (Bendix) 5-16
M o ra in e )................................................................... 5-1 Power Brake Cylinder D ual Diaphragm (Bendix) .. 5-21
Power Brake Cylinder D ual D iaphragm (Delco Vacuum Booster, Single D iaphragm (Bendix).......... ...5-27
M o ra in e )................................................................... 5-7 Special T o o ls .........................................................................5-31
DELCO-MORAINE POWER BRAKE CYLINDER

SINGLE DIAPHRAGM
INDEX
D isassem bly........................................................................ 5-1 Inspection ........................................................................... 54

C leaning............................................................................... 5-4 A ssem bly ............................................................................ 54
OVERHAUL OPERATIONS
Removal from Vehicle Straight Mounting Bracket (Fig. 4BJ.

a. Place spanner wrench Tool J-9504 over studs on
1. Disconnect push rod at brake pedal arm. rear shell and attach with nuts and washers. Draw
2. Remove vacuum hose from check valve. nuts down tight to eliminate bending or damaging
3. Disconnect hydraulic lines at main cylinder. of studs.
4. Remove four nuts and lock washers securing power
unit to fire wall, and remove power unit from engine
com partm ent. Tilt Mounting Bracket (Fig. 5B)
b. Place Tool J-22893 inside tilted m ounting bracket.
Place spanner wrench Tool J-9504 on top o f J-22893
Disassem bly and tighten nuts and washers to bolts securing span
ner wrench.
The following procedure applies to the power section of
the power brake unit only (fig. 1A) for service of the main
cylinder refer to applicable portion in the "Service" manual.
NOTE: When separating housings, maintain pres
1. Scribe across outer edge of both shells and, if used, sure on rear housing as it is under spring tension.
across mounting bracket flanges to provide a guide
m ark for reassembly. c. Press down on spanner bar wrench J-9504 and ro
2. Remove main cylinder attaching nuts and lockwashers tate the rear housing counter-clockwise to separate
and set main cylinder aside. the two housings. If the rear housing cannot be
3. A ttach base of Tool J-22805 to front shell with nuts and readily loosened, tap the rear housing lightly with
washers and draw n down tight to eliminate bending or plastic hammer.
damage to studs. Clam p base in bench vise with power 4. Lift Tools J-9504 and J-22893 on tilted mounting
section up (fig. 2B). bracket type and Tool J-9504 on regular type.

BRAKES 5-2
Fig. 1A~M oraine Vacuum Power C ylinder (Typical)
1. Front Shell 14. Reaction Bumper

2. Power Piston Return Spring 15. Snap Ring
3. Reaction Retainer 16. " 0 " Ring
4. M aster C ylind er Piston Rod 17. A ir Valve
5. " 0 " Ring 18. A ir Filters
6. Reaction Plate 19. Boot
7. Lock Ring 20. Push Rod
8. Diaphragm 21. Silencer
9. S u p po rt Plate 22. Lim iter W asher
10. Rear Shell 23. Floating C ontrol Valve
11. Power Piston A ssem bly
12. Reaction Levers 24. Floating C ontrol Valve
13. A ir Valve Spring Retainer
(Two fo r Nova only) 25. A ir Valve Spring Retainer
5. Lift the power piston assembly and rear housing from

CAUTION: Care must be exercised not to damage or the unit.
loosen studs in shell. Also, take care that no pres- 6 . Remove power piston and boot from the rear housing,
sure is brought to bear on plastic power piston ex
tension. 7. Remove the silencer from inside the boot (fig. 2A).

BRAKES 5-3
1' 2 3 4 5
Fig. 2A ~M oraine Power Unit Fig. 3A--Power Piston and Com ponents
1. A ir F ilter 10. A ir Valve Spring

1. Boot 7. Front Housing 2. Lim iter W asher Retainer
2. Silencer 8. Front Housing Seal 3. F loating Control 11. Reaction Bumper
3. Seal 9. Vacuum Check Valve Valve Cup 12. A ir Valve Spring
4. Rear Housing 10. M ain C ylinder 4. F loating Control 13. Reaction Levers
5. Power Piston Assem bly Valve Assem bly 14. Reaction Plate
Assem bly 5. " 0 " Ring 15. Reaction Retainer
6. Power Piston Return 6. Diaphragm 16. " 0 " Ring
Spring 7. S up po rt Plate 17. Main C ylinder Piston
8. Power Piston Rod
9. Snap Ring 18. Lock Ring
8. Remove the power piston return spring from the front
housing. 16. Pull the diaphragm edges away from the support plate
9. Remove Tool J-22805 from front shell and set aside. and grip the steel support plate by hand, press down
10. Remove the front housing seal from the center of the and rotate counter clockwise to separate the plate from
front housing. the power piston (fig. 4A).
11. Remove the check valve and grom m et from the front
housing.
12. Remove the power piston bearing from the rear hous
ing.
CAUTION: Extreme care must be taken in handling

the diaphragm of the power piston assembly (fig.
3A). The diaphragm should be guarded against
grease, oil, foreign matter and must be protected
from nicks, scratches and gouges.
13. Remove the lock ring from the power piston by prying
one o f the ends out from under the large divided locking
lug, and then pull it from under the rem aining two
small lugs.
14. Remove the reaction retainer, piston rod, reaction
plate, three reaction levers, air valve spring, small reac
tion bum per, and air valve spring retainer.
15. Place square shank of Tool J-2 1524 in a vise and posi
tion the assembly down on the tool so th at the three lugs
on the tool fit into the three notches in the power piston. Fig. 4A~Separating Power Piston from S upport Plate

BRAKES 5-4
22. Push the main cylinder piston rod from the reaction
retainer and remove the "O" ring from the rod.
C A U T IO N :
NOTE: A new floating control valve should always
D O N O T C L A M P TIGHT
O N POWER PISTON. be used whenever it is removed from the power pis
ton.
Cleaning
Use denatured alcohol to clean all metal, plastic and

rubber parts of the power cylinder. Im m erse parts in cleaning
fluid and use a hair brush to remove foreign m atter. Blow out
all passages, orifices and valve holes. A ir dry and place
cleaned parts on clean paper or lint-free cloth. If slight rust
is found on inside surface of power cylinder housing, polish
clean with crocus cloth or fine emery cloth, then follow with
Fig. 5A~Rem oving A ir Valve Snap Ring a thorough cleaning.
Use of gasoline, kerosene, anti-freeze alcohol or any other
cleaner with even a trace of mineral oil will damage rubber
parts. Be particularly careful during reassembly th at no
grease or mineral oil comes in contact with these rubber
17. Remove the diaphragm from the support plate and lay
parts.
both parts aside.
18. Remove the silencer from the neck of the power piston
tube.
19. Position the power piston in a vise padded with shop- Inspection
towels, w ith the tube down (fig. 5A).
20. Using Pliers J-4880 remove the snap ring from the air W ipe cleaning fluid from all parts and carefully inspect
valve. each part for damage and wear. Inspect rubber parts for cuts,
21. Place the power piston with tube down in an arbor nicks and distortion. These rubber parts are the key to con
press. Using a rod not exceeding 1/2" in diam eter press trol of air flow and should account for the m ajority of trou
the air valve assembly from the power piston (fig. 6 A). bles traceable to leakage. If there is any question whatever as
to serviceability of any part, replace it.
Assem bly (Figs. IA, 2A, and 3A)
Be sure that all parts are clean. If there is any doubt of

cleanliness, rewash and air dry. Lubricate rubber parts with
an approved rubber lubricant. Lubricante all plastic and
metal friction points with an approved lubricant.
1. Replace the vacuum check valve, using a new grommet,
if old one is cracked or damaged.
2. Place new front housing seal in the center of the front
housing so that the flat surface of the cup lies against
the bottom of depression in the housing.
3. Assemble the m aster cylinder onto the front housing
with the scribe m ark on the top of the housing lining up
with the center of the m aster cylinder cover. Install self
locking nuts and tighten finger tight only.
4. Install a new "O" ring in the groove on the main cylin
der piston rod. Apply a thin film of lubricant to "O"
ring.
5. Insert main cylinder piston rod through the reaction
retainer with round end of rod at tube end of retainer.
6 . Place the square shank of Tool J-2 1524 in a vise and
position power piston on tool with the three lugs fitting
Fig. 6A~Rem oving A ir Valve Assem bly from Power Piston into the notches of the power piston.

BRAKES 5-5
Fig. 7 A -ln s ta llin g A ir Valve and Retainer Fig. 8 A ~ ln sta llin g Power Piston to S upport Plate
7. Install a new "O" ring on the air valve in the second 19. Install the air valve spring retainer to seat on the snap
groove from the push rod end. ring.
8. Coat the new floating control valve rubber and the air 20. Install the reaction bum per into the groove in the end
valve "O" ring w ith a thin film of lubricant. of the air valve.
9. Press the air valve assembly (air valve first) to its seat 21. Position the air valve return spring, (large end down)
in the power piston tube. on the spring retainer.
10. Install a new floating control valve retainer over the 22. Install the 3 reaction levers into the slots of the power
push rod, (flat side tow ard the floating control valve.). piston with the small end resting on the air valve return
spring.
11. Start the floating control valve and retainer into the 23. Install main cylinder piston rod through the reaction
power piston tube. retainer with round end out tube side.
12. Seat retainer in the power piston tube by pressing it in 24. Center reaction plate on the reaction levers (numbered
place w ith Tool J -2 1601. (Scribe line on tool should line side up), and place reaction retainer down on power
up w ith top edge to power piston tube, Fig. 7A). piston. (M ake sure small end of push rod engages in
13. Install the push rod lim iter washer over the push rod center hole of reaction plate), (fig. 9A).
25. Push reaction retainer down and line up the lugs with
and then the air filter element.
the notches in the power piston.
14. Install the power piston diaphragm on the support plate
26. Secure w ith lock ring making sure ends of lock ring are
(opposite side of locking tang).
set in place on the large divided lug of the power piston,
(one end on each side of lug), (fig. 10A).
NOTE: Make sure the support plate is in the groove
27. Install a new power piston bearing in the center of the
in the center flange of the diaphragm.
rear housing (large flange of bearing on stud side of
housing). Lubricate the inside of the bearing.
15. H olding the suport plate assembly over the tube of the
power piston (Fig. 8A).
NOTE: Make sure flange on rear housing is engaged
in groove of power piston bearing.
NOTE: The flange of the diaphragm will fit into the
groove on the power piston.
28. Install air silencer over the holes on the power piston
16. Press down and rotate the support plate assembly tube and lubricate tube.
clockwise, until the lugs on the power piston come 29. Install power piston tube through rear housing, (from
against the stops on the support plate. side opposite of studs).
17. Place this assembly tube dow n in a padded vise, (Do Not 30. A ttach base of Tool J-22805 to front shell with nuts and
Clamp). washers and draw down tight to eliminate bending or
18. Install snap ring in groove of air valve with Pliers J- damaging of studs. Place power piston return spring
4880 (fig. 5A). over the insert in the front housing.

BRAKES 5-6
twist rear housing clockwise in relation to front shell

until housings are fully locked.
NOTE: If unit is not easily locked, hold shells
together and apply vacuum to check valve in front
shell. Do not put pressure on power piston exten
sion.
34. Install felt silencer over push rod to seat against end of
pow er piston tube, secure with snap ring retainer, and
place plastic boot with large holes in center of brackets.
Install locknut and clevis on push rod.
35. Remove unit from vise.
36. Place power unit in a vise so that m aster cylinder push
rod is up.
37. Place Tool J-7723-01 over the push rod so that it fits
between the studs on front housing. Gauge should be
parallel to studs resting on surface of housing. The
cutout portion of the gauge should never be lower than
the end of the piston rod, and the gap should never be
m ore than .010 inch (fig. 11 A).
NOTE: If push rod height adjustment gauge is not

available, the required dimensions for fabrication
Fig. 9 A -ln s ta llin g Reaction Retainer on Power Piston are given in Figure 9B.
38. Any variation beyond these two limits would require
replacem ent of the piston rod with the service adjusta
ble piston rod, and adjusting the screw in the end of the
rod to m atch the height of the gauge.
39. Position main cylinder to power cylinder. Install lock
washers and nuts and torque to 25 foot pounds.
NOTE: All brake attachments are important attach
ing parts in that they could affect the performance
of vital components and systems, and/or could re
sult in major repair expense. They must be replaced
with parts of the same part numbers or with equiva
lent parts if replacement becomes necessary. Do not
use replacement parts of lesser quality or substitute
design. Torque values must be used as specified dur
ing reassembly to assure proper retention of these
parts.
Fig. 1 0 A -ln s ta llin g Retainer Lock Ring
31. Lubricate the I.D . of the support plate seal and the
reaction retainer tube. Talcum powder the beaded edge
of the diaphragm .
32. Place the rear housing assembly over the front housing
assembly and align with scribe m arks of the two hous
ings so they will m atch when in locked position.
33. Position Tool J-22893 inside tilted m ounting bracket.
Place spanner wrench Tool J-9504 on top of J-22893
and tighten nuts and washers to bolts provided, secur
ing spanner wrench or place spanner wrench J-9504
over studs on rear shell and attach with nuts and
w ashers-draw nuts down tight to eliminate bending or
damaging of studs. Press down on spanner wrench and

BRAKES 5-7
DELCO MORAINE POWER BRAKE CYLINDER DUAL

DIAPHRAGM
INDEX
R em oval............................................................................... 5-7 A ssem bly............................................................................ 5-12

Installation......................................... ;............................... 5-7 G ag in g ................................................................................. 5-15
D isassem bly....................................................................... 5-8
Removal from Vehicle 2. Connect power brake push rod to brake pedal.
3. Connect vacuum hose to vacuum check valve.
1. D isconnect the brake lines from the two m aster cylin 4. Connect brake lines to main cylinder outlets.
der hydraulic outlets. Cover brake line fittings to pre 5. Bleed brakes as necessary and fill fluid reservoirs to
vent dust and dirt from entering brake lines. within 1/4" of top of the reservoirs.
2. D isconnect the vacuum hose from the vacuum check

valve on the front housing of the power head. Plug
vacuum hose to prevent dust and dirt from entering
hose. Testing
3. D isconnect the power brake push rod from the brake
1. W hen the engine is shut off, and the transmission is in
pedal.
neutral, apply brakes several times to deplete all
vacuum reserve in the system. Depress brake pedal,
4. Remove the four nuts (inside vehicle) from the m ount
hold light foot pressure on the pedal, and start the
ing studs th at hold the power brake to the firewall.
engine. If the vacuum system is operating, the pedal will
tend to fall away under foot pressure, and less pressure
5. C arry the power brake to a clean work area and clean
will be required to hold pedal in applied position. If no
the exterior of the power brake prior to disassembly.
action is felt, the vacuum system is not functioning.
2. Stop engine. Again deplete all vacuum reserve in the

system. Depress the brake pedal and hold foot pressure
Installation on the pedal. If the pedal gradually falls away under
1. M ount power brake assembly to dash. foot pressure, the hydraulic system is leaking.
3. If th e b ra k e p e d al travels to w ithin o ne in c h o f th e
NOTE: All brake attachments are important attach to e -b o a rd , th e b ra k e shoes re q u ire a d ju s tm e n t o r
ing parts in that they could affect the performance relining.
sult in major repair expense. They must be replaced 4. Start engine. W ith transm ission in Park or N eutral,
with parts of the same part numbers or with equiva open throttle to m edium speed. Close throttle and tu rn
lent parts if replacement becomes necessary. Do not off engine. This evacuates the housing chambers. W ait
use replacement parts of lesser quality or substitute no less than 90 seconds, then try brake action. If not
design. Torque values must be used as specified dur vacuum assisted for two or more applications, vacuum
ing reassembly to assure proper retention of these check valve is faulty or there is a leak in the vacuum
parts. system.

BRAKES 5-8
OVERHAUL OPERATIONS
Disassembly (Fig. 1-HI and 2-H) 2. Remove the power piston group from the rear housing
and remove the prim ary power piston bearing from the
center opening of the rear housing.
NOTE: Scribe a mark on the top center of the front
and rear housings in line with master cylinder reser
P o w e r P is to n G roup
voir cover to facilitate reassembly.
1. Lift the bead on the O.D. of the secondary diaphragm
1. Remove the two locknuts which hold the m aster cylin and remove the diaphragm support ring (Fig. 3-H).
der to the front housing, and remove the m aster cylin 2. If not already disengaged, remove the retainer plate
ders from the m ounting studs. Remove the front from the secondary piston. Remove the piston rod re
housing seal from the front housing. tainer and piston rod from the secondary piston.
2. M ount tool J-22805 to power booster and install two 3. M ount double-ended tool J-23101 (with large diameter
nuts. end up) in a vise. Position the secondary power piston
3. Position housing unlock tool J-9504 over the rear hous so th at the two radial slots in the piston fit over the ears
ing m ounting studs. Secure w ith nuts. Install tool J- (tangs) of the tool (Fig. 4- H).
9504 w ith power booster in a bench vise. Applying 4. Fold back prim ary diaphragm from the O.D. of the
dow nw ard pressure, rotate rear housing counter-clock prim ary support plate. G rip the edge of the support
wise to unlock the housings. It is norm al for this operat plate and rotate counter clockwise to unscrew the pri
ion to require heavy pressure to unlock the housings. m ary power piston from the secondary power piston.
NOTE: Rotate slowly as housing is under spring

tension.
NOTE: It is possible that the primary support plate
F ro n t H o u s in g G ro u p will unlock from the primary piston before the pri
1. Remove the power piston return spring. The retainer mary piston unscrews from the secondary piston. If
plate and power piston m ay come out w ith the power this happens, continue to turn the primary support
piston return spring. Rem ove the vacuum check valve plate counter-clockwise. Tabs (“ stops” ) on the pri
and grom m et from the front housing (if the check valve mary support will temporarily lock the primary
is defective or the grom m et cracked, cut or damaged). support plate to the primary power piston and
permit continued counterclockwise rotation to unscrew
the primary power piston from the secondary power
Rear H o u s in g G ro u p piston (Fig. 5 H).
1. Remove tool J-9504. Remove the boot from the rear

housing. Rem ove the felt silencer from inside the boot. 5. Remove the housing divider from the secondary power
piston. Remove the secondary power piston bearing
from the housing divider.
6. The secondary power piston should still be positioned
on tool J-23101. Fold back secondary diaphragm from
O.D. of secondary support plate. G rip the edges of the
support plate and rotate clockwise to unlock the sec
ondary support plate from the secondary power piston
(Fig. 6 -H).
7. Remove the secondary diaphragm from the secondary
support plate.
8. Remove the reaction piston and reaction disc from the
center of the secondary power piston by pushing down
on the end of the reaction piston with a small object,
such as a pencil, wooden dowel or m etal rod (Fig. 7-H).
9. Remove the air valve spring from the end of the air
valve (if it didn’t come off during disassembly of the
power piston).
10. M ount tool J-23101 in a vise (with small diam eter end
up). Position the prim ary power piston so th at the two
radial slots in the piston fit over the ears (tangs) of the
Fig. 1-H -U nlocking Front and Rear Housings tool (Fig. 8-H).

BRAKES 5-9
Fig. 2-H -Exploded V iew of M ajor Assem blies
11. Fold back prim ary diaphragm from the support plate. 16. Using T ruarc No. 2 pliers (J-4880), remove the retain
G rip the edge o f the support plate and rotate in a coun ing ring from the air valve (Fig. 10-H).
ter-clockwise direction to unlock the prim ary support
plate from the prim ary power piston (Fig. 9-H).
17. Remove the air valve-push rod assembly from the tube
end of the prim ary power piston. The following removal
12. Remove the prim ary diaphragm from the prim ary sup m ethod is recommended:
port plate. Place the prim ary power piston in an arbor press, and
press the air valve push rod assembly out the bottom of the
power piston tube with a rod not exceeding 1/ 2 " in diameter.
13. Remove the air filter and push rod lim iter washer from
the tubular section of the prim ary power piston.
18. Removal of the air valve push rod assembly will disas
semble the control valve retainer.
14. Remove the power head silencer from the neck of the
power piston tube.
19. Remove the "O" ring seal from the air valve.
15. Remove the rubber reaction bum per from the end of the
air valve.

BRAKES 5-10
Fig. 4 -H -P ositio nin g Secondary Power Piston in Tool J-23101 Fig 5-H -Locking or U nlocking Primary and S econdary Power
(Large Dia. End Up) Pistons

BRAKES 5-11
P RIM ARY
POW ER
P IS TO N
J-23101
Fig. 6-H -L o ckin g or U nlocking Secondary S upport Plate and Fig. 8 -H -P ositio nin g Prim ary Power Piston in Tool J-23 10 1
Secondary Power Piston (Small Dia. End Up)
PRIMARY
SUPPORT
PLATE
J-23101
Fig. 7-H -Rem oving Reaction Piston and Reaction Disc From Fig. 9-H~Locking o r U nlocking Prim ary S up po rt Plate From
S econdary Power Piston Prim ary Power Piston

BRAKES 5-12
Assem bly
Front Housing Group

parts.
If the grom m et was rem oved for replacem ent, insert the
new grom m et in the front housing and press the vacuum
check valve through the gromm et. Fig. 10-H~Removing Retaining Ring From A ir Valve
5. A fter the floating control valve is seated, place the push

rod lim iter washer over the push rod and position on
the floating control valve.
Power Piston Group 6. The filter element can now be stretched over the push
1. Lubricate the I.D. and O.D. o f the "O" ring seal with rod and pressed into the prim ary power piston tube.
silicone lubricant and place on the air valve.
J -2 3 1 7 5
2. W ipe a thin film of silicone lubricant on the large and

small O.D. of the floating control valve.
RETAINER
(LIP UP)
3. Place the air valve end of the air valve push rod assem
bly into the tube of the prim ary power piston. M anually
PRIMARY
press the air valve push rod assembly so th at the float
POW ER.
ing control valve bottom s on the tube section of the PIS TO N
prim ary power piston. Installer tool J-23175 can be
used to m anually press the floating control valve to its
seat.
J-23101
4. Place the I.D . of the floating control valve retainer on

the O.D. of floating control valve retainer installer J-
23175. Place over the push rod so th a t the closed side
of the retainer seats on the floating control valve (Fig.
11-H). W ith Installer J-23175, m anually press the re
tainer and floating control valve assembly to seat in the Fig. 1 1-H— Installing Floating Control Valve Retainer w ith
prim ary power piston tube (Fig. 12-H). Installer J - 2 3 175

BRAKES 5-13
8. Position the rubber reaction bum per on the end of the

air valve.
NOTE: Tolerances of those component parts affect

ing output of the tandem power brake are very criti
cal. In order to maintain correct power brake output
the power piston assembly must be gaged for selec
tive fit of reaction piston whenever the primary
power piston, and/or the secondary power piston
are replaced during servicing. This gaging operation
is not required if neither power piston is replaced
during servicing.
If replacing either power piston, the following procedure

should be followed (Fig. 13-H).
a. H and-tighten the secondary power piston to the pri
m ary power piston w ithout the air valve spring.
(The air valve push rod assembly should already be
assembled to the prim ary power piston as described
above.)
b. Insert the reaction piston into its cavity in the sec
ondary power piston. This is accomplished by plac
ing the reaction piston, small diam eter first, through
the large cavity and into the smaller cavity.
Fig. 12-H -S eating Floating C ontrol Valve Assem bly w ith c. W ith the secondary power piston up, push on the
Installer J-2 3 1 7 5 reaction piston to insure th at it is seated on the air
valve.
d. Place Gage J-23337 in the secondary power piston
7. Using T ruarc No. 2 pliers (J-4880, place the retaining
so th at the outer edges of the gage rest on the bottom
ring into the groove in the air valve (Fig. 10-H).
Fig. 13-H -P ow er Piston Gaging

BRAKES 5-14
o f the large cavity, with the two levels of the center 18. Apply silicone lubricant to the O.D. of the prim ary
section of the gage w ithin the smaller reaction pis power piston tube.
ton cavity. 19. Remove the prim ary piston assembly from tool J-23101
e. M ove the gage to the left or right of the "nose" of and lay it aside.
the reaction piston. The reaction piston is the cor 20. Assemble the secondary diaphragm to the secondary
rect length if the "nose" of the piston "hits" the support plate from the side of the support plate opposite
lower level of the gage and clears the higher level of the locking tangs. Press the raised flange on the I.D . of
the gage, while perm itting the outer edges of the the diaphragm through the center hole of the support
gage to rem ain seated on the larger cavity of the plate. Be sure that the edge of the support plate center
secondary power piston. hole fits into the groove in the raised flange of the
f. If the reaction piston is too long, the higher level of diaphragm . Apply a thin coat of silicone lubricant to
the gage will not clear the "nose" w ithout moving the I.D . of the secondary diaphragm and the raised
the outer edges of the gage off the seat in the large surface of the flange (that fits into a groove in the
cavity of the secondary power piston. If the reaction secondary power piston).
piston is too short, both levels of the gage will clear 21. M ount tool J-23101 (with large diam eter end up) in a
the "nose" of the reaction piston. If either condition vise. Position the secondary power piston so that the
exists, a separate kit of three selective reaction pis radial slots in the piston fit over the ears (tangs) of the
tons (differing in length and color) m ust be obtained tool. Apply a light coat of silicone lubricant to the tube
to perm it use of piston to meet correct size require of the secondary power piston (Fig. 4-H).
ments of step (e) above. 22. Fold the secondary diaphragm away from the O.D. of
the secondary plate.
23. Holding the edges of the support plate with the locking
NOTE: Care must be taken to insure that the gage tangs down, place the secondary diaphragm and sup
is n o t" cocked." port plate assembly over the tube of the secondary
power piston. The flange on the I.D . of the secondary
diaphragm will fit into the groove in the secondary
9. A fter determ ination of the correct reaction piston, ap piston.
ply a light film of silicone lubricant to the O.D. of the 24. G rip the edges of the secondary support plate, press
rubber reaction disc. down, and rotate counter-clockwise until the tabs on
10. Place the rubber reaction disc in the large cavity of the the secondary power piston contact the stops on the
secondary power piston and push the disc down to seat support plate. Fold the secondary diaphragm back into
on the reaction piston. position on the secondary support plate. Leave the sec
11. U nlock the secondary pow er piston from the prim ary ondary power piston assembly on tool J-23101 in the
power piston. vise (Fig. 6 -H).
12. Assemble the prim ary diaphragm to the prim ary sup 25. Apply a light coat of talcum powder or silicone lubri
port plate from the side of the support plate opposite the cant to the bead on the O.D. of the secondary dia
locking tangs. Press the raised flange on the I.D . of the phragm. This will facilitate reassembly of front and rear
diaphragm through the center hole of the support plate. housings.
Be sure th at the edge o f the support plate center hole 26. Place the secondary diaphragm support ring on the
fits into the groove in the raised flange of the dia secondary power piston assembly so that it rests on the
phragm . Lubricate the diaphragm I.D . and the raised edge of the diaphragm.
surface of the flange (that fits into a groove in the 27. Hold the housing divider so that the formed over flange
prim ary power piston) w ith a light coat of silicone lubri (that holds the prim ary diaphragm ) of the divider faces
cant. down. Place the secondary bearing in the I.D. of the
13. M ount tool J-23101 (small diam eter end up) in a vise. divider so that the extended lip of the bearing faces up.
Position the prim ary power piston so th at the two radial 28. Lubricate the I.D. of the secondary bearing with sili
slots in the piston fit over the ears (tangs) of the tool cone lubricant.
(Fig. 8-H). 29. Position secondary bearing protector tool J-23188 on
14. Fold the prim ary diaphragm away from the O.D. of the the threaded end of the secondary power piston (Fig.
prim ary support plate. 14H).
15. Holding the edges of the support plate, w ith the locking 30. H old the housing divider with the form ed flange (that
tangs down, place the prim ary support plate and dia holds the prim ary diaphragm ) facing up. Press the di
phragm assembly over the tube of the prim ary power vider down over the tool and onto the secondary power
piston. The flange on the I.D . of the prim ary diaphragm piston tube where it will rest against the diaphragm
will fit into a groove in the prim ary power piston. support ring. Remove tool J-23188 from secondary
16. G rip the edges o f the prim ary support plate, press power piston; however, do not remove the secondary
down, and rotate clockwise until the tabs on the pri power piston sub-assembly from tool J-23101.
m ary pow er piston contact the stops on the support 31. Pick up the prim ary power piston assembly and posi
plate (Fig. 9-H). tion the small end of the air valve return spring on the
17. Place the power head silencer on the tube of the pri air valve so that it contacts the air valve retaining ring.
m ary power piston so th at the holes at the base of the 32. Fold the prim ary diaphragm away from the O.D. of the
tube are covered. prim ary support plate.

BRAKES 5-15
FORMED FLANGE
Final Assem bly
I 1. M ount tool J-22805 in a vise and position the front

housing on the tool so th at the housing studs fit in the
holes provided in the tool.
2. Position the power piston return spring over the inset
in the front housing.
3. Assemble the power piston group to the rear housing by
pressing the tube of the prim ary piston through the rear
housing bearing. Press down until the housing divider
J-23188 seats in the rear housing and the prim ary power piston
bottom s against the housing.
4. Place the piston rod retainer plate on the end of the
power piston return spring in the front housing.
5. H old the rear housing assembly (with m ounting studs
up) over the front housing. (Make sure that the piston
rod retainer does not dislodge from the secondary
power piston during this operation.) Position the rear
housing so th at when the tangs on the edge of the front
housing are locked in the slots on the edge of the front
housing, the scribe m arks on the top of the housings will
be in line.
6 . Lower the rear housing assembly onto the front hous
ing. Check that the piston rod retainer goes through the
Fig. 1 4-H--Positioning Housing Divider Over Secondary center of the retainer plate on the power piston return
Bearing P rotector Tool J -2 3 1 8 8 spring. The retainer plate and power piston spring must
seat in the depression in the face of the secondary power
piston. Check that the bead on the O.D. of the second
33. Position the prim ary power piston on the tubular por ary diaphragm is positioned between the edges of the
tion of the secondary power piston, making sure that housings.
the air valve return spring seats down over the raised 7. Continue to press down on the rear housing and fit the
center section of the secondary piston. slots in the appropriate tangs on the front housing.
34. G rip the edge of the prim ary support plate, press down, 8 . Using tool J-9504, press down and rotate the rear hous
and start the threads on the secondary power piston ing clockwise into the locked position. Remove tool
into the threaded portion of the prim ary power piston J-9504.
by rotating in clockwise direction (Fig. 5H). 9. Place the silencer in the closed end of the power head
35. Continue to tighten the prim ary power piston until it is boot. Stretch the boot over the push rod and over the
securely attached (approxim ately 5-15 pounds) to the flange in the center of the rear housing.
secondary power piston. 10. Remove the power head assembly from holding fixture
36. Fold the prim ary diaphragm back into position on the J-22805 and remove fixture J-22805 from the vise.
prim ary support plate and pull the diaphragm O.D.
over the formed flange of the housing divider. Check Gaging
th at the bead on the diaphragm is seated evenly around
the complete circumference. 1. Place the power head assembly in a padded vise (front
37. W ipe a thin film of silicone lubricant on the O.D. of the housing up). Do not clamp tight!
piston rod retainer. Insert the m aster cylinder piston 2. Insert the m aster cylinder piston rod, flat end first, into
rod retainer into the cavity in the secondary power the piston rod retainer.
piston so th at the flat end bottom s against the rubber 3. Press down on the m aster cylinder piston rod (with
reaction disc in the bottom of the cavity. approxim ately a 40-50 pound load) to be sure it is prop
erly seated.
NOTE: Remove the front housing seat to assure that

no vacuum is in the power head while gaging.
Rear Housing Group
4. Place gage J-22647 over the piston rod in a position
1. Place the prim ary power piston bearing in rear housing which will allow the gage to be slipped to the left or
center hole so th at the formed flange of the housing right w ithout contacting the studs (Fig. 15-H).
center hole fits into the groove of the prim ary power 5. The center section of the gage has two levels. The piston
piston bearing. The thin lip of the bearing will protrude rod should always contact the longer section (lower
to the outside of the housing. level) of the gage. The piston rod should never contact
2. Coat the I.D . of the prim ary power piston bearing with the shorter section (higher level) of the gage. Move gage
silicone lubricant. from side to side to check piston rod height.
BRAKES 5-16
7. Wipe a thin film of silicone lubricant on the I.D . of the

front housing seal and position seal in the depression in
the housing.
8. Install the m aster cylinder assembly on the front hous

ing, positioning the cylinder on the m ounting studs so
th at the top of the m aster cylinder reservoir is toward
the scribe m arks on the housings.

9. Install nuts on the studs.
NOTE: This cylinder to dash fastener is an impor

tant attaching part in that it could affect the per
formance of vital components and systems, and/or
could result in major repair expense. It must be re
placed with one of the same part number or with an
equivalent part if replacement becomes necessary.
6. A ny variation beyond these two limits m ust be com pen Do not use a replacement part of lesser quality or
sated for by obtaining the service adjustable piston rod substitute design. Torque values must be used as
and adjusting the self- locking screw to meet the gaging specified during reassembly to assure proper reten
specifications. tion of this part.
BENDIX POWER BRAKE CYLINDER

SINGLE DIAPHRAGM TYPE
INDEX
Disassembly 5-18 Inspection .......................................................................... 5-19

C leaning...... 5-19 A ssem bly.......................................................................... 5-19
OVERHAUL OPERATIONS
Passenger car and light duty trucks use the power brake Removal from Vehicle
cylinders covered in this section. A noticeable difference is in
the valve rod. Passenger cars use a screw-on clevis with an 1. Disconnect push rod at brake pedal arm.
eye where light duty trucks use a straight rod w ith an eye to 2. Remove vacuum hose from check valve.
attach to the brake pedal. 3. D isconnect hydraulic lines at main cylinder.
4. Remove four nuts and lock washers securing power
unit to fire wall, and remove power unit from engine
com partm ent.

BRAKES 5-17
1. M ain C ylinder 14. Dust Boot

2. Vacuum Check Valve 15. Valve Push Rod
3. Grom m et 16. F ilter and Silencers
4. D iaphragm 17. Valve Return Spring
5. Diaphragm Plate 18. M ou ntin g Stud
6. Rear Shell 19. A ir Valve Lock Plate
7. Diaphragm Spring 20. D iaphragm Lip
8. Reaction Disc 21. Front Shell
9. Plunger 22. Push Rod Seal
10. Bearing Seal 23. Cylinder-to-Shell Seal
11. Poppet Valve 24. H ydraulic Push Rod
12. Poppet Valve Spring 25. A d ju stin g Screw
13. Poppet Retainer

BRAKES 5-18
1 2 3 4 5 6
7 8 9 10 11 12 13 14
Fig. 3 B -H o ld in g Fixture using Tool J-2 2 8 0 5
NOTE: To prevent chipping of the plastic diaphragm

plate, exercise extreme caution when removing the
air filter retainer. Use a small screw driver or other
Fig. 2B~Bendix Power C ylinder Components (Typical) suitable tool, and pry at several peripheral locations
until the retainer is freed.
1. Clevis 9. Diaphragm Plate 6. Scribe alignment m ark across surface at front and rear
2. Rubber Boot 10. Reaction Disc
shells.
3. Foam and Felt A ir 1 1. H ydraulic Push Rod
7. Position bar wrench (Tool J-9504) over studs of the rear
Filter-Silencers 12. Power Piston Return
4. Rear Shell
shell and tighten nuts (Fig. 4B).
Spring
5. Bearing Seal 13. Front Shell
6. Rolling Diaphragm 14. Push Rod Seal
7.
NOTE: Tilt mounting bracket. Place Tool J-22893
A ir Valve Push Rod 15. G rom m et
Assem bly 16. Check Valve
inside tilted mounting bracket. Place spanner
8. A ir Valve Lock wrench Tool J-9504 on top of J-22893 and tighten
nuts and washers to bolts securing spanner wrench
Disassem bly (Fig. I B and 2B) (Fig. 5B).
The following procedure applies to the power section of

the power brake unit only. F o r service of the m ain cylinder
refer to applicable portion of "Standard Brakes" in the "Ser
vice" m anual. J-9504
1. Remove main cylinder filter, piston seal assembly and

main cylinder push rod from front shell (fig. 2B) pulling
the push rod from the front shell will also remove the
filter and seal assembly.
2. Position and secure Tool J-22805 (fig. 3B) to m ain cyl
inder m ounting studs, and place tool and power unit in
a vise. Be sure to align tool so that check valve in front
shell is not damaged.
3. Disconnect linkage at air valve push rod, and remove
m ounting bracket from rear shell.
4. Remove rubber boot and retainer plate from rear shell.
5. Remove filter retainer from end of diaphragm plate

extension and remove air filter element from location Fig. 4 B -S e p a ra tin g Shells w ith Tools J-9 5 0 4 and
w ithin the diaphragm plate extension. J-22 8 0 5 -(P a sse n g e r Car Shown as Typical)

BRAKES 5-19
11. Disassemble power piston (fig. 6 -B).

a. Remove rolling diaphragm from the groove in the
diaphragm plate hub.
J-9504
b. H old the diaphragm plate so that the push rod is in
its norm al (horizontal) installed position, depress
the push rod slightly (approximately 1/16 inch),
and rotate piston so the air valve lock will fall from
its location in the piston hub. Remove the air valve
push rod assembly from the piston. Remove the
reaction disc from its location in the diaphragm
plate bore. (Insert the main cylinder push rod or
other suitable tool through diaphragm plate exten
sion and push disc from its seat.) Exercise care so
as not to chip surface of passages in the diaphragm
plate.
NOTE: Perform Step 12 only if seal is defective and

new seal is available. Do not reuse seal once it has
been removed from the unit.
Fig. 5B~Separating T ilt B racket Type S h e lls-w ith Tools
J-9 5 0 4 and J-2 2 8 9 3
12. Support outer surface of rear shell on blocks of wood
8. R otate Tool J-9504 until cutouts of rear shell are or other suitable m aterial (stud side up) and drive out
aligned with lances in front shell. seal with a punch or a thin blade screw driver. D iscard
seal.
NOTE: It may be necessary to straighten the c u t 13. Remove check valve from grommet; then remove grom-
lanced areas flush with the shell. If the tangs break met from front shell.
during this operation, it will be necessary to replace 14. Remove front shell and holding fixture from vise; then
that half of the shell. remove holding fixture from front shell.
9. If shells do not begin to separate, tap rear shell with a

soft faced ham m er.
Cleaning
Use denatured alcohol to clean all metal parts. Use al
CAUTION: Hold rear shell firmly. Pressure exerted cohol or an approved commercial cleaning solvent for clean
by internal diaphragm spring may cause rear shell to ing rubber and plastic parts. Immerse parts in cleaning
fly off when shells are in the released position. solvent and use a hair brush to remove foreign m atter. Blow
out all passages crevices and valve holes. A ir dry by placing
10. Remove power piston from front shell, separate power cleaned parts on clean paper or lint-free cloth. If slight rust
piston from rear shell, and remove Tool J-9504 from is found on inside surface of power cylinder housing, polish
unit. clean with crocus cloth or fine emery cloth, then follow with
a thorough cleaning.
The use of gasoline, kerosene, antifreeze, alcohol or any
other cleaner with even a trace of mineral oil will damage
rubber parts. Be particularly careful during reassembly that
no grease or mineral oil comes in contact with these rubber
parts.
Inspection
Carefully inspect each part for damage and wear, inspect
rubber parts for cuts, nicks and distortion. These rubber
parts are the key to control of air flow and should account
for the majority of trouble traceable to leakage. If there is any
question whatever as to serviceability of any part, replace it.
Assem bly
D uring assembly, make sure all parts are free of foreign
Fig. 6 B -B e n d ix Power C ylinder Com ponents (Typical)
m aterial before applying lubricant. If there is any doubt of
cleanliness, rewash and air dry. W hen applying lubricant as
1. Spring 5. A ir Valve Lock
2. H ydraulic Push Rod 6. A ir Valve Push Rod
specified in assembly procedure, use an approved lubricant
3. Reaction Disc Assem bly of known quality and composition that will not be harmful
4. Diaphragm Plate 7. Diaphragm to rubber and plastic materials.

BRAKES 5-20
5. Apply lubricant to I.D. of bearing seal and diaphragm

bead contact surface of rear shell. Install power piston
assembly in rear shell.
6 . Position bar wrench (Tool J-9504) over studs of rear
shell.
7. Place power piston return spring in front shell and
position rear shell assembly on front shell. Position rear
shell so that when shells are locked scribe m arks on
front and rear shells will be in alignment.
8 . Depress rear shell assembly. R otate Tool J-9504 until
scribe m arks on front and rear shells are in alignment.
Remove Tool J-9504 from unit.
NOTE: Bend lances in on shell if they were straight

ened on removal. If the tangs break during this oper
ation it will be necessary to replace that half of the
shell.
9. Install air cleaner element and retainer to piston exten

sion.
10. Install boot retainer and boot over piston extension and
secure boot to air cleaner retainer.
11. Align and install m ounting bracket to rear shell. Con
nect linkage to air valve push rod.
Fig. 7 B— Installing Piston Bearing Seal 12. Remove unit from fixture.
13. Apply lubricant sparingly to the hydraulic push rod,
1. Install check valve grom m et in front shell beveled edge keeping lubricant away from adjusting screw end of
of grom m et is to be inside shell. Dip check valve in rod. G uide push rod into center bore of power piston
clean alcohol and install in grom m et-check valve stem until it is fully seated against reaction disc.
is to be outside shell. 14. Install seal and main cylinder filter and press filter and
2. Position and secure Tool J-22805 (fig. 4B) to m ain cyl seal into front shell until seal is bottom ed in recess of
inder m ounting studs, and place tool and front shell in shell.
a vise. Be sure to align tool so th at check valve is not 15. Place Tool J-7723-01 over the push rod so that it fits
damaged. between studs on front shell (fig. 8B). Gauge should be
parallel to studs and resting on surface of front shell.
NOTE: If either or both of the shells are replaced, C utout portion of gauge should just m atch height of
make sure alignment marks are transferred to new push rod. A ny variation may be compensated for by
shell. turning adjusting screw.

3. Place rear shell on block, stud side down, and position
available, the required dimensions for fabrication
bearing seal in center hole. Use Tool J-22677 (fig. 7B)
are given in Figure 9B.
to seat seal in recess of rear shell. Tool bottom s against
shell when seal is in place.
4. Assemble power piston assembly. (See Fig. 6 B).
a. Apply lubricant to outside diam eter of diaphragm
plate and extension, to bearing surfaces of valve and
plunger, and to outer edge of valve poppet. Insert
valve and rod assembly in extension of diaphragm
plate.
b. Depress the push rod slightly and install the air
valve lock. M ake sure the lock indexes and retains
the air valve.
c. Install the rolling diaphragm in the groove of dia
phragm plate.
d. A pply lubricant to surface of reaction disc and posi
tion disc in center bore of diaphragm plate. Use
m ain cylinder push rod to seat disc in bore. M ake
sure disc is fully seated before removing push rod.
NOTE: If reaction disc is not fully seated, it will

result in an erroneous push rod height adjustment.

BRAKES 5-21

2 15/i < N O . 15 OR 16 parts.
U.S.S. GAUGE
SHEET STEEL
M ount the power brake assembly in place and install

four attaching nuts and lock washers. Be certain to
place push rod through cutout in fire wall.
2. A ttach vacuum line to check valve.
3. Secure hydraulic line to main cylinder.
4. A djust push rod clevis to brake pedal assembly. Adjust
pedal height by means of clevis on brake pedal push rod
1%2 3/4 at pedal. Pedal height is obtained by measuring from
floor covering at toe pan to top of pedal pad.
NOTE: Check operation of stoplight after adjusting

F ig . 9 B - P u s h R od G a u g e pedal height.
16. A fter push rod adjustm ent is correct, assemble main

cylinder to front shell and securely tighten retaining 5. Bleed brakes as outlined in this section.
nuts.
Installation NOTE: After completing the bleeding operation,

make sure reservoir fluid level is at correct height.
The reservoir should be filled to 1/4 inch of filler cap
opening.
with parts of the same part numbers or with equiva 6. Check operation of the brakes as outlined in this sec
lent parts if replacement becomes necessary. Do not tion.
BENDIX POWER BRAKE CYLINDER

DOUBLE DIAPHRAGM TYPE
INDEX
D isassem bly................. ...................................................... 5-22 Inspection .......................................................................... 5-25

Cleaning............................................................................... 5-25 A ssem bly............................................................................ 5-25
Corvette and light duty trucks use the power brake cylin light duty trucks use a straight rod with an eye to attach to
ders covered in this section. A noticeable difference is in the the brake pedal.
valve rod. Corvette uses a screw-on clevis with an eye where
OVERHAUL OPERATIONS
Removal from Vehicle 2. Remove vacuum hose from check valve.
3. Disconnect hydraulic line at main cylinder.
1. Disconnect push rod at brake pedal arm. 4. Remove m ain cylinder attaching nuts, lock-washers,
rubber seal and metal retainer and set aside.
NOTE: It may be necessary to remove the clevis Remove four nuts and lock washers securing power
from the push rod on Corvette models. Note approxi unit to fire wall, and remove power unit from engine
mate location of clevis on the rod. com partm ent.

BRAKES 5-22
REAR SHELL
VACUUM
CHECK
V ALVE
R E AC TIO N DISC
V ALVE RETURN S PR IN G
CHECK V A LV E PLUNGER
V ALVE V A LV E POPPET
GROM M ET
POPPET S PR IN G
VA LV E ROD
FRO N T V A C U U M
SEAL
DUST B O O T FILTER S-SILEN CER S

H Y DR AU LIC
PUSH R O D
D IA P H R A G M
RETURN
S PR IN G
REAR D IA P H R A G M
FR O N T D IA P H R A G M
PLATE
FR O N T D IA P H R A G M REAR D IA P H R A G M PLATE
CENTER PLATE
Fig. 1C~Bendix Double Diaphragm Cross Section
Disassembly (Fig. 1C and 2C) 5. Place assembly in bench vise with rear shell up using
holding fixture Tool J-22805 and tighten vise jaws se
1. Scribe across the flanges of both power section shells in curely.
line w ith m ain cylinder cover to provide a guide m ark
for re-assembly. D o not remove vacuum check valve
(Step 2) unless a new valve is to be installed. 6. Using a thin-bladed screw driver carefully pry silencer
retainer off hub of rear diaphragm plate, being careful
2. Remove vacuum check valve from front shell by pulling not to chip plastic.
straight out on valve. T hen remove rubber grommet
from front shell.
7. Place a block of wood 3 inches long on rear shell, (Fig.
3C). Insert a heavy round shanked screw driver into eye
3. U nseat dust boot from flange of rear shell and remove
of valve rod or wrench as shown and pry out valve rod,
boot.
air silencer and air filter. D o not pry with strokes or
rear plate may be damaged. A considerable force will
4. Use an ice pick to remove two valve silencers and air be required.
filter from diaphragm plate hub. Position power section
with valve operating rod up and squirt alcohol down rod to
wet rubber grommet in valve plunger at ball end of rod.

BRAKES 5-23
REAR DIAPHRAGM
PLATE
REAR DIAPHRAGM SEAL
\ VALVE
\ RETURN
DIAPHRAGM RETAINER
SPRING
REAR SHELL VALVE PLUNGER
VACUUM CHECK
VALVE
CHECK VALVE
GROMMET
VALVE OPERATING
ROD
VACUUM SEAL
DUST
BOOT
FRONT SHELL
DIAPHRAGM RETURN SPRING
HYDRAULIC PUSH ROD
REACTION DISC
FRONT DIAPHRAGM PLATE
FRONT DIAPHRAGM
CENTER PLATE
Fig. 2C~Bendix Double Diaphragm C om ponents
NOTE: On Corvette models, place a box end wrench

over the valve operating rod and hold in place with
suitable flat washers and a nut (fig. 3C).
CAUTION: When separating valve rod from

plunger, be careful to avoid damage to plastic dia
phragm plate hub.
J-22805 8. Slide air filter and air silencer from ball end of valve
rod.
9. Remove valve rod spring, poppet retainer and valve
Fig. 3C -R em oving Valve Rod, A ir Silencer and F ilter poppet from hub of rear diaphragm plate (Fig. 5C).

BRAKES 5-24
13. Place spanner wrench Tool J-9504 over studs on rear

shell (fig. 4C). Use three washers and nuts to attach
wrench to shell. Use a suitable piece of pipe of approxi
mately 2 inches. I.D. and approxim ately three inches in
length. Place over plastic diaphragm plate hub. Place a
piece of flat stock steel over end of pipe and press rear
shell down far enough to relieve tension of diaphragm
rubber lip and spring.
14. R otate spanner bar counter-clockwise and unlock
shells.
15. Release press and remove diaphragm return spring.
CAUTION: Be careful when separating shells not to

allow diaphragm return spring to fly out.
16. Remove three nuts and washers from bar and remove
rear shell.
17. Remove holding fixture Tool J-22805 from front shell.
Fig. 4C-Holding and separating Fixture using Tools
J-22805 and J-9504 in Arbor Press 18. W ith rim of front diaphragm disengaged from scallops
in rear shell, align any lug on center plate with any
groove on rear shell. This may be done by sighting
10. Remove assembly from vise. between shell and center plate. Using finger pressure
11. Remove front vacuum seal and hydraulic push rod
and screw driver, as little as possible, separate assembly
from power head by pulling push rod straight out. from rear shell.
19. Examine rear bearing vacuum seal in rear shell and
NOTE: It will be necessary to straighten the c u t
remove only if defective. If necessary, place on work
lanced, areas (around the outside of the can) flush
bench with studs up and drive out seal with punch or
with the shell. If the tangs break, replace that half chisel and hammer.
of the shell. 20. Clam p front holding fixture J-22839 in a vise and posi
tion front diaphragm plate on it (fig. 6 C).
s
12. Place power unit w ith holding fixture Tool J-22805 in
an arbor press with rear shell up and secure to plate of
press by a suitable m eans of holding Tool J-22805 (fig.
4C). By using a 1-1/2" open end wrench on Tool J-
22805 and allowing unit to turn against back of arbor
press will hold it from turning.
Fig. 6>C--lnstalling Seal Protector Using Tool J-22733 and

Front Plate Holding Fixture Tool J-22839
21. W et rear diaphragm in area of retainer with sili

cone lubricant. Remove diaphragm retainer using fin
Fig. 5C--Removing Valve Operating Rod, Retainer, Filters ger pressure. If necessary, a thin-bladed screw driver
and Poppet may be used to pry it free. Be careful not to chip plastic.
1. Valve Operating Rod 4. Valve Rod Spring
2. Filter Retainer 5. Poppet Retainer 22. Remove rear diaphragm from rear diaphragm plate
3. Silencer R etainer 6. Poppet (fig. 7C).

BRAKES 5-25
Assem bly
Be sure all parts are clean before assembling unit. D o not
let grease or m ineral oil come in contact with any rubber
parts. Lubricate rubber parts of power piston group with
special lubricant included in service kit.
1. W et valve poppet in alcohol and insert poppet in hub
or rear diaphragm plate, small end first.
2. W et poppet retainer in alcohol and insert hub with
flange side up. Press against poppet retainer to make
certain shoulder of retainer is positioned inside poppet.
3. Assemble air silencer and air filter over ball end and
shoulder of valve rod.
4. Install valve rod spring over ball end of valve rod, with
small diam eter of spring against shoulder of valve rod.
5. G uide valve rod spring, air silencer, air filter and valve
rod into hub of rear diaphragm plate.
6 . A pply a light coat of silicone lubricant to front and rear
bearing surfaces of valve plunger.
Fig. 7C~Removing D iaphragm s, Plates, Retainer and Plunger 7. W et rubber grom m et in valve plunger w ith alcohol.
P our out any excess alcohol from valve plunger.
8 . Secure valve rod in vise. Place valve plunger and a
hard-w ood block no wider than threaded bore of rear
1. Diaphragm Retainer 6. Seal plate over it. While holding rear plate down with hand,
2. Rear Diaphragm 7. Center Plate tap wood with plastic headed ham m er to secure valve
3. Rear D iaphragm Plate 8. Front Diaphragm rod to valve plunger.
4. Valve Plunger 9. Front Diaphragm Plate
9. Remove rear plate from vise.
5. Valve Return Spring 10. Reaction Disc
10. Install silencer retainer on hub of rear diaphragm plate
being careful not to chip plastic.
11. Secure F ront Plate Holding Fixture J-22839 in a vise
23. Twist rear plate counter-clockwise using hand leverage and position front plate on it (fig. 6 C).
only at outer edge of plate or atm ospheric pressure 12. Install front diaphragm on front diaphragm plate.
channel and unscrew rear plate from hub of front dia 13. Apply a light coat of silicone lubricant to outside sur
phragm plate. face of front diaphragm plate hub and apply liberal coat
to seal in center plate bore.
NOTE: Vacuum seal may stay in front or rear dia 14. Install Seal Protector J-22733 on front plate hub and
phragm plate. If seal assembly is defective, center install center plate and seal assembly, seal side first on
plate and seal assembly must be replaced as an as hub (fig. 6 C). Remove Seal Protector J-22733.
sembly. 15. Place square-cut vacuum seal firmly against shoulder of
front diaphragm plate hub.
24. Rem ove front diaphragm and front diaphragm plate. 16. Install valve return spring in recess of hub on front
25. Rem ove front diaphragm plate from F ront Plate H old diaphragm plate.
ing Fixture Tool J-22839. 17. Screw rear diaphragm plate over front diaphragm plate
26. Use a screw driver through center bore of front dia and hand tighten. Valve return spring may cock when
phragm plate to push out reaction disc. tightening. Be sure assembly is tight but do not over
tighten.
18. Install rear diaphragm on rear diaphragm plate over lip
Cleaning
of center plate.
A fter disassembly, all m etal parts should be cleaned in 19. W et diaphragm retainer with silicone and press retainer
metal parts cleaner. Plastic parts and rubber parts should be onto center plate until it fully seats against shoulder of
cleaned O N L Y in alcohol. Care should be taken to prevent center plate.
chipping or cracking plastic parts. Replace all rubber parts,
except power diaphragm s. A fter parts have been cleaned,
wash them thoroughly w ith alcohol and use clean, dry com
pressed air to blow dirt and fluid out of recesses and internal NOTE: Retainer must seat on center plate to prop
passages. Use all parts furnished in the repair kit. erly assemble front and rear shell.
Inspection
Inspect all parts for dam age or excessive wear. The power NOTE: use Bearing Seal Installer J-22677, to press
diaphragm s m ust be free o f kinks, cracks and tears. Replace new seal into rear shell until flat rubber is about
any damaged, worn or chipped parts. 5 /1 6 " below flat inside surface of shell (fig. 8C).

BRAKES 5-26
33. Press rear shell down far enough to compress rubber

diaphgram and spring.
34. R otate spanner bar clockwise until tang on front shell
butts against rear shell stop.
NOTE: Bend lanced areas "in " on the shell to secure

in place. If the tangs break during this operation, it
will be necessary to replace that half of the shell.
35. Remove three nuts and lock washers securing rear shell
to spanner wrench.
36. Remove H olding Fixture J-22805 from front shell by
removing two nuts and washers.
37. D ip check valve grom m et in alcohol and install into
front shell, beveled side first.
38. Dip end of vacuum check valve in alcohol and install
valve through grommet.
39. Apply liberal coat of silicone lubricant to entire surface
of reaction disc and to piston end of hydraulic push rod;
apply a light coat of silicone lubricant to push rod stem.
Keep lubricant away from adjusting screw end of push
rod.
40. Insert reaction disc and push rod in opening of front
shell and into bore of front diaphragm plate hub. Twist
Fig. 8C ~lnstalling Rear Bushing Vacuum Seal
push rod to make certain reaction disc is seated in bore
and there are no air pockets between disc and end of
push rod.
41. Install front vacuum seal, metal support plate side first,
21. Apply talcum powder to inside of rear shell. A pply light over adjustm ent screw end of push rod, pressing seal
coat of silicone lubricant to outside surface of rear dia until it bottom s in recess of front shell.
phragm plate hub and liberal coat to bearing vacuum 42. Assemble main cylinder to front shell and securely
seal in rear shell. tighten retaining nuts.
22. G uide rear shell over assembly so as not to dam age rear 43. Install backing plate on rear shell and thread clip nut
bearing vacuum seal. on stud m arked during disassembly.
23. Align any lug on center plate and seal assembly with
any groove in rear shell. Press down on rear shell evenly
to slide lances on rear shell past center plate.
NOTE: The push rod is designed with a self-locking
24. Assemble air silencer inside dust guard and install a adjustment screw to provide the correcting relation
valve rod with dust guard over scallops on rear shell
ship between vacuum piston and main cylinder pis
hub.
ton. The adjustment is important as it provides for
25. Remove assembly from F ro n t Plate Holding Fixture
the compensating port being kept open while unit is
J-22839.
in released position. Adjustment screw is set to the
26. Secure front shell to H olding Fixture J-22805. correct height when assembled, and under normal
27. Secure Holding Fixture J-22805 on arbor press plate by
service, will not require further adjustment. After
a suitable means (fig. 4C). unit has been disassembled however, the height
28. Place Spanner W rench Tool J-9504 over studs on rear
should be checked as follows.
shell. Use three washers and nuts to attach wrench to
shell. Using a suitable piece of pipe approxim ately 2
inches I.D . and approxim ately three inches in length,
place over plastic diaphragm plate hub. Place a piece of
flat stock steel over end o f pipe.
29. Line up scribe m arks on front shell so th at front shell
is slightly counter-clockwise of scribe m ark on rear
Hydraulic Push Rod Adjustment
shell.
30. Install diaphragm return spring so th at small end of If adjustm ent is necessary, grasp push rod with pliers at
serrated end and turn adjusting screw either in or out as
spring is against front shell.
31. Lubricate outer rim o f front diaphragm with silicone required.
1. Place top of Push R od H eight Gauge J-7723-01 (truck)
lubricant and w ork rim so it is under each of the retain
or J- 21183 (Corvette) over push rod w ith legs of gauge
ing lances of rear shell.
resting on front of rear shell Figure 9C. Top of screw
32. A pply liberal coat of silicone lubricant to cut-out trim
surface of front shell th at will engage front diaphragm. should touch gauge.

BRAKES 5-27
# 1 5 OR **16
U.S.S. GAUGE
SH EET STEE L
Fig. 9C ~A djustm ent of Push Rod Fig. 10C-Push Rod Gauge
In s ta lla tio n 2. A ttach vacuum line to check valve.

3. Secure hydraulic line to main cylinder.
4. A djust push rod clevis to brake pedal assembly. Adjust
pedal height by means of clevis on.brake pedal push rod
at pedal. Pedal height is obtained by measuring from
floor covering at toe pan to top of pedal pad.
NOTE: Check operation of stoplight after adjusting
pedal height.
5. Bleed Brakes as outlined in the service m anual.
parts.
1. M ount the power brake assembly in place and install available, the required dimensions for fabrication
four attaching nuts and lock washers. Be certain to are given in Figure 9B for Truck and Figure 10C for
place push rod through cutout in fire wall. Corvette.
BENDIX
SINGLE DIAPHRAGM TYPE HYDROVAC
INDEX
D isassem bly........................................................................ 5-28 A ssem bly............................................................................ 5-30

Cleaning and In sp ectio n ................................................. 5-30
DESCRIPTION AND OPERATION

The Single D iaphragm H ydrovac is a self contained tional four-cycle gasoline engine (fig. ID). The Hydrovac
vacuum hydraulic power brake unit for use on a vehicle with consists of three basic elements:
a vacuum source such as the intake manifold of the conven-

BRAKES 5-28
Fig. 1 D—Bendix Single Diaphragm Hydrovac Fig. 2D~Removal of Control Tube, Clamp Band, Rear Shell and
Diaphragm
1. A vacuum power chamber which consists of a power ^ H ydraulic C ylinder 6. Rear Shell
diaphragm and a push rod th at connects the power 2. C ontrol Tube Seal 7. Nut
diaphragm to the hydraulic piston. 3. Control Tube Nut 8. Clamp Band
2. A hydraulic (slave) cylinder which contains a hydraulic 4. Vacuum Hose 9. Clamp Bolt
piston with a drilled passage to perm it the filling of the 5 Rear Shell Control Tube
hydraulic cylinder and return of the fluid to the m aster
cylinder upon release of the brakes.
3. A v a c u u m c o n tro l valve b u ilt in te g ra l w ith th e

h y d ra u lic cy lin d er w hich c o n tro ls th e p o w er o u tp u t
o f th e v a c u u m p o w e r c h a m b e r in a c c o rd a n c e w ith
the h y d ra u lic p ressu re d ev elo p ed w ith in th e vehicle
m aste r cylinder.
The H ydrovac is attached to the vehicle frame by means

of a m ounting bracket attached to the power cham ber shell
and a m ounting pad boss on the side of the hydraulic cylin
der. The vacuum inlet port of the vacuum control valve is
connected to the intake manifold or other vacuum source
through a vacuum check valve. The atm ospheric port in the
control valve is connected to an air cleaner installed in a
location protected from road dirt and splash. The hydraulic
line from the brake m aster cylinder is attached to the fluid
inlet port on top of the H ydrovac hydraulic cylinder. The
outlet port of the H ydrovac is located in the end cap of the
hydraulic cylinder and is connected to the vehicle brake
wheel cylinders. Fig. 3D -R em oval of Diaphragm , Spring, Front Shell and
Gasket
Disassembly (Fig. 2D)
1. Scribe across front and rear shells. Clam p hydraulic 1. H ydraulic C ylinder 8. Return Spring
cylinder ( 1) in bench vise. 2. Snap Ring 9. W asher
2. Slide vacuum hose (4) on control tube tow ard hydraulic 3. Gasket 10. D iaphragm Plate
4. Front Shell 1 1. Diaphragm
cylinder end. Remove control tube and nut (3) with
5. Capscrews 12. W asher
hose from control valve body. 6. Push Rod 13. Nut
3. Remove nut (7), clam p bolt (9) and clamp ring ( 8), then 7. Nut
re move rear shell ( 6 ).

BRAKES 5-29
Fig. 5D -R em oval and Disassembly of C ontrol Valve
1. Piston 8. Push Rod 1. End Cap 11. Poppet Spring

2. Seal Retainer 9. Piston Cup 2. Gasket 12. C ontrol Valve Body
3. Push Rod Seal Cup 10. Piston (Same as Item 1) 3. H ydraulic C ylinder Housing 13. Capscrews
4. Push Rod Bearing 1 1. Retainer Pin 4. Cup 14. Poppet
5. " 0 " Ring Seal 12. Retainer Ring 5. Valve Piston 15. Retainer
6. Stop W asher 13. Push Rod Seal 6. W asher 16. Valve Body Cover
7. Snap Ring 7. Diaphragm A. Pressure Check Valve
8. W asher B. Spring
Diaphragm , Spring and Front Shell (Fig. 3D) 9. Valve Body Spring C. Spring Retainer
10. Vacuum Poppet and Stem D. Snap Ring
1. W ith hydraulic cylinder held securely in vise in a hori
zontal position, press in on diaphragm ( 11) and plate
( 10) to compress diaphragm return spring.
2. T urn rim of diaphragm back and, still m aintaining pres (3), push rod bearing (4), stop washer ( 6 ) and snap ring
sure with your stom ach, use both hands and snap ring (7) off piston end of push rod.
pliers to re move snap ring ( 2 ) from groove inside bore 4. Remove "O" ring seal (5) from bearing groove.
o f cylinder ( 1). 5. If necessary to replace push rod seal (13) located in end
of push rod, grip seal with pliers and pull it from end
CAUTION: After snap ring is free lay pliers aside of push rod. D iscard seal.
and use both hands to pull complete assembly of
diaphragm, spring, push rod and piston parts Control Valve (Fig. 5D)
straight out of cylinder. If necessary to replace dia
phragm or other parts (6 through 13), use open end 1. Scribe across flanges of control valve body (12) and
wrench on nut (7) and remove nut (13), washer (12), hydraulic cylinder housing (3).
diaphragm (11), plate (10), washer (9), return spring 2. Remove four capscrews (13) and lift off valve body and
(8), nut (7). Remove three capscrews (5) and lift front spring (9).
shell (4) off flange of cylinder. Remove rubber gas 3. Remove w asher ( 8), diaphragm (7), washer ( 6), and cup
ket (3) from groove in flange of hydraulic cylinder. (4) from valve piston (5).
4. Using screwdriver, carefully pry off plastic valve body
cover (16).
5. Pry off plastic retainer (1st stage poppet) (15), lift off
atm ospheric (2nd stage) poppet (14) and then remove
Push Rod and Piston (Fig. 4D)
vacuum poppet and stem ( 10) and poppet spring ( 11)
1. W orking on clean bench, remove piston parts (2 from valve body ( 12).
through 12) from push rod ( 8) off piston end of push 6. Using 1-3/8" wrench, remove end cap (1) and gasket
rod. (2).
2. Slide retainer ring (12) out of groove in piston (10) and 7. To disassemble residual pressure check valve (if used)
separate piston from push rod ( 8) by removing retainer contained in end cap, use pliers or screwdriver to lift
pin ( 11). snap ring (D) from groove inside end cap. Remove
3. W ith ice pick or thin-bladed screwdriver, remove cup spring retainer (C) spring (B) and residual pressure
(9) from piston. Slide seal retainer (2), push rod seal cup check valve (A).

BRAKES 5-30
Cleaning and Inspection CAUTION: Make sure snap ring is seated all the
way around its groove before releasing pressure
Thoroughly clean all m etal parts in Bendix M etalclene or
against return spring. Failure to seat snap ring se
equivalent. A fter cleaning, rewash all hydraulic system parts
curely can result in parts damage and personal in
in clean isopropyl alcohol or equivalent before reassembly.
jury.
Inspect all parts for excessive w ear or damage. Replace worn
or dam aged parts. Inspect control valve body atm ospheric
valve seat. If damaged, replace housing. Always use the cor
rect repair kit when overhauling unit. Assem bly of Control Valve (Fig. 5D)
1. Assemble cup (4) facing up on control valve piston (5),
Assembly (Fig. 4D) as shown. If two cups are used, install them on piston
back to back. Then assemble piston, washer ( 6 ) and
Piston and Push Rod diaphragm (7) and seat inner bead of diaphragm in
piston groove.
1. To install a new push rod seal (13) in push rod ( 8), place 2. Lay piston and diaphragm assembly aside. Assemble
new seal (R ubber side down) on a clean block of wood. poppet return spring ( 11), vacuum poppet ( 10) and at
m ospheric poppet (14) in valve body ( 12) from opppsite
2. H old push rod vertically (threaded end up) with drilled sides, as shown.
end of rod resting on shaft end of seal and then strike 3. Snap poppet retainer (15) over end of vacuum poppet
threaded end of push rod with soft ham m er to seat seal stem. (Set valve body with vacuum poppet down on 1"
w ith its shoulder firm ly against end of push rod. wooden cube and tap retainer with soft ham m er until
3. D ip cup (9) in brake fluid and assemble cup on piston it snaps onto stem of vacuum poppet).
( 10) with lip of cup as shown. 4. Assemble cover (16) securely in groove of valve body.
4. Install piston parts (2 through 12) on push rod from Assemble spring retainer washer ( 8) and spring (9) on
seal end of push rod in order shown. end of control valve piston, from end shown. Insert
5. Slide snap ring (7), stop washer (6 ), bearing (4) with control valve piston, diaphragm and spring assembly in
"O" ring (5) installed in bearing groove, push rod seal valve body with spring around bosses.
cup (3), seal retainer (2), retainer ring (12) and piston 5. Press outer bead of diaphragm into valve body groove
assembly ( 1) on push rod. and, while holding spring compressed, dip piston and
6 . Assemble retainer pin (11) through holes in piston and cup(s) in clean brake fluid.
rod. Secure pin in place with retainer ring (12), making 6. Align valve body to scribe m arks and assemble control
certain ring is seated in groove on piston. valve piston carefully in its bore below hydraulic cylin
der bore. Secure valve body with four capscrews (13).
Front Shell Assem bly to Piston (Fig. 3-D)
7. Tighten screws to 40-60 in. lbs. Install check valve (A),
1. Place new gasket (3) in groove on flange of hydraulic spring (B), retainer (C) and snap ring (D) in end fitting
cylinder ( 1). (1). Install fitting and gasket (2) on end of hydraulic
2. Assemble front shell (4) to cylinder, aligning cutout in cylinder and tighten fitting to 50-85 ft. lbs. If removed,
shell with porting in cylinder flange. install bleed screw(s), tighten to 10-15ft. lbs.
3. Assemble capscrew tighten to 130-230in. lbs.
4. If diaphragm ,plate and return spring were disassem
bled, install nut (7) (if n u t is undercut, install undercut,
Assem bly of Rear Shell,Control Tube, Hose
side first) and tighten to 160-200in. lbs., then washer
(Fig. 2D)
(9), diaphragm plate (10), concave side first, on
threaded end of push rod. 1. C oat bead of diaphragm or flanges of front and rear
5. Install diaphragm (11), washer (12) and nut (13) on shells with talcum pow der or equivalent and place rear
push rod, as shown, and securely tighten nuts (7 and 13) shell ( 6 ) on diaphragm .
to 160-200 in. lbs. 2. Align scribe m arks on both shells. M ake certain bead
6 . Coat hydraulic cylinder bore with clean brake fluid. of diaphragm is seated in outer flanges of both shells
Dip hydraulic piston and bearing parts in clean brake and hold rear shell in position while assembling clamp
fluid. Slide diaphragm return spring ( 8 ) onto push rod band ( 8) over flanges of shells and bead of diaphragm .
large diam eter of spring first, over hydraulic piston end. Position opening in band 45 degrees off vertical center
7. Seat spring against concave surface of diaphragm plate
line of Hydrovac on side away from m ounting bracket.
( 10) and align entire assembly with hydraulic cylinder
3. Squeeze ends of band together and assemble bolt (9)
bore. and nut (7). Tap band lightly with soft ham m er while
8 . Carefully insert hydraulic piston assembly, retainer,
tightening bolt to seat band securely on shells. After
seal and bearing in cylinder bore. Press against dia
tapping, re-tighten to 40-60 in. lbs.
phragm and plate to com press return spring and seat
4. Place new seal (2) on control tube (3), as shown, and
stop washer against bearing inside bore and then, using
assemble hose (4) to tube (5) of rear shell and to control
snap ring pliers, install snap ring ( 2 ) securely in groove
tube. A ttach tube and nut (3) to control valve body
in cylinder bore. port. Securely tighten to 7-10 ft. lbs.

BRAKES 5-31
Special Tools
9 10
Fig. 6D--Special Tools
1. J-4 8 8 0 Snap Ring 8. J -2 2 6 7 7 Power 13. J-23 10 1 Power Piston

Pliers C ylinder Seal H olding Tool
2. J -7 7 2 3 -0 1 H eight Gage Installer 14. J-23 1 75 C ontrol Valve
3. J-2 1 183 H eight Gage 9. J-2 2 7 3 3 Seal Installer Installer
4. J-2 1524 Power Piston and P rotector 15. J-23 188 Secondary
Remover and 10. J -2 2 8 0 5 Power Bearing
Installer Cylinder P rotector
5. J - 2 1601 Power Brake H olding 16. J-2 3 3 3 7 Power Piston
Retainer and Fixture Gage
Installer 11. J -2 2 8 3 9 Front Plate 17. J-9 5 0 4 Power
6. J -2 2 6 5 7 Bushing Holding C ylinder
Retainer Fixture Spanner
Socket 12. J-2 2 8 9 3 Booster W rench
7. J-2 2 6 4 7 H eight Gage Separating
A da pter

SECTION 6
ENGINE
INDEX
SU BJECT PA G E SUBJECT PA G E
Introduction........................................................................ 6-1 Connecting Rod and Piston Assemblies ................... .....6-22

General D escription ........................................................ 6-2 R em oval...............................................................................6-22
In-Line E ngines............................................................ 6-2 D isassem bly................................................................... .....6-23
V 8 Engines...................................................................... 6-2 Cleaning and In sp ectio n ............................................ .....6-24
Repair P rocedures............................................................ 6-2 Connecting R o d s ..................................................... .....6-24
Engine A ssemblies........................................................ 6-2 P is to n s .............................................................................6-24
D isassem bly............................................................... 6-2 Piston P in s......................................................................6-24
A sse m b ly ................................................................... 6-6 A ssem bly.............................................................................6-24
Cylinder Head A ssem blies........................................ 6-9 Piston R ings....................................................................6-24
D isassem bly............................................................... 6-9 Installation..................................................................... .....6-29
C leaning...................................................................... 6-10 C ran k sh aft.......................................................................... .....6-28
Inspection................................................................... 6-10 R em oval.......................................................................... .....6-29
R ep airs........................................................................ 6-11 Cleaning and In sp ectio n ................... ........................ .....6-29
Rocker A rm Studs and Push Rod Guides Sprocket or G ear Replacem ent ....................................6-29
(M ark IV V 8) ................................................. 6-11 Installation..................................................................... .....6-29
R ocker A rm Studs (In-Line and Small V 8) 6-11 C a m sh a ft............................................................................ .....6-29
Valve Guide Bores............................................... 6-11 Inspection ..................................................................... .....6-29
Valve Seats............................................................ 6-12 Oil Nozzle Replacem ent (In L ine).......................... .....6-29
V alves..................................................................... 6-13 Camshaft G ear Replacem ent (In L in e )................. .....6-29
A ssem b ly ................................................................... 6-14 Camshaft Bearings .......................................................... .....6-32
Valve Lifters (H y d ra u lic ).......................................... 6-15 Inspection ......... .................................................................6-32
D isassem bly............................................................... 6-15 R em oval.......................................................................... .....6-32
Cleaning and In sp e c tio n .................. ..................... 6-16 Installation..................................................................... .....6-32
A ssem b ly ................................................................... 6-16 Cylinder Block ................................................................. .....6-33
Valve Lifters (M echanical)........................................ 6-17 Cleaning and In sp ectio n............................................ .....6-33
Cleaning and In sp e c tio n ........................................ 6-17 Oil Filter Bypass Valve Inspection and
Oil P u m p ........................................................................ 6-17 Replacem ent ............................................................ .....6-33
D isassem bly............................................................... 6-18 D istributor Lower Bearing and T hrust W asher
Cleaning and In sp e c tio n ........................................ 6-18 Replacem ent (In Line) .......................................... .....6-34
A sse m b ly ................................................................... 6-18 R epairs......................................................................................6-34
M ain B earings............................................................... 6-19 Cylinder C onditioning............................................ .....6-34
Inspection................................................................... 6-19 Cylinder B oring.............................................................6-35
Checking C learan ces.......................................... 6-19 Cylinder H o n in g ...........................................................6-35
Replacement ............................................................ 6-20 Piston Selection.............................................................6-35
W ith C rankshaft Removal ............................... 6-20 Torque S pecifications...........................................................6-37
W ithout Crankshaft R em oval.......................... 6-20 Special T o o ls..................................................................... .....6-38
Connecting R od B earings................... ...................... 6-21
Inspection and R eplacem ent............... ................. 6-21
INTRODUCTION
This section, convering all gasoline engines, has been M any operations outlined in this section, when done as
condensed using only typical illustrations and procedures single operations and not p art of a general overhaul, should
(except where specific illustrations and procedures will help be performed with the engine in the vehicle.
clarify the operation). The sim ilatity of engines, engine parts In order to avoid repetition and to identify the engines
and engine sub-assemblies and the resulting similarity of involved in a particular procedure, the 307-, 3 50-, and 400-
procedures required to service these units should aid the cu. in. V 8 engines are identified as "Small V 8 ’s". The 402-
technician in servicing the m any engines. and 454- cu. in. V 8 engines are identified as "M ark IV V 8’s".

ENGINE 6-2
GENERAL DESCRIPTION
IN-LINE EN GIN ES V8 ENGINES

Cylinders are num bered front to rear. Firing order is Cylinders are num bered front to rear, 1-3-5-7 on the left
1-5-3- 6-2-4 for the L 6 engines. C rankshaft rotation as viewed bank and 2-4-6-8 on the right bank. Firing order is, 1-8-
from the rear is counter-clockwise. 4-3-6-5-7-2. Crankshaft rotation as viewed from the rear is
The L 6 crankshaft has seven m ain bearings and the cam counter-clockwise.
shaft has four bearings. The crankshaft has five main bearings and the camshaft
Full pressure lubrication, through a full flow oil filter is has five bearings.
furnished by a gear-type oil pum p. The distributor, driven by Full pressure lubrication through a full flow oil filter, is
a helical gear on the cam shaft, drives the oil pump. The main furnished by a gear-type oil pump. The distributor, driven by
oil gallery feeds oil, through drilled passages, to the camshaft a helical gear on the camshaft, drives the oil pump. The main
and crankshaft to lubricate the bearings. The m ain oil gallery oil gallery feeds oil, through drilled passages, to the camshaft
also feeds the valve lifters which, through hollow push rods, and crankshaft to lubricate the bearings. The valve lifter oil
feed the individually m ounted rocker arm s (fig. 1). gallery feeds the valve lifters which, through hollow push
rods, feed the individually m ounted rocker arm s (fig. 2 and
3).
REPAIR PROCEDURES
ENGINE A S S E M B L IE S push rods and valve lifters in a rack so they may be

installed in the same location during engine assembly.
5. Remove the cylinder head(s).
Disassem bly ^ Using Tool J-23523, remove the torsional damper.
Remove the oil pan.
8 . Remove crankcase front cover.
NOTE: For partial disassembly of the engine refer to 9. On the performance engines, remove the oil baffle.
the applicable "Chassis Service Manual" under the 10. Remove oil pump and screen assembly. On V 8 engines,
part or sub-assembly to be serviced. For complete remove the extension shaft.
disassembly of the engine (into sub assemblies) fol- 11 • Check connecting rods and caps for cylinder num ber
low the outline below. identification and if necessary, m ark them. Check cylin
der bores for ridge and if necessary, remove ridge.
1. W ith the engine m ounted on an engine stand (transmis- 12. Remove connecting rod caps and using connecting rod
sion a n d /o r clutch housing removed from the engine), guide set, Tool J-5239 (3 /8 ") or J-6305 (11/32"), push
remove the following sub-assemblies (if applicable). R e connecting rod and piston assemblies out of block.
fer to the appropriate section of the applicable "Chassis
Service M anual."
—A ir Injection R eactor System (with brackets). NOTE: It will be necessary to turn the crankshaft to
—D elcotron (with brackets). disconnect and remove some of the connecting rod
—Accessory D rive Pulley(s) (and belts). and piston assemblies.
—W ater Pum p (and by pass hose).
—Fuel Pum p (and fuel pum p push rod on V 8 13. Remove the camshaft as follows:
engines).
—D istributor Cap (with spark plug wires). CAUTION: Use care in removing camshaft to avoid
—C arburetor (and fuel lines). damaging bearings.
—Oil Filter.
—Starter. W IT H T IM IN G C H A IN (V 8)
—C lutch Pressure Plate and Disc. —Remove camshaft sprocket bolts then remove cam
—G round Strap. shaft sprocket and timing chain.
—Oil Dip Stick and Oil Dip Stick Tube.
2. Remove intake and exhaust manifolds.
3. On In-Line engines, remove push rod covers. NOTE: Sprocket is a light press fit on camshaft. To
4. Loosen valve rocker arm nuts until rocker arm s can be dislodge, tap lightly on lower edge of camshaft
pivoted, then remove push rods and valve lifters. Place sprocket with a plastic hammer.

ENGINE 6-3
OIL PRESSURE
SENDING UNIT
Fig. 1-In-Line Engine Lubrication

ENGINE 6-4
FUEL PUMP PUSH ROD OILING 0)L FILTER AND

BY-PASS VALVE
Fig. 2 --''S m all V 8 " Engine L u b ric a tio n

ENGINE 6-5
TO OIL COOLER
(HI-PERFORMANCE ONLY)
OIL COOLER BY-PASS VALVE,_

(HI-PERFORMANCE ONLY)
OIL FILTER BY-PASS VALVE
CYLINDER WALLS ARE OILED BY

OIL THROWN OFF PRESSURE FED
CONNECTING ROD BEARINGS
OIL FILTER AND DISTRIBUTOR OILING
CYLINDER WALL AND CAMSHAFT LOBE OILING
FUEL PUMP PUSH ROD OILING
CROSS DRILLED MAIN BEARING

JOURNALS WITH HIGH PERFORMANCE
ENGINE ONLY.
CRANKCASE AND CRANKSHAFT OILING VALVE MECHANISM OILING
Fig. 3 --"M a rk I V ” Engine L u b ric a tio n

ENGINE 6-6
—Install two 5/16-18 bolts in cam shaft sprocket bolt

holes and carefully remove camshaft.
W IT H T IM IN G G E A R (In-Line)
—Remove cam shaft th ru st plate screws (through holes
in cam shaft gear), then remove cam shaft and gear as an
assembly.
14. Remove the flywheel.
NOTE: Refer to Truck Chassis Service Manual for

removal and installation procedures of 292 cu. in.
engine flywheel.
15. Remove m ain bearing caps and lift crankshaft out of

cylinder block.
16. Remove rear m ain bearing oil seal from cylinder block
and rear m ain bearing cap.
17. D iscard all gaskets and seals removed during engine
disassembly.
NOTE: For further disassembly, cleaning and in Fig. 4--Sealing Bearing Cap and Block
spection refer to the part or sub-assembly to be ser
viced.
2. Install flywheel and torque to specifications. A wood
block placed between the crankshaft and cylinder block
will prevent crankshaft from rotating.
Assem bly
NOTE: Align dowel hole in flywheel with dowel hole
NOTE: For inspection, repair, assembly or replace in crankshaft. On vehicles equipped with automatic
ment of any engine part or sub-assembly refer to transmissions, install flywheel with the converter
this section under the part or sub assembly being attaching pads towards transmission.
serviced. Use new gaskets and seals on engine as
sembly. 3. Install the camshaft as follows:
1. Install the crankshaft as follows: NOTE: Whenever a new camshaft or new lifters are
a. Install rear main bearing oil seal in cylinder block installed, lubricate camshaft lobes and foot of lifters
and rear main bearing cap grooves. Install with lip with “ Molykote” or its equivalent.
of seal tow ard front of engine. W here seal has two
lips install lip with helix tow ards front of engine. W IT H T IM IN G C H A IN (V 8)
b. Lubricate lips of seal with engine oil. Keep oil off a. Install two 5/16-18 bolts in camshaft bolt holes,
parting line surface. then lubricate cam shaft journals with engine oil and
c. Install main bearings in cylinder block and main install camshaft, being careful not to damage bear
bearing caps then lubricate bearing surface with en ings (fig. 5). Remove the two 5/16- 18 bolts.
gine oil.
d. Install crankshaft, being careful not to damage
bearing surfaces.
e. Apply a thin coat of brush-on type oil sealing com
pound to block m ating surface and corresponding
surface of cap only (fig. 4). Do not allow sealer on
crankshaft or seal lip.
f. Install main bearing caps with arrow s pointing to
w ard front of engine.
g. Torque all except rear main bearing cap bolts to
specifications. T orque rear main bearing cap bolts
to 10-12 ft. lbs. then tap end of crankshaft, first
rearw ard then forw ard with a lead ham m er. This
will line up rear m ain bearing and crankshaft thrust
surfaces. R etorque all main bearing cap bolts to
specifications.
h. M easure crankshaft end play with a feeler gauge.
Force crankshaft forw ard and m easure clearance
between the front of the rear main bearing and the
crankshaft thrust surface. Refer to Figure 42.

ENGINE 6-7
Fig. 7 -T im in g Gear A lig nm e nt M arks
Fig. 6--Tim ing S procket A lig nm e nt Marks
b. Install timing chain on cam shaft sprocket then align

m arks on cam shaft and crankshaft sprockets and
connect chain to crankshaft sprocket. Align dowel
on cam shaft with dowel hole in cam shaft sprocket
and install sprocket on cam shaft (fig. 6 ).
CAUTION: Do not hammer camshaft sprocket onto

camshaft. This may loosen camshaft rear welsh
plug.
c. D raw cam shaft sprocket onto camshaft, using the

m ounting bolts. T orque bolts to specifications.
d. Lubricate tim ing chain with engine oil.
W IT H T IM IN G G E A R (In Line)
Fig. 8 -C he cking T im ing Gear Runout

a. Lubricate cam shaft journals with engine oil, then
rotating crankshaft and cam shaft so th at m arks on
gears will line up, install cam shaft and gear assem d. Lubricate timing gears with engine oil.
bly being careful not to dam age bearings (fig. 7).
4. Install connecting rod and piston assemblies as follows:
b. Check cam shaft and crankshaft gear run out with a a. Install connecting rod bearings in connecting rods
dial indicator (fig 8 ). The cam shaft gear run out and connectiong rod caps then lubricate bearings,
should not exceed .004", and the crankshaft gear pistons, piston rings, connecting rod bolts and cylin
run out should not exceed .003". der walls lightly with engine oil.
b. Install connecting rod guide set J-5239 (3 /8 ") or
c. Check the backlash between the tim ing gear teeth Tool J-6305 (11/32") on connecting rod bolt and
with a dial indicator (fig. 9). The backlash should be using Tool J-8037 to compress the rings, install
not less than .004" nor more than .006". num ber one connecting rod and piston assembly in

ENGINE 6-8
Fig. 10 -C e nterin g Tool in Cover (In-Line)

b. Lubricate seal lip with engine oil then place crank
case front cover in position over dowel pins and
torque bolts to specifications.
7. Install the oil pan as follows:
a. Install side gaskets on cylinder block. D o not use
sealer.
b. Install rear oil pan seal, in groove in rear main
bearing cap, with ends butting side gaskets.
c. Install oil pan front seal, in crankcase front cover,
with ends butting side gaskets.
Fig. 9~Checking T im ing Gear Backlash d. Install oil pan and torque bolts to specifications.
8 . Install torsional dam per as follows:
its respective bore. Use a ham m er handle and light
blows. Hold the ring com pressor firmly against the CAUTION: The inertia weight section of the tor
cylinder block until all piston rings have entered the sional damper is assembled to the hub with a rubber
bore.
type material. The installation procedures (with
proper tool) must be followed or movement of the
CAUTION: Be sure ring gaps are properly positioned inertia weight section on the hub will destroy the
on piston and piston is properly positioned in cylin
tuning of the torsional damper.
der block. Refer to Figures 58, 60 and 61.
D R IV E O N TY PE (W ithout Retaining Bolt)
c. Remove connecting rod guide set then install con a. Coat front cover seal area (on dam per) with engine
necting rod cap and torque nuts to specifications. oil.
R epeat Step b and c for the remaining connecting b. A ttach dam per Installer Tool J-22197 to damper.
rod and piston assemblies. Tighten fingers of tool to prevent weight from mov
d. M easure connecting rod side clearance (see specifi ing (fig. 11).
cations). M easure between connecting rod cap and
side of crankpin on In Line engines and between
connecting rod caps on V 8 engines. Refer to Figures
46 and 47.
5. Install oil pum p and screen assembly (and extension
shaft on V 8 engines). On hi-perform ance engines, in
stall the oil baffle.
6 . Install the crankcase front cover as follows:
IN -L IN E E N G IN E S
a. Lubricate seal lip with engine oil then install crank
case front cover aligning Tool J-23042 in seal (fig.
10).
b. Place crankcase front cover gasket in position on
cover, then install crankcase front cover on cylinder
block and torque bolts to specifications. Remove
tool.
V 8 E N G IN E S
a. Place crankcase front cover gasket in position over
dowel pins on cylinder block. Fig. 1 1--Installing Torsional Damper (Drive on Type)

ENGINE 6-9
c. Carefully guide cylinder head into place over dowel

pins and gasket.
d. Coat threads of cylinder head bolts with sealing
com pound and install finger tight.
e. Tighten cylinder head bolts a little at a time in
torque sequence shown in Figure 77 until the speci
fied torque is reached. (See Engine Torques.)
NOTE: All engines using composition STEEL ASBESTOS

gaskets must have the cylinder head retorqued
after engine warm-up.
10. Install valve lifters and push rods. Install in the same
location from which removed during engine disassem
bly.
NOTE: Whenever new valve lifters and/or rocker

arms and balls are being installed coat foot of valve
lifters and surfaces of rocker arms and balls with
“ MOLYKOTE” or its equivalent.
Fig. 12—Installing Torsional Damper (Pull on Type) 11. In sta ll valve ro c k e r arm s, ro c k e r a rm b alls a n d
n u ts a n d tig h te n ro c k e r arm n u ts u n til all p u sh
r o d e n d p la y is ta k e n up.
c. Position dam per on crankshaft and drive into posi 12. On In-Line engines, install push rod covers.
tion using J-5590 until it bottom s against crankshaft 13. Install intake and exhaust manifolds. Torque to specifi
gear or sprocket (fig. 11). Remove installer tool. cations in the sequence outlined under "Torque Specifi
cations" Figure 77.
P U L L O N T Y P E (W ith Retaining Bolt) 14. Install the following sub-assemblies (if applicable) as
a. Coat front cover seal contact area (on dam per) with outlined in the applicable "Chassis Service M anual".
engine oil. • Oil D ip Stick Tube and Oil Dip Stick
b. Place dam per in position over key on crankshaft. • G round Strap
c. Using Tool J-23523 pull dam per onto crankshaft • Clutch Pressure Plate and Disc
(fig. 12). • Starter
• Oil Filter (new)
CAUTION: Install bolt in crankshaft with sufficient • C arburetor and Fuel Lines
thread engagement (min. 1/2"). • D istributor Cap (with spark plug wires)
• Fuel Pum p (and fuel pump push rod on V 8
d. Rem ove tool from crankshaft. engines)
e. Install dam per retaining bolt and torque to specifi • W ater Pum p (and by pass hose)
cations. • Accessory Drive Pulley(s) (and belts)
9. Install cylinder head(s) as follows: • D elcotron (with brackets)
• A ir Injection R eactor System (with brackets)
CAUTION: The gasket surfaces on both the head 15. A djust all belts as necessary.
and the block must be clean of any foreign matter 16. A djust valves as outlined under Valve M echanism, In
and free of nicks or heavy scratches. Cylinder bolt stallation and A djustm ent in the applicable "Chassis
threads in the block and threads on the cylinder Service M anual".
head bolts must be cleaned. (Dirt will effect bolt 17. A ttach engine lift at appropriate cylinder head bolt
torque). location or at engine lift brackets.
a. O n engines using a STEEL gasket, coat both sides
o f gasket with sealer, spread the sealer thin and C YLIN D ER HEAD A S S E M B L IES
even. Too m uch sealer may hold the beads of the
gasket away from the head or block. One m ethod of Disassem bly
applying the sealer th at will assure the proper coat
is w ith the use of a paint roller. 1. W ith cylinder head removed, remove valve rocker arm
nuts, balls and rocker arms (if not previously done).
CAUTION: Use no sealer on engines using a compo 2. Using Tool J-8062, compress the valve springs (fig. 13)
sition STEEL ASBESTOS gasket. and remove valve keys. Release the compressor tool and
remove spring caps, spring shields (if so equipped)
b. Place the gasket in position over the dowel pins, springs and spring dam per, then remove oil seals and
with the bead up. valve spring shims.

ENGINE 6-10
Fig. 15 -C le an ing Valve Guides
Fig. 13-C om pressing Valve Spring

noisy and sticky functioning of the valve and disturb
3. Remove valves from cylinder head and place them in a engine smoothness.
rack in their proper sequence so th at they can be assem
M easure valve stem clearance (fig. 16) as follows:
bled in their original positions.
Clam p a dial indicator on one side of the cylinder head
Cleaning rocker arm cover gasket rail, locating the indicator so
that movement of the valve stem from side to side
1. Clean all carbon from com bustion chambers and valve (crosswise to the head) will cause a direct m ovement of
ports using Tool J-8089 (fig. 14). the indicator stem. The indicator stem m ust contact the
2. Thoroughly clean the valve guides using Tool J-8101 side of the valve stem just above the valve guide. With
(fig- 15). the valve head dropped about 1/16" off the valve seat;
3. Clean all carbon and sludge from push rods, rocker move the stem of the valve from side to side using light
arm s and push rod guides. pressure to obtain a clearance reading. If clearance ex
4. Clean valve stems and heads on a buffing wheel. ceeds specifications it will be necessary to ream valve
5. Clean carbon deposits from head gasket m ating surface. guides for oversize valves as outlined.
Inspection
1. Inspect the cylinder head for cracks in the exhaust
ports, com bustion cham bers, or external cracks to the
w ater chamber.
2. Inspect the valves for burned heads, cracked faces or
damaged stems.
NOTE: Excessive valve stem to bore clearance will

cause excessive oil consumption and may cause
valve breakage. Insufficient clearance will result in
Fig. 14-C leaning Com bustion Chambers Fig. 16 -M ea surin g Valve Stem Clearance

ENGINE 6-11
Fig. 18~Rocker Arm Stud and Push Rod Guide
Fig. 17--Checking Valve Spring Tension

2. Ream hole for oversize stud using Tool J-5715 for .003"
oversize or Tool J-6036 for .013" oversize (fig. 20).
4. Check valve spring tension with Tool J-8056 spring
tester (fig. 17).
CAUTION: Do not attempt to install an oversize
NOTE: Springs should be compressed to the speci stud without reaming stud hole.
fied height and checked against the specifications
chart. Springs should be replaced if not within 10
lbs. of the specified load (without dampers). 3. Coat press-fit area of stud with hypoid axle lubricant.
Install new stud, using Tool J-6880 as a guide. Gauge
5. Inspect rocker arm studs for wear or damage. Inspect should bottom on head (fig. 21 ).
push rod guides on M ark IV V 8 engines for wear or
damage.
VALVE G U ID E BORES
Repairs Valves with oversize stems are available (see specifica
R O C K E R A R M STUDS A N D PU SH R O D G U ID ES tions). To ream the valve guide bores for oversize valves use
(M ark IV V 8 and 350 Cu. In. high perform ance) Tool Set J 5830 (In-Line and "Small V 8 ") or J-7049 (M ark
IV V 8) (fig. 22).
T h e p u sh ro d guides are re la te d to th e cy lin d er h ead

by th e ro c k e r a rm stu d s (fig. 18). R e p la c e w h e re n e c
e ssa ry a n d to rq u e ro c k e r a rm s tu d s to sp e c ific a tio n s.
NOTE: Coat Threads on cylinder head end of rocker

arm studs with sealer before assembling to cylinder
head.
R O C K E R A R M STUDS (In-Line and "Small V 8 ")
R ocker arm studs th at have dam aged threads or are loose

in cylinder heads should be replaced with new studs available
in .003" and .013" oversize. Studs may be installed after
ream ing the holes as follows:
1. Remove old stud by placing Tool J-5 802-1 over the
stud, installing nut and flat washer and removing stud Fig. 1 9 -R e m o v in g R ocker A rm Stud
by turning nut (fig. 19). (In -L in e and “ Small V 8 ” )

ENGINE 6-12
Fig. 20--R eam ing R o cker A rm Stud Bore

(In -L in e and “ Sm all V 8 ” )
VALV E SEATS Fig. 22 -R eam ing Valve Guide
Reconditioning the valve seats is very im portant, because

the seating of the valves m ust be perfect for the engine to
deliver the power and perform ance built into it. Install expanding pilot in the valve guide bore and ex
A nother im portant factor is the cooling of the valve heads. pand pilot.
G ood contact between each valve and its seat in the head is
im perative to insure th at the heat in the valve head will be
properly carried away.
Place roughing stone or forming stone over pilot and
Several different types of equipm ent are available for re
ju st clean up the valve seat. Use a stone cut to specifica
seating valves seats. The recom m endations of the m anufac
tions.
turer of the equipm ent being used should be carefully
followed to attain proper results.
Regardless o f w hat type o f equipm ent is used, however, it
is essential th at valve guide bores be free from carbon or dirt 3. Remove roughing stone or forming stone from pilot,
to insure proper centering o f pilot in the guide. place finishing stone, cut to specifications, over pilot
and cut just enough metal from the seat to provide a
sm ooth finish. Refer to specifications and Figure 23.
N arrow down the valve seat to the specified width.
NOTE: This operation is done by grinding the port

side with a 30 degree stone to lower seat and a 60
degree stone to raise seat.
Remove expanding pilot and clean cylinder head care

fully to remove all chips and grindings from above oper
ations.
Fig. 2 1 -ln s ta llin g R ocker A rm Stud (In -L in e and “ Small V 8 ” ) Measure valve seat concentricity (fig. 24).

ENGINE 6-13
/
250 & 292 LIQUID PETROLEUM
GAS TRUCK ENGINES HAVE
ALLOY CAST INLET AND
EXHAUST VALVE SEAT INSERTS
nW W W XW W ^ PARALLEL
INLET & EXHAUST VALVES 250 & 292
LPG TRUCK ENGINES
350 LIQUID PETROLEUM

GAS TRUCK ENGINES HAVE
ALLOY CAST INLET AND
INTERFERENCE
INLET & EXHAUST VALVES 350
LPG TRUCK ENGINES Fig. 2 4 -M e a su rin g Valve Seat C o nce ntricity
wear, or valves that are warped excessively should be re

placed. W hen a valve head which is warped excessively is
refaced, a knife edge will be ground on part or all of the valve
head due to the am ount of metal that m ust be removed to
CYLINDER HEAD completely reface. Knife edges lead to breakage, burning or
CCAT
pre-ignition due to heat localizing on this knife edge. If the
VAIVC edge of the valve head is less than 1/32" thick after grinding,
FACE
INTERFERENCE replace the valve.
INTAKE & EXHAUST VALVES ALL 6-CYL. Several different types of equipment are available for
SMALL V-8 & MARK IV V-8 PASSENGER CARS refacing valves. The recom m endations of the m anufacturer
of the equipm ent being used should be carefully followed to
2 9 2 ,& 350 ENGINES attain proper results.
HAVE ALLOY CAST IRON 1. If necessary, dress the valve refacing m achine grinding
wheel to make sure it is smooth and true. Set chuck at
angle specified for valve. Refer to specifications and
Figure 23.
2. Clamp the valve stem in the chuck of the machine.
3. Start the grinder and move the valve head in line with
the grinder wheel.
^ FACE
IS PARALLEL 4. T urn the feed screw until the valve head just contacts
EXHAUST VALVES 292,& 350 TRUCK ENGINES wheel. Move valve back and forth across the wheel and
regulate the feed screw to provide light valve contact.
5. Continue grinding until the valve face is true and
sm ooth all around the valve. If this makes the valve
Fig. 2 3 -R e la tio n of Valve and Seat Angles
head thin (1/32" min.) the valve must be replaced as the
valve will overheat and burn.
6 . Remove valve from chuck and place stem in "V" block.
NOTE: Valve seats should be concentric to within Feed valve squarely against grinding wheel to grind any
.002" total indicator reading. pit from rocker arm end of stem.
VALVES
Valves th at are pitted can be refaced to the proper angle, NOTE: Only the extreme end of the valve stem is
insuring correct relation between the head and stem on a hardened to resist wear. Do not grind end of stem
valve refacing mechanism. Valve stems which show excessive excessively.
ENGINE 6-14
7. A fter cleaning valve face and cylinder head valve seat

o f grinding particles, m ake pencil m arks about 1/4"
apart across the valve face, place the valve in cylinder
head and give the valve 1 /2 tu rn in each direction while
exerting firm pressure on head of valve.
8. Remove valve and check face carefully. If all pencil

m arks have not been rem oved at the point of contact
with the valve seat, it will be necessary to repeat the
refacing operation and again recheck for proper seating.
9. G rind and check the rem aining valves in the same m an
ner.
Assem bly
1. Insert a valve in the proper port. Fig. 26--E xhaust Valve Spring In s ta lla tio n (“ M ark IV V 8 ” )
2. Assemble the valve spring and related parts as follows:

c. Compress the spring with Tool J-8062.
IN -L IN E A N D "SM A LL V 8 " d. Install the valve locks and release the compressor
a. Set the valve spring shim, valve spring (with dam per tool, making sure the locks seat properly in the
if used), valve shield and valve cap or rotator in groove of the valve stem.
place (fig. 25).
NOTE: Grease may be used to hold the locks in
b. Com press the spring with Tool J-8062. place, while releasing the compressor tool.
c. Install oil seal in the lower groove of the stem, m ak
ing sure that the seal is flat and not twisted.
d. Install the valve locks and release the com pressor 3. Install the remaining valves.
tool, m aking sure th at the locks seat properly in the
upper groove of the valve stem. 4. O n In-Line and "Small V 8 " engines check each
M A R K IV V 8 valve stem oil seal by placing a vacuum cup or
similar device over the end of the valve stem and
a. Install valve spring shim on valve against the cap. O perate the vacuum cup and make
spring seat then install a new valve stem oil seal over sure no air leaks past the seal. A vacuum cup can
valve and valve guide. be made from a small syringe and a high voltage
b. Set the valve spring (w ith dam per), and valve cap in shield (fig. 27).
place (fig. 26).
5. Check the installed height of the valve springs, using a
narrow thin scale. A cutaway scale will help (fig. 28).
M easure from the top of the shim or the spring seat to
the top of the valve spring or valve spring shield (fig.
29). If this is found to exceed the specified height, install
a valve spring seat shim approximately 1/16" thick. At
no time should the spring be shimmed to give an in
stalled height under the minimum specified.
Fig. 25--Valve S pring In sta lla tio n (In -L in e and “ Sm all V 8 ” ) Fig. 27--Vacuum Cup

ENGINE 6-15
,
-G- ^R I N D O U T THI S P O R T I O N
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: 1 4 'I 6
Fig. 28--C utaw ay Scale
V A LV E L IFT E R S (H Y D R A U L IC )
Two types of hydraulic lifters are used. Both types of

lifters operate on the same principle and are serviced basi
cally in the same m anner. The com plete lifter assemblies are
interchangeable but parts from one lifter are not interchange
able with another. Both lifters are easily identified by the
outside configuration of the lifter body. F o r purposes of iden
tification we refer to them as lifter "A" and lifter "B" (fig. LIFTER “ A ” LIFTER 'B”
30).
Disassem bly
1. H old the plunger down with a push rod, and using

the blade of a small screw driver, remove the push
rod seat retainer.
2. Remove the push rod seat and m etering valve (lifter

"A ") or the push rod seat and inertia valve assembly
(lifter "B") (fig. 30).
3. Remove the plunger, ball check valve assembly and

the plunger spring.
4. Remove the ball check valve and spring by prying

the ball retainer loose from the plunger with the Fig. 30--H ydraulic Valve Lifters
blade of a small screw driver (fig. 31).
1. Lifter Body 6. Push Rod Seat

2. Push Rod Seat Retainer
SEE SPEC IFIC ATIO N S!
3. M etering Valve (Lifter A) 7. Plunger
Inertia Valve (Lifter B) 8. Check Ball Spring
4. Check Ball 9. Plunger Spring
5. Check Ball Retainer
Fig. 29--M easuring Valve Spring Installed Height

ENGINE 6-16
Fig. 31 -R e m o vin g Ball Check Valve
Cleaning and Inspection

Fig. 3 2 —Installing Ball Check Valve
Thoroughly clean all parts in cleaning solvent, and inspect
them carefully. If any parts are dam aged o r worn the entire
lifter assembly should be replaced. If the lifter body wall is CAUTION: Do not attempt to force or pump the
scuffed or worn, inspect the cylinder block lifter bore, if the plunger.
bottom o f the lifter is scuffed or worn inspect the camshaft
lobe, if the push rod seat is scuffed or worn inspect the push 5. Insert a 1/16" drift pin through both oil holes to hold
rod. the plunger down against the lifter spring tension (fig.
33).
NOTE: Inertia valve and retainer (lifter “ B” ) (fig. 30)
should not be removed from the push rod seat. To
check the valve, shake the push rod seat and inertia
valve assembly and the valve should move.
Assem bly ’/a " DRIFT PIN
1. Place the check ball on small hole in bottom of the

plunger. OIL FEED HOLE
2. Insert check ball spring on seat in ball retainer and
place retainer over ball so th at spring rests on the ball.
Carefully press the retainer into position in plunger
w ith the blade of a small screw driver (fig. 32).
3. Place the plunger spring over the ball retainer and slide
the lifter body over the spring and plunger, being care Yit" DRIFT
PIN
ful to line up the oil feed holes in the lifter body and
plunger.
4. Fill the assembly w ith SAE 10 oil, then insert the end
of a 1/ 8 " drift pin into the plunger and press down
solid. A t this point oil holes in the lifter body and
plunger assembly will be aligned (fig. 33). Fig. 3 3 -A sse m b lin g H ydraulic L ifter

ENGINE 6-17
NOTE: On lifter “ B” (fig. 30) the drift pin must not NOTE: Before installing lifter, coat the bottom of
extend inside the plunger. the lifter w ith “ Molykote” or its equivalent.
6. Remove the 1/8" drift pin, refill assembly with SAE 10

oil.
7. Install the metering valve and push rod seat (lifter "A ")
or the push rod seat and inertia valve assembly (lifter
"B") (fig. 30).
8. Install the push rod seat retainer, press down on the
push rod seat and remove the 1/16" drift pin from tne
oil holes. The lifter is now completely assembled, filled OIL PUMP
with oil and ready for installation.
The oil pum p consists of two gears and a pressure regula
NOTE: Before installing lifters, coat the bottom of tor valve enclosed in a two-piece housing. The oil pum p is
the lifter w ith “ Molykote” or its equivalent. driven by the distributor shaft which is driven by a helical
gear on the camshaft.
A baffle is incorporated on the pickup screen to eliminate
pressure loss due to sudden surging stops.
V A LV E LIFT ER S (M ECHANICAL)

The mechanical valve lifter (fig. 34) should never be disas
sembled. W ash lifter assembly in cleaning solvent and dry
with compressed air. Blow out oil holes in lifter body and
push rod seat with com pressed air. Inspect push rod seat
retainer. Inspect lifter for scuffed or worn lifter body or push
rod seat. If the lifter body wall is scuffed or worn inspect the
cylinder block lifter bore. If the bottom of the lifter is scuffed
or worn inspect the cam shaft lobe, if the push rod seat is
scuffed or w orn inspect the push rod. Additive containing EP
lube such as EOS should always be added to crankcase oil for
run-in when any new cam shaft or lifters are installed. All
damaged or w orn lifters should be replaced.
Fig. 3 5 -O il Pump (L6 Engine)
1. Pressure Regulator 6. Cover Gasket

Valve 7. Idler Gear
2. Pressure Regulator 8. Drive Gear and Shaft
Spring 9. Pump Body
3. Retaining Pin 10. Pickup Screen and
4. Screws Pipe
Fig. 3 4 -M e c h a n ic a l Valve Lifter 5. Pump Cover

ENGINE 6-18
NOTE: Mark gear teeth so they may be reassembled

with the same teeth indexing.
2. Remove the idler gear and the drive gear and shaft from
the pum p body.
3. Remove the pressure regulator valve retaining pin,
pressure regulator valve and related parts.
4. If the pickup screen and pipe assembly need replacing,
m ount the pum p in a soft-jawed vise and extract pipe
from pump.
CAUTION: Do not disturb the pickup screen on the

pipe. This is serviced as an assembly.

1. W ash all parts in cleaning solvent and dry with com
pressed air.
2. Inspect the pump body and cover for cracks or exces
Fig. 36--OM Pum p (“ Small V 8 ” )
sive wear.
3. Inspect pum p gears for damage or excessive wear.
4. Check the drive gear shaft for looseness in the pump
1. S haft Extension 7. Pressure Regulator
2. Pump Body Spring
body.
3. Drive Gear and S haft 8. Retaining Pin 5. Inspect inside of pum p cover for wear th at would per
4. Idler Gear 9. Screws m it oil to leak past the ends of the gears.
5. Pump Cover 10. Pickup Screen and 6. Inspect the pickup screen and pipe assembly for dam
6. Pressure Regulator Pipe age to screen, pipe or relief grommet.
Valve 7. Check the pressure regulator valve for fit.
NOTE: The pump gears and body are not serviced

Disassem bly separately. If the pump gears or body are damaged
or worn, replacement of the entire oil pump assem
R E F E R TO F IG U R E S 35, 36, A N D 37 bly is necessary.
1. Remove the pum p cover attaching screws, the
pum p cover and on In-Line engines the pum p cover
gasket.
Assem bly
R E F E R TO FIG U R E S 35, 36 and 37
1. If the pickup screen and pipe assembly was removed, it
should be replaced with a new part. Loss of press fit
condition could result in an air leak and loss of oil
pressure. M ount the pum p in a soft-jawed vise, apply
sealer to end of pipe, and using Tool J 8369 for In-Line
and "Small V 8 " (fig. 38) or J-22144 for "M ark IV V 8 "
(fig. 39) tap the pipe in place with a plastic hammer.
Fig. 3 7 -O il Pum p (“ M ark IV V 8 ” )
1. S haft Extension 8. Pressure Regulator

2. S haft Coupling Valve
3. Pump Body 9. Pressure Regulator
4. Drive Gear and S haft Spring
5. Idler Gear 10. W asher
6. Pickup Screen and 1 1. Retaining Pin
Pipe 12. Screws
7. Pump Cover Fig. 3 8 — Insta llin g Screen (In -L in e and “ M ark IV V 8 ” )

ENGINE 6-19
Inspection
In general, the lower half of the bearing (except No. 1
bearing) shows a greater wear and the most distress from
fatigue. If upon inspection the lower half is suitable for use,
it can be assumed that the upper half is also satisfactory. If
the lower half shows evidence of wear or damage, both upper
and lower halves should be replaced. Never replace one half
w ithout replacing the other half.
Checking Clearance
To obtain the most accurate results with "Plastigage", (or
its equivalent) a wax-like plastic m aterial which will com
press evenly between the bearing and journal surfaces w ith
out damaging either surface, certain precautions should be
observed. If the engine is out of the vehicle and upside down,
the crankshaft will rest on the upper bearings and the total
Fig. 39 --ln sta llin g Screen (“ M ark IV V 8 " ) clearance can be measured between the lower bearing and
journal. If the engine is to remain in the vehicle, the crank
CAUTION: Be careful of twisting, shearing or col shaft should be supported both front and rear (dam per and
lapsing pipe while installing in pump. Pickup screen flywheel) to remove the clearance from the upper bearing.
on In-Line engines must be parallel to bottom of oil The total clearance can then be measured between the lower
pan when oil pump is installed. bearing and journal.
NOTE: To assure the proper seating of the crank
2. Install the pressure regulator valve and related parts. shaft all bearing cap bolts should be at their speci
3. Install the drive gear and shaft in the pum p body. fied torque. In addition, preparatory to checking fit
4. Install the idler gear in the pum p body with the smooth of bearings, the surface of the crankshaft journal
side of gear tow ards pum p cover opening. and bearing should be wiped clean of oil.
5. Install the pum p cover (with new gasket on In-Line
engines) and torque attaching screws to specifications. 1. W ith the oil pan and oil pum p removed, and starting
6. T urn drive shaft by hand to check for sm ooth operat with the rear main bearing, remove bearing cap and
ion. wipe oil from journal and bearing cap.
2. Place a piece of gauging plastic the full width of the
bearing (parallel to the crankshaft) on the journal (fig.
MAIN BEA R IN G S 40).
M ain bearings are of the precision insert type and do not
utilize shim for adjustm ent. If clearances are found to be
excessive a new bearing, both upper and lower halves will be
required. Bearings are available in standard size and .001",
.002", .009", .010",.020" and .030" undersize.
Selective fitting of both rod and main bearing inserts is
necessary in production in order to obtain close tolerances.
F or this reason you m ay find one half of a standard insert
with one half of a .00 1 " undersize insert which will decrease
the clearance .0005" from using a full standard bearing.
W hen a production crankshaft cannot be precision fitted
by this m ethod, it is then ground .009" undersize on main
journals only. A .009"undersize bearing and .OIO"undersize bear
ing may be used for percision fitting in the same manner as
previously described. Any engine fitted with a .009"undersize
crankshaft will be identified by the following markings.
• “ .009” will be s ta m p e d on th e c ra n k s h a ft c o u n te r
w eig h t fo rw a rd o f th e c e n te r m a in jo u rn a l.
• A figure “ 9 ” w ill be sta m p e d o n th e b lo ck at th e left
fro n t oil p a n rail.
NOTE: If, for any reason, main bearing caps are

replaced, shimming may be necessary. Laminated
shims for each cap are available for service. Shim
requirement will be determined by bearing clear
Fig. 40~G auging Plastic on Journal
ance.

ENGINE 6-20
CAUTION: Do not rotate the crankshaft while the NOTE: If a new bearing cap is being installed and
gauging plastic is between the bearing and journal. clearance is less than .001'' inspect for burrs or
nicks; if none are found then install shims as re
quired.
3. Install the bearing cap and evenly torque the retaining
bolts to specifications. 7. A standard, .001" or .002" undersize bearing may pro
4. Remove bearing cap. The flattened gauging plastic will duce the proper clearance. If not, it will be necessary to
be found adhering to either the bearing shell or journal. regrind the crankshaft journal for use with the next
5. On the edge of gauging plastic envelope there is a gra undersize bearing.
duated scale which is correlated in thousandths of an 8 . Proceed to the next bearing. After all bearings have
inch. W ithout removing the gauging plastic, measure its been checked rotate the crankshaft to see that there is
compressed w idth (at the widest point) with the gradua no excessive drag.
tions on the gauging plastic envelope (fig. 41). 9. M easure crankshaft end play (see specifications) by
forcing the crankshaft to the extreme front position.
M easure at the front end of the rear main bearing with
NOTE: Normally, main bearing journals wear evenly a feeler guage (fig. 42).
and are not out-of- round. However, if a bearing is 10. Install a new rear main bearing oil seal in the cylinder
being fitted to an out-of-round journal (.001 ' max.), be block and main bearing cap.
sure to fit to the maximum diameter of the journal:
If the bearing is fitted to the minimum diameter and
Replacement
the journal is out-of-round .001',' interference be
tween the bearing and journal will result in rapid
bearing failure. If the flattened gauging plastic ta NOTE: Main bearings may be replaced with or with
pers toward the middle or ends, there is a difference out removing the crankshaft.
in clearance indicating taper, low spot or other ir
regularity of the bearing or journal. Be sure to meas
ure the journal with a micrometer if the flattened
W IT H C R A N K S H A F T REM OVAL
gauging plastic indicates more than .001 'difference.
1. Remove and inspect the crankshaft.
2. Remove the main bearings from the cylinder block and
main bearing caps.
6. If the bearing clearance is within specifications, the
3. Coat bearing surfaces of new, correct size, main bear
bearing insert is satisfactory. If the clearance is not
ings with oil and install in the cylinder block and main
within specifications, replace the insert. Always replace
bearing caps.
both upper and lower insert as a unit.
4. Install the crankshaft.
Fig. 4 1 -M e a su rin g G auging Plastic Fig. 4 2 -M e a su rin g C rankshaft End Play

ENGINE 6-21
W IT H O U T C R A N K S H A F T R EM O V A L 4. Oil new lower bearing and install in bearing cap.

1. W ith oil pan, oil pum p and spark plugs removed, 5. Install main bearing cap with arrows pointing toward
remove cap on main bearing requiring replacement and front of engine.
remove bearing from cap. 6. Torque main bearing cap bolts to specifications.
2. On the In-Line engine crankshaft, the rear main journal
has no oil hole. Replace the rear m ain bearing upper
half as follows: CONNECTING ROD BEARIN G S
a. Use a small drift punch and ham m er to start the Connecting rod bearings are of the precision insert type
upper bearing half rotating out of block. and do not utilize shims for adjustment. D O N O T FIL E
b. Use a pair of pliers (with taped jaws) to hold the RODS O R R O D CAPS. If cleanances are found to be exces
bearing thrust surface to the oil slinger and rotate sive a new bearing will be required. Bearings are available in
the crankshaft to remove bearing (fig 43). standard size and .0 0 1 " and .0 0 2 " undersize for use with new
c. Oil new selected size upper bearing and insert plain and used standard size crankshafts, and in .0 1 0 " and .0 2 0 "
(unnotched) end between crankshaft and indented undersize for use with reconditioned crankshafts.
or notched side of block.
d. Use pliers as in removing to rotate bearing into
place. The last 1/4 movement may be done by hold Inspection and Replacement
ing just the slinger with the pliers or tap in place
with a drift punch. 1. W ith oil pan and oil pum p removed, remove the con
3. All other crankshaft journals (In-Line and V 8) have oil necting rod cap and bearing.
holes. Replace the m ain bearing upper half as follows: 2. Inspect the bearing for evidence of wear or damage.
(Bearings showing the above should not be installed.)
3. Wipe the bearings and crankpin clean of oil.
a. Install a main bearing removing and installing tool
4. M easure the crankpin for out-of-round or taper with a
in oil hole in crankshaft journal.
micrometer. If not within specifications replace or
recondition the crankshaft. If within specifications and
NOTE: If such a tool is not available, a cotter pin
a new bearing is to be installed, measure the maximum
may be bent as required to do the job.
diam eter of the crankpin to determ ine new bearing size
b. R otate the crankshaft clockwise as viewed from the required.
front of engine. This will roll upper bearing out of 5. If within specifications measure new or used bearing
block. clearances with Plastigage or its equivalent.
c. Oil new selected size upper bearing and insert plain
(unnotched) end between crankshaft and indented NOTE: If a bearing is being fitted to an out-of-round
or notched side of block. R otate the bearing into crankpin, be sure to fit to the maximum diameter of
place and remove tool from oil hole in crankshaft the crankpin. If the bearing is fitted to the minimum
journal. diameter and the crankpin is out-of-round .001, in
terference between the bearing and crankpin will
result in rapid bearing failure.
a. Place a piece of gauging plastic the full width of the

crankpin (parallel to the crankshaft) (fig. 44).
b. Install the bearing in the connecting rod and cap.
c. Install the bearing cap and evenly torque nuts to
specifications.
CAUTION: Do not turn the crankshaft with the

gauging plastic installed.
d. Remove the bearing cap and using the scale on the

gauging plastic envelope, measure the gauging plas
tic width at the widest point (fig. 45).
6. If the clearance exceeds specifications, select a new,
correct size, bearing and remeasure the clearance.
7, Coat the bearing surface w ith oil, install the rod cap and
torque nuts to specifications.
W hen all connecting rod bearings have been installed
tap each rod lightly (parallel to the crankpin) to make
sure they have clearance.
9, M easure all connecting rod side clearances (see specifi
cations), between the connecting rod cap and side of
crankpin on In-Line engines (fig. 46) or between con
Fig. 43--Replacing U pper Main Bearing (In-Line) necting rod caps on V 8 engines (fig. 47).

ENGINE 6-22
Fig. 4 6 -M e a su rin g Connecting Rod Side Clearance (In-Line)
NOTE: Before ridge and/or deposits are removed,

turn crankshaft until piston is at the bottom of
stroke and place a cloth on top of piston to collect
the cuttings. After ridge and/or deposits are
removed, turn crankshaft until piston is at top of
Fig. 4 4 -G a u g in g Plastic on Crankpin
stroke and remove cloth and cuttings.
CONNECTING ROD AND PISTON

Inspect connecting rods and connecting rod caps for
A S S E M B L IE S 2
cylinder identification. If necessary m ark them.
3 Remove connecting rod cap and install Tool J-5239
Removal (3 /8 ") or J 6305 (11/32") on studs. Push connecting
rod and piston assembly out of top of cylinder block
1. W ith oil pan, oil pum p and cylinder head removed, use
(fig. 48).
a ridge reamer to remove any ridge a n d /o r deposits
from the upper end of the cylinder bore.
Fig. 4 5 -M e a su rin g Gauging Plastic Fig. 4 7 -M e a su rin g C onnecting Rod Side Clearance (V8)

ENGINE 6-23
Fig. 5 0 -P isto n Support Tool Rework
M odification of the tool as described does not affect tool

application on other pistons.
1. Remove connecting rod bearings from connecting rods
and caps.
NOTE: If connecting rod bearings are being reused,

place them in a rack so they may be reinstalled in
their original rod and cap.
Fig. 48--Removing C onnecting Rod and Piston Assem blies 2. Remove piston rings by expanding and sliding them off
the pistons. Tools J-8020 (3-9/16"), J-8021 (3 7/8"),
J-8032 (4"), J- 22249 (3-15/16"), J-22147 (4-3/32"),
NOTE: It will be necessary to turn the crankshaft and J-22250 (4-1/4") are available for this purpose.
slightly to disconnect some of the connecting rod 3. Using Tool J-9510 for In-Line and "Small V 8 " (fig. 51)
and piston assemblies and push them put of the cyl or Tool J-6994 for "M ark IV V 8 " (fig. 52), place con
inder. necting rod and piston assembly in an arbor press with
piston on Support then using Remover, press piston pin
out of connecting rod and piston.
Disassem bly
PIST O N SU PPO R T TO O L
If bosses on pistons (fig. 49) do not allow piston support
Tool J-9510-1 to seat squarely on the piston for press operat
ions, m odifications to the tool are necessary. To allow ade
quate clearance for these bosses, turn or grind the upper
portion of the tool to the dimensions shown in Figure 50.
BOSSES
Fig. 4 9 -P is to n Bosses Fig. 5 1 -R e m o v in g Piston Pin (In -L in e and “ Small V 8 ” )

ENGINE 6-24
4. Remove assembly from arbor press and remove tools,

piston pin, connecting rod and piston.
C O N N E C T IN G RO D S
W ash connecting rods in cleaning solvent and dry with
compressed air.
Check for twisted or bent rods and inspect for nicks or
Fig. 53--Piston Pin and T o o l L a y o u t (In -L in e and “ Small V 8 ” )
cracks. Replace connecting rods th at are damaged.
PISTONS Assem bly
Clean varnish from piston skirts and pins with a cleaning
1. Lubricate piston pin holes in piston and connecting rod
solvent. D O N O T W IR E BRU SH A N Y PA R T O F T H E
to facilitate installation of pin.
PISTON . Clean the ring grooves with a groove cleaner and
2. Using Tool J-9510 for In-Line and "Small V 8 " (fig. 53)
make sure oil ring holes and slots are clean.
or Tool J-6994 for "M ark IV V 8 " (fig. 54) place Sup
Inspect the piston for cracked ring lands, skirts or pin
port with spring and pilot in place on an arbor press.
bosses, wavy or worn ring lands, scuffed or dam aged skirts,
3. Position piston on connecting rod with appropriate side
eroded areas at top of the piston. Replace pistons that are
of piston (fig. 55) and connecting rod bearing tangs
damaged or show signs of excessive wear.
aligned (fig. 53 or 54).
Inspect the grooves for nicks or burrs th at might cause the
4. Place piston on support, indexing pilot through piston
rings to hang up.
and rod.
M easure piston skirt (across center line of piston pin) and
5. Place Installer on piston pin, start piston pin into piston
check clearance as outlined under "Piston Selection".
and press on installer until pilot bottom s in support.
PISTO N PIN S
6 . Remove installer from connecting rod and piston as
The piston pin clearance is designed to m aintain adequate
sembly and check piston for freedom of movement on
clearance under all engine operating conditions. Because of
piston pin.
this, the piston and piston pin are a m atched set and not
serviced separately.
Inspect piston pin bores and piston pins for wear. Piston Piston Flings
pin bores and piston pins m ust be free of varnish or scuffing
All compression rings are m arked on the upper side of the
when being measured. The piston pin should be measured
ring. W hen installing compression rings, make sure the
with a m icrom eter and the piston pin bore should be mea
m arked side is tow ard the top of the piston. The top ring is
sured with a dial bore gauge or an inside m icrometer. If
chrome faced, or treated with m olybdenum for maximum
clearance is in excess of the .0 0 1 " wear limit, the piston and
piston pin assembly should be replaced. life.

ENGINE 6-25
4. If the gap between the ends of the ring is below specifi

cations, remove the ring and try another for fit.
REMOVER
A N D INSTALLER 5. Fit each compression ring to the cylinder in which it is
going to be used.
C O N N E C T IN G ROD
BEARING T A N G SLOTS
6. If the pistons have not been cleaned and inspected as

previously outlined, do so.
PISTO N
PIN
7. Slip the outer surface of the top and second com pres
sion ring into the respective piston ring groove and roll
the ring entirely around the groove (fig. 57) to make
sure that the ring is free. If binding occurs at any point
the cause should be determ ined, and if caused by ring
groove, remove by dressing with a fine cut file. If the
binding is caused by a distorted ring, check a new ring.
8. Install piston rings as follows (fig. 58).

VALVE
DEPRESSION
PILOT
G R IN D TO O L
NOTE: Tools J-8020 (3-9/16"), J-8021 (3-7/8"), J-8032
FOR CLEARANCE (4 ") J-22249 (3-15/16"), J-22147 (4-3/32"), and
J-22250 (4-1/4") are available for this purpose.
SPRING
a. Install oil ring spacer in groove and, except on 250

cu. in. engine, insert anti-rotation tang in oil hole.
b. Hold spacer ends butted and install lower steel oil

ring rail with gap properly located.
c. Install upper steel oil ring rail with gap properly

SUPPORT located.
d. Flex the oil ring assembly to make sure ring is free.

Fig. 5 4 -P is to n Pin and T o o l L a y o u t (“ M ark IV V 8 " ) If binding occurs at any point the cause should be
determined, and if caused by ring groove, remove by
dressing groove with a fine cut file. If binding is
T h e oil c o n tr o l rin g s a re o f th r e e p ie c e ty p e , c o n
caused by a distorted ring, check a new ring.
sisting o f tw o segm ents (rails) a n d a sp acer.
1. S elect rin g s c o m p a ra b le in size to th e p is to n b eing
e. Install second compression ring expander then ring
used.
with gaps properly located.
2. Slip the compression ring in the cylinder bore; then f. Install top compression ring with gap properly
press the ring down into the cylinder bore about 1/4 located.
inch (above ring travel). Be sure ring is square with
cylinder wall.
9. Proper clearance of the piston ring in its piston ring
groove is very im portant to provide proper ring action
and reduce wear. Therefore, when fitting new rings, the
3. M easure the space or gap between the ends of the ring clearances between the surfaces of the ring and groove
w ith a feeler gauge (fig. 56). should be measured (fig. 59). (See Specifications.)

ENGINE 6-26
PISTON-VIEWED FROM TOP
SIDE OF PISTON ALIGNED WITH

ENGINE PISTON CYLINDER CONNECTING ROD BEARING TANGS
250 CU. IN. ALIGNMENT NOT NECESSARY
“ C” ALL NOTCH ON PISTON TOWARD
292 CU. IN. FRONT OF ENGINE
307 CU. IN. “ A” 1-3-5-7 LE F T
2-4-6-8 RIGHT
350 CU. IN. (215 HP.) “ D” 1-3-5-7 LE F T
2-4-6-8 RIGHT
350 CU. IN. (245 HP.)
350 CU. IN. (250 HP.) 1-3-5-7 LE F T
“ G”
350 CU. IN. (270 HP.) 2-4 6-8 RIGHT
350 CU. IN. (330 HP.) “ H” 1-3-5-7 LE FT
2-4-6-8 RIGHT
350 TRUCK (LPG) “ E” 1-3-5-7 LE F T
2-4-6-8 RIGHT
400 CU. IN. (255 HP.) “ G” 1-3-5-7 LEFT
2-4-6-8 RIGHT
402 CU. IN. (300 HP.) 1-3-5-7 LE F T
“ B”
2-4-6-8 RIGHT
454 CU. IN. (365 HP.) 1-3-5-7 LE F T
2-4-6-8 RIGHT
454 CU. IN. (425 HP.) “ B” 1-3-5-7 LE FT
2-4-6-8 RIGHT
Fig. 55 -C o n n e ctin g Rod and Piston Relationship

ENGINE 6-27
Fig. 5 6 -M e a s u rin g Ring Gap
Installation
NOTE: Cylinder bores must be clean before piston

installation. This may be accomplished with a hot
water and detergent wash or with a light honing as Fig. 58 -R in g Gap Location
necessary. After cleaning, the bores should be
swabbed several times with light engine oil and a
clean dry cloth.

ENGINE 6-28
1. Lubricate connecting rod bearings and install in rods

and rod caps.
2. Lightly coat pistons, rings and cylinder walls with light
engine oil.
3. W ith bearing caps removed, install Tool J-5239 (3 /8 ")
or J-6305 (11/32") on connecting rod bolts.
CAUTION: Be sure ring gaps are properly positioned

as previously outlined.
4. Install each connecting rod and piston assembly in its

respective bore. Install with connecting rod bearing
tang slots on side opposite camshaft on V 8 engines (fig.
60). In-Line engine pistons m ust have piston notch fac
ing front of engine (fig. 61). Use Tool J-8037 to com
press the rings (fig. 62). G uide the connecting rod into
place on the crankshaft journal with Tool J-5239 (3 /8 ")
or J-6305 (11/32"). Use a ham m er handle and light
blows to install the piston into the bore. H old the ring
com pressor firmly against the cylinder block until all
piston rings have entered the cylinder bore.
5. Remove Tool J-5239 or J-6305. Fig. 6 1~Pistons~lnstalled Position (In-Line)
6 . Install the bearing caps and torque nuts to specification.
should be marked, beginning at the front of the en
gine. On V8 engines 1, 3, 5 and 7 in the left bank
NOTE: If bearing replacement is required refer to and, 2,4,6 and 8 in the right bank. The numbers on
'■ Connecting Rod Bearings". the connecting rod and bearing cap must be on the
same side when installed in the cylinder bore. If a
connecting rod is ever transposed from one block or
cylinder to another, new bearings should be fitted
NOTE: Be sure to install new pistons in the same and the.connecting rod should be numbered to corre
cylinders for which they were fitted, and used pis spond with the new cylinder number.
tons in the same cylinder from which they were
removed. Each connecting rod and bearing cap
C R A N K SH A FT
The crankshaft can be removed while the engine is disa-
sembled for overhaul, as previously outlined or w ithout com
plete disassembly as outlined below.
C O N N E C T IN G ROD
B EA R IN G T A N G
SLOTS INSTALLED
OPPOSITE
CA M S H A FT
SLOT
SLOT
Fig. 6 0 -C o n n e ctin g Rods--lnstalled Position V8 Fig. 6 2 — Installing C onnecting Rod and Piston Assemblies

ENGINE 6-29
Removal Sprocket or Gear Replacem ent (Refer to Fig. 63)
1. W ith the engine removed from the vehicle and the • O n In -L in e e n g in e s, re m o v e c ra n k s h a ft g e a r u sin g
transm ission a n d /o r clutch housing removed from the T o o l J-8105, in sta ll using T o o l J-5590.
engine, m ount engine in overhaul stand and clamp se • O n “ Sm all V 8 ” engines, rem ove c ra n k sh a ft sp ro c k et
curely. u sin g T o o l J-5825, install using T o o l J-5590.
• O n M ark IV V 8 engines, rem ove c ra n k sh a ft sp rocket
2. Remove the oil dip stick and oil dip stick tube, (if
u sin g T o o l J-1619, install using T o o l J-21058.
applicable).
3. Remove the starting m otor, clutch assembly (if

equipped) and flywheel. Installation
F or installation of crankshaft, refer to the applicable steps
4. Remove the spark plugs.
under "Engine Assembly" previously outlined.
5. Remove crankshaft pulley and torsional damper.
6. R em ove oil pan and oil pump. C A M SH A FT

7. Remove crankcase front cover, and if so equipped,
remove tim ing chain and cam shaft sprocket. Inspection
8. Check the connecting rod caps for cylinder num ber
identification. If necessary m ark them. The cam shaft bearing journals should be measured with
a m icrom eter for an out-of-round condition. If the journals
9. Remove the connecting rod caps and push the pistons exceed .0 0 1 " out-of-round, the camshaft should be replaced.
to top of bores. The camshaft should also be checked for alignment. The
best m ethod is by use of "V" blocks and a dial indicator (fig.
10. Remove m ain bearing caps and lift crankshaft out of 64). The dial indicator will indicate the exact am ount the
cylinder block. camshaft is out of true. If it is out more than .0015" dial
indicator reading, the cam shaft should be replaced.
11. Remove rear main bearing oil seal and main bearings
from cylinder block and main bearing caps. O n In -L in e e n g in e s in s p e c t th e c a m s h a ft g e a r a n d
th ru st p late for w ear or dam age. M easure the c am sh a ft
end play. T his sh o u ld be .001" to .005" (fig. 65).
Cleaning and Inspection Oil Nozzle Replacem ent (In Line)
1. Remove nozzle with pliers (fig. 66 ).

1. W ash crankshaft in solvent and dry with compressed
air.
2. Drive new nozzle in place (oil hole in vertical position)
using a suitable light plastic or rubber hammer.
2. M easure dimensions of m ain bearing journals and
crankpins with a m icrom eter for out-of-round, taper or
undersize. (See Specifications.) Cam shaft Gear Replacem ent (In Line)
!*
3. Check crankshaft for run-out by supporting at the front 1. If the inspection indicated that the camshaft, gear or
and rear main bearings journals in "V" blocks and thrust plate should be replaced, the gear m ust be
check at the front and rear interm ediate journals with removed from the camshaft. This operation requires the
a dial indicator. (See Specifications.) use of camshaft gear remover J-971.
2. Place the camshaft through the gear remover, place end

4. Replace or recondition the crankshaft if out of specifi of remover on table of a press and press shaft out of gear
cations. (fig. 67).

ENGINE 6-30
REMOVAL INSTALLATION
IN LIN E
J-8105 J-5590
SM ALL
V -8’ *
J-5825 !J-5590
MARK IV V-8
J-1619 WASHER
J-21058
Fig. 6 3 -S p ro c k e t or Gear Replacement

ENGINE 6-31
BEARING JOURNALS
FUEL PUMP DRIVE DISTRIBUTOR

ECCENTRIC DRIVE GEAR
Fig. 6 4 -C h e ckin g Cam shaft A lig nm e nt
CAUTION: Thrust plate must be positioned so that

woodruff key in shaft does not damage it when the
shaft is pressed out of gear. Also support the hub of
the gear or the gear will be seriously damaged. Fig. 6 6 -O il Nozzle Replacement (In-Line)
3. To assemble cam shaft gear thrust plate and gear spacer

ring to camshaft, firmly support cam shaft at back of
front journal in an arbor press.
4. Place gear spacer ring and thrust plate over end of shaft,
and install w oodruff key in shaft keyway. Install cam
shaft gear and press it onto the shaft until it bottom s
against the gear spacer ring. The end clearance of the
thrust plate should be .001" to .005" (fig. 65).
Fig. 6 5 -M e a su rin g Cam shaft End Play Fig. 67-R em oving Cam shaft Gear

ENGINE 6-32
C A M SH A FT B EA R IN G S
Inspection
W ith the cam shaft removed, inspect the bearings for evi
dence of wear or damage. (Bearings showing the above
should be replaced.)
Removal
Cam shaft bearings can be replaced while engine is disas
sembled for overhaul, or w ithout complete disassembly of the
engine. To replace bearings w ithout complete disassembly
remove the camshaft and crankshaft leaving cylinder heads
attached and pistons in place. Before removing crankshaft,
tape threads of connecting rod bolts to prevent damage to
crankshaft. Fasten connecting rods against sides of engine so
they will not be in the way while replacing camshaft bearings.
1. W ith cam shaft and crankshaft removed, drive camshaft
rear plug from cylinder block.
NOTE: This procedure is based on removal of the

bearings nearest center of the engine first. With this
method a minimum amount of turns are necessary
to remove all bearings.
2. Using Tool Set J-6098, with nut and thru st washer

installed to end of threads, index pilot in cam shaft front
bearing and install puller screw through pilot.
3. Install remover and installer tool with shoulder toward
bearing, making sure a sufficient am ount of threads are
engaged.
4. Using two wrenches, hold puller screw while turning
nut. W hen bearing has been pulled from bore, remove Fig. 68--Replacing Cam shaft Center Bearing
remover and installer tool and bearing from Duller
screw (fig. 68 ). * 2. Using Tool Set J-6098, with nut then thrust washer
installed to end of threads, index pilot in camshaft front
5. R em ov e re m a in in g b earin g s (except fro n t a n d rear) bearing and install puller screw through pilot.
in th e sam e m a n n e r. It will be n e c e ssa ry to in d ex
3. Index cam shaft bearing in bore (with oil hole aligned as
p ilo t in c a m s h a ft re a r b e a rin g to re m o v e th e re a r
outlined below), then install remover and installer tool
in te rm e d ia te b earin g .
on puller screw with shoulder tow ard bearing.
6. A ssem b le re m o v e r a n d in sta lle r to o l o n d riv e r
h a n d le a n d re m o v e c a m sh a ft fro n t a n d re a r b e a r
a. In Line E ngines-A ll cam bearing oil holes must be
in g s b y d riv in g to w a rd s c e n te r o f c y lin d e r b lo c k
aligned with oil hole in cam bore.
(fig. 67).
b. Small V 8 E ngines-N um ber one cam bearing oil

hole m ust be positioned so that oil holes are equidis
tant from 6 o’clock position. N um ber two through
num ber four bearing oil holes m ust be positioned at
5 o" clock position (toward left side of engine and at
Installation a position even with bottom of cylinder bore). N um
ber five bearing oil hole must be in 12 o" clock posi
The cam shaft front and rear bearings should be installed tion.
first. These bearings will act as guides for the pilot and center
the remaining bearings being pulled into place. c. M ark IV V 8 E ngines-N um ber one through num ber
four cam bearing oil hole m ust be aligned with oil
1. Assemble remover and installer tool on driver handle holes in cam bearing bore. The num ber five bearing
and install camshaft front and rear bearings by driving bore is annulus and cam bearing m ust be positioned
tow ards center of cylinder block (fig. 69). at or near the 6 o" clock position.

ENGINE 6-33
3. Clean and inspect w ater passages in the cylinder block.
4. Inspect the cylinder block for cracks in the cylinder

walls, w ater jacket valve lifter bores and main bearing
webs.
5. M easure the cylinder walls for taper, out-of-round or

excessive ridge at top of ring travel. This should be done
with a dial indicator. Set the gauge so that the thrust pin
m ust be forced in about 1/4" to enter gauge in cylinder
bore. Center gauge in cylinder and turn dial to "0".
Carefully work gauge up and down cylinder to deter
mine taper and turn it to different points around cylin
der wall to determ ine the out-of-round condition. If
cylinders were found to exceed specifications, honing or
boring will be necessary (fig. 70).
Oil Filter Bypass Valve
Inspection and Replacement
IN -L IN E E N G IN E S
W ith the oil filter removed, check the spring and fibre
valve for operation. Inspect for a cracked or broken valve. If
replacement is necessary, remove valve by prying it out with
a screw driver. Install and seat a new valve by tapping it in
place, using a 9 /16 thin-wall deep socket (fig. 71).
Fig. 69 -R e p la cin g Cam shaft Front Bearing
V 8 E N G IN E S
W ith the oil filter removed, check the spring and fibre
4. Using two wrenches, hold puller screw while tu rn
valve for operation. Inspect for a cracked or broken valve. If
ing nut. A fter bearing has been pulled into bore,
replacement is necessary, the oil filter adapter and bypass
remove the rem over and installer tool from puller
valve assembly must be replaced as an assembly. Clean valve
screw and check alignm ent of oil hole in camshaft
cham ber in cylinder block thoroughly. Torque retaining
bearing (fig. 68 ).
screws to specifications (fig. 72).
5. Install remaining bearings in the same manner. It
will be necessary to index pilot in the camshaft rear
bearing to install the rear interm ediate bearing.
6. Install a new cam shaft rear plug.
NOTE: Plug should be installed flush to 1/32" deep

and be parallel with rear surface of cylinder block.
C YLIN D ER B LO CK

1. W ash cylinder block thoroughly in cleaning solvent and
clean all gasket surfaces.
2. Remove oil gallery plugs and clean all oil passages.
NOTE: These plugs may be removed with a sharp

punch or they may be drilled and pried out. Fig. 7 0 -M e a su rin g C ylinder Bore

ENGINE 6-34
Fig. 7 1 -O il F ilter By-Pass Valve (In-Line)
Distributor Lower Bearing and Thrust W asher

Replacement (In Line)
The distributor lower bearing is a bronze bushing pressed

into the lower side of the engine block. Its upper inside
diameter pilots the distributor shaft and the outside diam eter
extending below the block pilots the oil pump.
Some engines have a th ru st washer at the upper end of the
bushing bore. The thrust washer, where used, may be re
placed at the same time the bushing is replaced.
The lower bushing will ordinarily require only a clearance
or wear check during engine overhaul. W hen distributor
shaft-to-bushing clearance exceeds .0035" the bushing
should be replaced as follows:
Fig. 73 -R e p la cin g D istrib utor Bearing and T hrust W asher
1. W ith oil pum p and distributor removed install Tool
J-9534 into bushing and using a slide ham m er, remove
the bushing (fig. 73). 5. Using Tool J-9535 with driver-bolt in driver handle
2. Using a drift up through bushing bore, drive thrust install driver into new bushing from large inside diame
washer (if installed) out of bore and remove from block. ter.
3. Clean bushing bore in block and check for burrs or 6. Position bushing and driver to block and drive the
damage. bushing in position, which is determ ined by tool bot
4. If thru st washer was removed, start new washer in toming against the block.
position in bore and drive into place using J-9535. 7. Remove tool from bushing. It is possible that the bush
ing with minimum I.D. will collapse enough during
installation to slightly seize the installer arbor. If this
happens, remove installer tool using slide ham m er in
driver bolt hole or driver handle.
NOTE: This will not damage the bushing and tool is

designed for this purpose, should it occur.
Repairs
C Y L IN D E R C O N D IT IO N IN G
The performance of the following operation is contingent
upon engine condition at time of repair.
If the cylinder block inspection indicated th at the block
was suitable for continued use except for out-of-round or
tapered cylinders, they can be conditioned by honing or bor
ing.
If the cylinders were found to have less than .005" taper
or wear they can be conditioned with a hone and fitted with
the high limit standard size piston. A cylinder bore of less
then .005" wear or taper may not entirely clean up when
fitted to a high limit piston. If it is desired to entirely clean
Fig. 7 2 -O il Filter By-Pass Valve (V8) up the bore in these cases, it will be necessary to rebore for

ENGINE 6-35
an oversize piston. If m ore than .005" taper or wear, they 3. W hen finish honing a cylinder bore to fit a piston, the
should be bored and honed to the smallest oversize that will hone should be moved up and down at a sufficient speed
perm it complete resurfacing of all cylinders. to obtain very fine uniform surface finish m arks in a
W hen pistons are being fitted and honing is not necessary, cross-hatch pattern of approximately 45° to 65° in
cylinder bores may be cleaned with a hot water and detergent cluded angle. The finish m arks should be clean but not
wash. A fter cleaning, the cylinder bores should be swabbed sharp, free from imbedded particles and torn or folded
several times with light engine oil and a clean cloth and then m etal (fig. 74).
wiped with a clean dry cloth.
4. Perm anently m ark the piston for the cylinder to which

it has been fitted and proceed to hone cylinders and fit
C Y L IN D E R B O R IN G
the remaining pistons.
1. Before using any type boring bar, the top of the cylinder
block should be filed off to remove any dirt or burrs.
This is very im portant. Otherwise, the boring bar may CAUTION: Handle the pistons with care and do not
be tilted which would result in the rebored cylinder wall attempt to force them through the cylinder until the
not being at right angles to the crankshaft. cylinder has been honed to correct size as this type
piston can be distorted through careless handling.
2. The piston to be fitted should be measured with a m i

crom eter, m easuring at the center of the piston skirt and
at right angles to the piston pin. The cylinder should be 5. Throughly clean the bores with hot w ater and deter
bored to the same diam eter as the piston and honed to gent. Scrub well with a stiff bristle brush and rinse
give the specified clearance. thoroughly with hot water. It is extremely essential that
a good cleaning operation be performed. If any of the
abrasive m aterial is allowed to remain in the cylinder
bores, it will rapidly wear the new rings and cylinder
NOTE: Hone cylinders as outlined under "Cylinder bores in addition to the bearings lubricated by the con
Honing and Piston Fitting". tam inated oil, the bores should be swabbed several
times with light engine oil and a clean cloth and then
wiped with a clean dry cloth. Cylinder should not be
cleaned with kerosene or gasoline. Clean the rem ainder
3. The instructions furnished by the m anufacturer of the of the cylinder block to remove the excess m aterial
equipm ent being used should be carefully followed. spread during the honing operation.
C Y L IN D E R H O N IN G
1. W hen cylinders are to be honed follow the hone m anu PISTO N SELEC TIO N
facturer’s recom m endations for the use of the hone and
cleaning and lubrication during honing.
1. Check U SED piston to cylinder bore clearance as fol
lows:
2. Occasionally during the honing operation, the cylinder a. M easure the "Cylinder Bore Diam eter" with a tele
bore should be thoroughly cleaned and the piston se scope guage ( 2 - 1/ 2 " from top of cylinder bore).
lected for the individual cylinder checked for correct fit.
b. Measure the "Piston D iam eter" (at skirt across cen

ter line of piston pin).
c. Subtract piston diam eter from cylinder bore diame

ter to determine "Piston to Bore Clearance".
d. Locate piston to bore clearance on Piston Selection

C hart (fig. 75) and determine if piston to bore clear
Fig. 7 4 -C y lin d e r Finish Marks ance is in the acceptable range.

ENGINE 6-36
307 PASSENGER
----- 307 TRUCK
350 (330 HP)
350 (245, 250 & 270 HP)

------ 402 (300 HP) TRUCK
402 (300 HP) PASSENGER
400 (255 HP)
454 (365 HP)
nin o >o o
o o o
io o
o o
,o, i O, , , ,o. i O, , , ,o.
PISTON TO BORE CLEARANCE
Preferable piston clearance— New piston in new or reconditioned cylinder bore.
Acceptable piston clearance— Used or new piston in worn cylinder bore.
Measure piston skirt 2 W from top of piston. Measure cylinder bore 2 '/i" from top of bore.
Fig. 7 5 -P isto n Selection Chart
2. If used piston is not acceptable, check Piston Size C hart hone cylinder bore to correct clearance (preferable
(fig. 76) and determ ine if a new piston can be selected range).
to fit cylinder bore within the acceptable range. 4. M ark the piston to identify the cylinder for which it was
3. If cylinder bore m ust be reconditioned, measure new fitted.
piston diam eter (across center line of piston pin) then
PISTONS A V A IL A B L E
ENGINE
OVERSIZE
(D ISPLAC EM ENT) STD.
.0 0 1 " .0 2 0 " .030" .040
3.8750 3.8760 3.8935 3.9035
250 & 307
3.8760 3.8770 3.8955 3.9055
3.8730 3.8740 3.8938 3.9038 3.9138
292
3.8740 3.8750 3.8962 3.9062 3.9162
3.9998 4.0008 4.0183 4.0283
350 (245, 255 & 270 HP) -
4.0008 4.0018 4.0203 4.0303
3.9953 3.9963 4.0138 4.0252
350 (330 HP) -
3.9963 3.9973 4.0158 4.0272
4.1241 4.1251 4.1426 4.1526
400 (265 HP) -
4.1251 4.1261 4.1446 4.1546
4.1237 4.1247 4.1450 4.1550
402 (300 HP) -
4.1247 4.1257 4.1470 4.1570
4.2481 4.2491 4.2675 4.2775
454 (365 HP) -
4.2491 4.2501 4.2695 4.2795
4.2465 4.2475 4.2657 4.2757
454 (425 HP) -
4.2475 4.2485 4.2677 4.2777
Fig. 76--Piston Size Chart

ENGINE 6-37
C Y L I N D E R HE A D T ORQUE S EQ U E N C E
S M A L L V 8 '1 jJM ARK IV V 8 "
IN T A K E M A N IF O L D T O R Q U E S E Q U E N C E
FRONT
FRONT
“ SMALL V8" ,JMARK IV V8”
Fig. 77--Torque Specifications

ENGINE 6-38
SPECIAL TOOLS
Fig, 78 -E ng ine Special Tools
1. J-4536 Engine L i f t K it 10. J-52 39 ( 3 /8 ” ) C o nnecting Rod G uide Set

2. J-1264 (0-2 00 F t. L b .) T orqu e W rench J-6305 (1 1 /3 2 ” )
J-8058 (0-50 F t. Lb .) 11. J-8062 Valve Spring Com pressor
J-5853 (0-100 in lb.) 12. J-8101 Valve G uide Cleaner
3. J-8087 In d ic a to r Set (C y lin d e r Bore) 13. J-5830 (1 1 /3 2 ” ) Valve G uide Reamer
4. J-8001 In d ic a to r Set (U niversal) Set
5. J-23600 Belt Tension Gauge J-7049 (3 /8 ” )
6. J-8037 Piston Ring Com pressor 14. J-8089 Carbon Rem oving Brush
7. J-8020 (3 -9 /1 6 ” ) Piston Ring E xpander 15. J-5860 C ylin d e r Head B o lt W rench
J-8021 (3 -7 /8 ” ) 16. J-5715 (.0 0 3 ” ) R ocker A rm S tud
J-8032 (4 ” ) Reamer
J-22249 (3 -1 5 /1 6 ” ) 17. J-6036 (.0 1 3 ” )
J-22 14 7 (4 -3 /3 2 ” ) J-6880 R ocker A rm S tud Installer
J-22 25 0 (4 -1 /4 ” ) 18. J-5802 R ocker A rm S tud Remover
8. J-6994 Piston Pin Assem bly T ool 19. J-9534 D is trib u to r L o w e r Bushing
9. J-9510 Piston Pin Assem bly T ool Remover

ENGINE 6-39
20. J-95 35 D istrib u to r Lower Bushing 28. J-58 25 C rankshaft Sprocket Puller
Installer 29. J -81 05 C rankshaft Gear Puller
21. J-2 2 1 4 4 Oil Pick-up Screen Installer 30. J-5 5 9 0 C rankshaft Sprocket or Gear
22. J-8 3 6 9 Oil Pick-up Screen Installer Installer
23. J-6 0 9 8 Cam Bearing Tool 31. J -2 3 0 4 2 Crankcase Cover Centering
24. J-097 1 Cam shaft Gear Support Gauge
25. J-2 3 5 2 3 Torsional Damper Puller 32. J -2 2 1 0 2 Crankcase Cover and Seal
26. J-2 2 1 9 7 Torsional Damper Installer Installer
27. J-1 6 1 9 C rankshaft S procket Puller

SECTION 6M
CARBURETORS
Introduction............................................................................6M-1 Rochester 4MV (Q uadrajet)........................................... 6M-27

Rochester M and MV (M onojet)................................. ....6M-1 Holley 41 5 0 ......................................................................... 6M-34
Rochester 2G and 2GV (SAE 1 1/4 and SAE 1 Special T o o ls...................................................................... 6M-43
1 /2 ) ............................................................................ ....6M-9
INTRODUCTION
(SEE R O C H E S T E R C A R B U R E T O R S ID E N T IFIC A T IO N , FIG. M1;
H O L L E Y C A R B U R E T O R S ID E N T IFIC A T IO N , FIG. S2)
Various carburetors, designed to meet the particular re a general overhaul, should be performed (if practical) with
quirem ents of engines, transm ission and vehicles, are used on the carburetor on the engine. Typical illustrations and proce
passenger vehicles and although carburetors may look alike dures are used except where specific illustrations or proce
they are not always interchangeable. Refer to carburetor part dures are necessary to clarify the operation.
num ber a n d /o r specifications.
This section, divided into sub-sections by carburetor
CAUTION: If the C.E.C. solenoid on the carburetor
model, covers the repair procedures for the various carburet
is used to set engine idle or is adjusted out of limits
ors, assembly and disassembly procedures and internal car
specified in the Service Manual, decrease in engine
buretor adjustm ent. A lthough illustrations showing bench
braking may result.
operations are used, most single operations, when not part of
ROCHESTER M AND MV (M ONOJET)

INDEX
General Description ..........................................................6M-1 Assembly and Adjustm ents .......................................... .. 6M-7

D isassem bly.......................................................................... 6 M-6 Throttle Body .......................................................... .. 6M-7
A ir H o r n ................................................................... .. 6 M-6 Float B ow l................................................................. 6M-7
Float B ow l................................................................. .. 6 M-6 Adjust Float Level ................................................. 6 M-8
T hrottle Body .......................................................... .. 6 M-6 Adjust M etering Rod ............................................ 6 M-8
Cleaning and In sp e c tio n ..........................................6M-7 Air H orn Assembly and In stalla tio n ................. 6M-9
GENERAL DESCRIPTION
The model MV (Fig. M2) carburetor used on the Chev enrichm ent system is used to provide good performance dur
rolet, 6 cylinder engine is a single bore, down draft unit using ing moderate to heavy acceleration and at higher engine
a triple venturi in conjunction with a plain tube nozzle. The speeds.
main venturi is 1 5/16" in diam eter and the throttle bore is
1 11/16". The idle system incorporates a ho. idle com pensator to
Fuel flow through the main m etering system is controlled m aintain smooth engine idle during periods of extreme hot
by a main well air bleed and a variable orifice jet. A power engine operation.

SHIFT IDENTIFICATION
I— A
Or
ASSEMBLY
— MODEL NO. PLANT CODE
OF YEAR
MODEL NO. _
I SHIFT
SHIFT I— IDENTIFICATION
IDENTIFICATION ASSEMBLY
PLANT CODE
ASSEMBLY
YEAR
PLANT CODE
YEAR
DAY OF YEAR
DAY OF THE YEAR
'M’ TYPE '2 G ’ TYPE '4M’ TYPE

CA R B U R ETO R IDENTIFICATIO N
Fig. M 1 -R o ch e ste r C arburetors Id e n tific a tio n
CARBURETOR 6M-3
The model MV carburetor has an autom atic choke system. screw will be pre-set at the factory and capped, and no fur
The vacuum diaphragm unit is an integral part of the air ther adjustm ent should be required except during the clean
horn. The choke coil is m ounted on the manifold and is ing &nd overhaul.
connected to the choke valve shaft by a rod. An overhaul idle m ixture adjustm ent procedure will be
An internal fuel inlet filter is m ounted in the fuel bowl provided, should the idle m ixture needle need replacement or
behind the fuel inlet nut to give m aximum filtration of incom the m ixture channels cleaned during the overhaul process. A
ing fuel. new idle m ixture needle limiter cap will be provided in the
O ther features of the model MV include an alum inum overhaul kit.
throttle body and a thick throttle body to bowl insulator
gasket. The carburetor has internally balanced venting
through a vent hole in the air horn which leads from the float
DISASSEMBLY OF CARBURETOR
bowl into the bore beneath the air cleaner. The float bowl is
Removal of C.E.C. Valve Assembly
externally vented through a pressure relief valve system
which allows vapors to be vented during hot engine operat 1. Remove vacuum hose from the C.E.C. valve and timed
ion. spark tube.
The carburetor part num ber is stam ped on a vertical sec 2. Bend back retaining tabs on lock washer; then remove
tion of the float bowl, next to the fuel inlet nut. W hen replac large C.E.C. valve nut and remove valve from bracket.
ing the float bowl assembly, follow the m anufacturer’s
instructions contained in the service package so that the part
num ber can be transferred to the new float bowl. NOTE: Do not remove C.E.C. valve bracket from the
float bowl assembly unless replacement of the
The idle stop solenoid has been replaced by a combination bracket is necessary. Complete replacement in
emission control valve (C.E.C. valve). The valve, when ener structions are included in the replacement bracket
gized through the transmission, acts as a throttle stop by
kit.
increasing idle speed during high gear operation of the engine
which helps in controlling overrun hydrocarbons during de
CAUTION: Do not immerse the C.E.C. valve assem
celeration. The C.E.C. valve also provides full spark vacuum
bly in any type of carburetor cleaner.
advance during high gear operation and is de-energized in the
lower gears and at idle, for retarded spark timing during this
period. N orm al idle speed setting will be made with the idle Air Horn Removal
stop screw.
The idle m ixture screw will have a lim iter cap installed and 1. Remove the fast idle cam attaching screw. Then remove
no adjustm ent will be provided on the vehicle. The mixture the fast idle cam from choke rod at lower end by rotat-
CHOKE VACUUM BREAK CHOKE LEVER
C.E.C. SOLENOID
VACUUM TUBE
FAST IDLE ROD
FUEL INLET
AND FILTER
FUEL BOWL
PUMP LEVER
THERMAC
C.E.C. SOLENOID (VALVE)
TUBE
IDLE MIXTURE LIMITER CAP AND

THROTTLE LEVER
NEEDLE
Fig. M2~Rochester M onojet C arburetor

6M-4 CARBURETOR
\ .TOP IDLE AIR BLEED
IDLE CHANNEL
RESTRICTION
AIR INLET
IDLE TUBE
BI-METAL
STRIP ~~
VALVE -
GASKET-
HOT IDLE
COMPENSATOR
THROTTLE VALVE
IDLE SYSTEM FLOAT SYSTEM
MAIN DISCHARGE
NOZZLE
METERING
ROD
BOOST VENTURI I ,POWER PISTON

MAIN VENTUR SPRING ■POWER PISTON
MAIN FUEL WELL SPRING
MAIN METERING
JET MAIN METERING
JET
METERING ROD AND
METERING ROD AND POWER PISTON
POWER PISTON ACTUATING LINKAGE
ACTUATING LINKAGE
^ POWER PISTON VACUUM
THROTTLE VALVE
t
POWER
PISTON
VACUUM
POWER ENRICHMENT SYSTEM
MAIN METERING SYSTEM
CHOKE VALVE
PUMP LEVER
VACUUM BREAK
DIAPHRAGM
DURATION SPRING
PUMP FILL SUDT
PUMP CUP
PUMP RETURN SPRING
PUMP
DISCHARGE
BALL
t
PUMP
ACTUATING
LINK
THERMOSTATIC
COIL — LINKAGE
PUMP CUP
PUMP SYSTEM o p e ra tio n
Fig. M 3--M onojet Fuel Systems

CARBURETOR 6M-5
Fig. M 4--T ypical M o n o je t-E x p lo d e d V ie w (See N e x t Page fo r Legend)

6M-6 CARBURETOR
Legend for Fig. M4.

1. A ir Horn Assem bly 15. S crew -C over 29. Idle Com pensator 43. S cre w -S lo w Idle
2. Screw --Air H orn-Long 16. Choke Rod Assem bly 44. Pump Assem bly
3. S c re w -A ir Horn-Short 17. Choke Lever 30. G asket-Idle 45. Lever-Pum p
4. B ra c k e t-A ir Cleaner 18. S crew -C hoke Lever C om pensator A ctua tin g
Stud 19. C am -Fast Idle 31. C over-Idle 46. S pring-P u m p Return
5. S cre w -B ra cke t 20. S crew -C am C om pensator 47. T hrottle Body
A ttaching A tta chin g 32. S crew -C over Assem bly
7. G a ske t-A ir Horn 21. Float Bowl Assembly 33. Float Assembly 48. G aske t-T hro ttle Body
8. Choke S haft and 22. Idle Tube Assembly 34. Hinge P in-F loat 49. Idle Needle
Lever Assem bly 23. J e t-M a in M etering 35. Power Piston 50. S p rin g -Id le Needle
9. Choke Valve 24. B all-P um p Discharge Assem bly 51. S cre w -T h ro ttle Body
10. S crew -C hoke Valve 25. S pring-P u m p 36. S prin g -P o w e r Piston 52. Lever-Pum p and
11. Lever-Vacuum Break Discharge 37. R od-P ow er Piston Power R ods-New
Link 26. G uide-Pum p 38. M etering Rod and 53. S crew -Lever
12. Vacuum Break Link Discharge Spring Assem bly A ttaching
Assem bly 27. Needle and Seat 39. Filter N ut-F uel Inlet 54. Lin k-P o w e r Piston
13. D iaphragm -V acuum Assem bly 40. G aske t-F ilter Nut Rod
Break 28. G asket-N eedle Seat 41. FiIter—Fuel Inlet 55. Link-P um p Lever
14. C over-V acuum Break 42. S pring-F ue l Filter
ing over squirt on rod and from upper lever by rotating 4. Remove fuel inlet nut, gasket, paper filter element and
rod out of slot in lever. N ote position of rod and cam pressure relief spring.
for ease in reassembly. 5. Using long nosed pliers, remove "T" pum p discharge
2. Rem ove six air horn to float bowl attaching screws. spring retainer. Pum p discharge spring and ball may be
3. Remove air horn by lifting straight up. Invert air horn removed by inverting bowl.
and place on clean bench. A ir horn to bowl gasket can 6. The idle tube can be removed at same time by inverting
rem ain on bowl for removal later. bowl.
7. To remove accelerating pump plunger and metering
rod -p o w er piston drive assemblies, perform following
Air Horn Disassembly operation:
1. Remove two vacuum break diaphragm cover screws. a. Remove actuating lever on throttle shaft by remov
Then carefully remove diaphragm cover. ing attaching screw at end of shaft.
2. To remove vacuum break diaphragm and plunger rod, b. Remove upper end of drive link from power piston
hold choke valve wide open. Then push upw ard on rod.
eyelet on choke valve at a 45 degree angle until the c. R otate drive link from keyhole in actuating lever.
looped end of rod slides off wire lever attached to the d. Remove actuating lever from pum p link by rotating
choke valve. Then remove diaphragm and plunger rod off tang on rod.
assembly through the hole in air horn. (Figure M4). e. Remove upper end of pum p link by rotating from
3. If desired, the choke valve, vacuum break lever, and keyhole in pump slide.
choke shaft can be removed from air horn by first 8. The power piston—metering rod assembly and drive rod
removing the therm ostatic coil lever from the end of can now be lifted from float bowl.
choke shaft, by removing the attaching screw. After 9. Remove power piston spring from power piston cavity.
removing the therm ostatic coil lever, remove the two
choke valve attaching screws; then remove the choke 10. Remove pum p plunger assembly from float bowl.
valve and choke shaft from air horn. 11. Remove pum p return spring from pum p well.
12. Remove main metering jet from bottom of fuel bowl.
NOTE: The choke valve screws are held in place by 13. Remove two screws from idle com pensator cover. Then
lock-tite so it will be necessary to re-stake after as remove cover, hot idle com pensator and gasket from
sembly. recess in bowl beneath compensator.
14. Idle adjustm ent screw and fast idle cam can be removed
at this time if desired. No further disassembly of the
float bowl is required.
Float Bowl Disassembly
1. Remove air horn to float bowl gasket. G asket is slit next Throttle Body Removal and Disassembly
to m etering rod hanger so that it can be easily removed.
1. Invert carburetor bowl on bench and remove two th ro t
2. Remove float assembly from float bowl by lifting up tle body to bowl attaching screws. Throttle body and
ward on float hinge pin. Remove hinge pin from float insulator gasket may now be removed from float bowl.
arm.
3. Remove float needle, float needle seat and gasket. Use NOTE: Do not tamper with the idle mixture needle
caution in removing needle seat to prevent damage. with a limiter cap unless performing an overhaul or

CARBURETOR 6M-7
due to needle damage. This has been set to test re 8. Check throttle and choke levers and valves for binds
quirements by the manufacturer. and other damage.
9. Replace filter element.
10. Check all springs for distortion or loss in tension, re
place as necessary.
2. N o fu rth e r disassem bly o f the th ro ttle b o d y is nec
e ssa ry u n le ss th e id le m ix tu re n e e d le is d a m a g e d
o r th e id le ch a n n e ls n eed cleaning. I f n e cessary to CARBURETOR ASSEMBLY
re m o v e th e idle m ix tu re needle, d e stro y plastic
Throttle Body Assembly
lim ite r c a p as a n ew o n e is p ro v id e d in th e o v e r
haul kit. New Part Replacement
If a new throttle body is being replaced, install and bottom
the new idle m ixture needle and back off four turns. Do not
IMPORTANT: If CO Reading equipment is not avail install plastic lim iter cap at this time until proper screw
able, before removing idle mixture needle, be certain settings have been made.
to count number of turns to bottom the old idle mix A fter completing assembly of the carburetor, and when
ture needle. This is required so that when it is neces installed in the vehicle, adjust the mixture screw to achieve
sary to install a new needle, you may bottom the the required percent of "CO" in the exhaust gas (see Service
new needle and then back off the same number of M anual under, "A dditional External Settings and A djust
turns it took to bottom the old needle. m ents") -which is the recommended method; however, if
equipment for a "CO" reading is not available, you may set
3. R em o v e th e idle m ix tu re n eed le a n d spring, if the idle speed and idle m ixture settings as outlined also under
req u ired . "A dditional External Settings and A djustm ents".
1. If removed, install idle m ixture needle and spring until
lightly seated. Back out four turns as a prelim inary idle
adjustment.
NOTE: The plastic limiter cap should not be installed

NOTE: Due to the close tolerance fit of throttle on the idle mixture needle until the idle mixture has
valve in the bore of the throttle body, do not remove been adjusted, as specified, on the engine.
the valve or shaft.
NOTE: A new red plastic idle mixture needle limiter

cap is provided in the carburetor repair kit and also
Cleaning and inspection in the idle mixture needle and limiter cap kit. This
The carburetor should be cleaned in a cold immersion cap must be installed after the idle mixture needle
type cleaner. has been set on engine by the CO reading (see
1. Thoroughly clean carburetor castings and metal parts Specifications), or another method may be used, by
in an approved carburetor cleaner. backing off the new mixture needle the same num
ber of turns, after bottoming, as was required to
CAUTION: Any rubber parts, plastic parts, dia bottom the original needle which was pre-set and
phragms, pump plunger, electric parts and solenoids sealed by the manufacturer before it left the factory.
should not be immersed in carburetor cleaner. How (See"Note" in disassembly procedures).
ever, the air horn which was the pressure relief
valve will withstand normal cleaning in carburetor
cleaner. Make sure the cleaning solution is 2. Invert float bowl and install new throttle body to bowl
thoroughly removed from pressure relief valve area. insulator gasket.
3. Install throttle body on bowl gasket so that all holes in
throttle body are aligned with holes in gasket.
2. Blow out all passages in castings with compressed air. 4. Install two throttle body to bowl attaching screws.
D o not pass drills through jets or passages. Tighten evenly and securely (12 to 15 foot lbs. of
3. Inspect idle m ixture needle for damage. torque). The throttle body to bowl screws do not use
4. Examine float needle and seat assembly for wear. Install lock washers as they have an interference fit designed
a new factory m atched set if worn. into the thread for holding proper torque.
5. Inspect upper and lower casting sealing surfaces for
damage. Float Bowl Assem bly
6. Inspect holes in levers for excessive wear or out of
round condition. If levers or rods are worn they should 1. Install fast idle cam to boss on float bowl, attaching
be replaced. with fast idle cam screw. Tighten securely. Part number
7. Examine fast idle cam for excessive wear or damage. on cam faces outward.

6M-8 CARBURETOR
2. Install idle adjustm ent screw, if removed. 15. Install float needle seat and gasket. Tighten securely
3. Install gasket into recess in idle com pensator cavity in and carefully to avoid damage to seat.
float bowl, then install idle com pensator assembly. 16. Install float needle valve into needle seat.
4. Install idle com pensator cover, with (2) attaching 17. Insert straight portion of float hinge pin into float arm.
screws. Tighten securely. Install float and hinge pin into float bowl.
5. Install pum p return spring into pum p well. Make sure
spring is properly seated in bottom of well.
6. Install pump plunger assembly into pum p well with Float Level Adjustment (Fig. M5)
slide protruding through bottom of bowl casting. Push 1. Hold float retainer firmly in place and push down on
dow nw ard on pum p slide and install pum p drive link float arm at outer end.
into hole in lower end of shaft. Ends of drive link point 2. W ith adjustable T -scale, measure distance from top of
tow ards carburetor bore. Tang on upper end of link float at index point on toe, to float bowl gasket surface
retains link to pum p slide. (gasket removed).
Install power piston and pum p actuating lever to lower 3. Bend float pontoon up or down at float arm junction to
end of link. Projection on this lever points downward. adjust.
Install power piston spring into power piston cavity.
Install end of power piston actuating rod into groove on
side of power piston. Then install power piston m eter Metering Rod Adjustment (Fig. M6)
ing rod assembly and actuating rod into float bowl. End 1. To check adjustm ent back out idle adjusting screw to
of metering rod must enter jet orifice. ensure closed throttle valve. R otate fast idle cam so that
10. Install drive link into keyhole in actuating lever. fast idle cam follower is not contacting steps on cam.
11. Hold complete assembly dow nard in bowl, then install 2. W ith throttle valve completely closed, apply pressure to
upper end of power piston drive link into hole in lower hanger directly above power piston and hold piston
end of power piston actuating rod. Align "D" hole in down against its stop.
actuating lever with flats on throttle shaft and install 3. Holding downward pressure on power piston, swing
lever on end of throttle shaft. Install retaining screw in metering rod holder over flat surface of bowl casting
end of throttle shaft and tighten securely. until metering rod rests lightly against inside edge of
bowl.
NOTE: Before installing air horn, check operation of 4. Use specified plug gauge and insert between bowl cast
entire drive mechanism, metering rod and accelera ing and lower surface of metering rod holder against
tor pump to ensure free operation from closed to metering rod. Gauge should have a slide fit between
wide open throttle. both surfaces, as shown.
5. To adjust, carefully bend metering rod holder up or
12. Install idle tube into cavity in float bowl. down at point shown.
13. Install pump discharge ball, spring and spring retainer.
M ake sure spring retainer is flush with top of bowl
casting.
14. Install fuel filter relief spring, fuel inlet filter, filter nut
and gasket. Tighten securely. Open end of filter should
face hole in fuel inlet nut.
BEND HERE
GAUGE FROM TOP OF
CASTING TO TOP OF SEE
INDEX POINT AT TOE SPECIFICATIONS
OF FLOAT
HOLD FLOAT RETAINING

PIN FIRMLY IN PLACE -
PUSH DOWN ON END OF
FLOAT ARM, AGAINST
BEND HERE TO
ADJUST FLOAT TOP OF FLOAT NEEDLE
UP OR DOWN
Fig. M 5--Float Level A djustm en t Fig. M 6--M etering Rod A djustm en t

CARBURETOR 6M-9
of plunger rod over end of vacuum break lever on the

choke valve shaft.
3. Seat vacuum break diaphragm over sealing bead on air
horn casting. W ith diaphragm held in place, carefully
install diaphragm cover and two retaining screws.
Tighten screws securely.
4. Install air horn to float bowl by lowering gently onto
float bowl until seated. Install three long and three
short air horn to float bowl attaching screws. Tighten
securely using tightening sequence. (Figure M7).
5. Assemble choke rod into the slot in the upper choke
lever. End of rod points away from air horn casting
when installed properly. (Figure M7).
6. Install fast idle cam to lower end of choke rod by rotat
ing until slot in fast idle cam slides over tang on rod.
Steps on the fast idle cam should face tang on throttle
lever. Install fast idle cam screw. Tighten securely.
7. Install C.E.C. valve into bracket on float bowl. Install
large retaining nut and tighten securely. Then, bend
retaining ears over on flats of nut so that the nut is
locked securely in place.
8. Install vacuum hose to tube on float bowl and to outer
tube on the C.E.C. valve.
Fig. M 7~T ightening Sequence--Air Horn NOTE: Refer to the adjustment chart for the remain
ing adjustments; adjustments must be performed in
the sequence shown. Slow and fast idle RPM
6. Install air horn gasket on float bowl by carefully sliding specifications are also shown on the chart.
slit portion of gasket over metering rod holder. Then
align gasket with dowels provided on top of bowl cast
ing and press gasket firmly in place.
IM PORTANT: After carburetor overhaul, throttle

Air Horn Assembly body part replacem ent, mixture needle part
1. Install choke shaft, choke valve and vacuum break replacement, or limiter cap and needle rem oval,
lever, if removed. Align choke valve, tighten two retain
ing screws and stake securely.
the procedures in Section 6M, 1971 Chassis
2. Install vacuum break diaphragm and plunger into Service M anual, under “ A d d ition al External
cavity at side of air horn. W ith choke valve in the open Settings and Adjustm ents,” must be followed.
position, hold eyelet tang at 45 degree angle. Slide eyelet
ROCHESTER 2G AND 2 G V (SAE W * AND SAE l 1

/ :)
INDEX
General Description ........................................................6M-9 Rochester 2G and 2GV (SAE 1 1/2") Repair

Rochester 2GV (SAE 1 1/4") Repair Procedures .. 6M-14 Procedures ............................................................. 6M-20
GENERAL DESCRIPTION
The Rochester Models 2G and 2GV carburetors (fig. G1 These are two barrel carburetors with two venturi and a
and G2) are used in conjunction with a tem perature sensing separate fuel feed for each. All fuel metering is centerally
choke coil (m ounted on the intake manifold over the exhaust located so that each system will give instantaneous response
crossover passage). for maximum efficiency and performance.

6M-10 CARBURETOR
The removable venturi cluster contains the main nozzles, On air conditioned passenger cars and trucks with auto
idle tubes, m ixture passages, air bleeds and pum p jets. The matic transmission the carburetor contains a hot idle com
main nozzles and idle tubes are suspended in the main wells pensator (fig. G3). The hot idle com pensator consisting of a
of the float bowl which helps insulate them from engine heat bi-metal strip, a valve and a m ounting bracket located in a
and to minimize percolation spill over during hot engine cavity at the rear of the carburetor bowl is a therm ostatically
operation (fig. G4 and G5). controlled air bleed, which supplies additional air to the idle
m ixture during prolonged hot idle periods.
C H O K E K IC K LEVER C H O K E LEVER FUEL INLET N U T
C H O K E V A C U U M BREAK
PUMP LEVER
PUMP R O D
C .E.C. S O L E N O ID
(VALVE)
DISTRIBUTOR
IDLE SPEED V A C U U M TUBE
SCREW
THERMAC TUBE
FAST IDLE C A M
IDLE MIXTURE LIM ITER C A P A N D NEEDLE
THROTTLE LEVER
Fig. G1~Rochester 2GV (SAE 1 1/4) C arburetor
FUEL INLET FUEL INLET

CHOKE VACUUM A IR H O R N N U T A N D FILTER
BREAK
\
CHOKE
VACUUM
PUMP BREAK
LEVER
PUMP R O D
DISTRIBUTOR
IDLE SPEED VACUUM
SC R E W
TH E R M A C
TUBE
IDLE M IXTURE LIMITER

C.E.C. S O L E N O ID
C A P A N D NEEDLE
(VALVE) THROTTLE LEVER
Fig. G2--Rochester 2G (1 1/2) C arburetor

CARBURETOR 6M-11
IDLE AIR B LEEDS IDLE RESTRICTION a p u m p cup g a rter spring to m a in ta in c o n s ta n t

p u m p cup to p u m p w all co ntact. T he p u m p cup is
th e se lf-v e n tin g “ flo a tin g ” ty p e. A n ew d u r a tio n
sp rin g a n d p u m p re tu rn sp rin g are u se d w ith th e
new pum p.
10. On the 1 1/4" and 1 1/2" 2GV model carburetors
(except 1 1/ 2 " truck), the throttle closing solenoid has
been replaced by a Combination Emission Control
Valve (C.E.C. Valve). The C.E.C. valve with bracket is
m ounted on the carburetor float bowl. The valve, when
energized through the transmission, acts as a throttle
stop by increasing idle speed of the engine during high
gear operation to help in controlling overrun hydrocar
bons during deceleration. Further, the C.E.C. valve
controls distributor vacuum spark advance by provid
Fig.G3--Hot Idle Com pensator
ing full spark vacuum advance during transmission
high gear operation, and retarded spark timing during
The Rochester models 2G and 2GV carburetors are used operation in the transmission lower gears and at idle.
in two different sizes for Chevrolet engines. The SAE 1 1/4" N orm al idle speed setting is made with the idle stop
model is used on the 307" (light duty) V -8 engine. The SAE screw. Idle speed settings should be made using emis
1 1/2" model is used on the 307" Heavy D uty and the larger sion control inform ation on the label located in the
350" and 400" V -8 engines for increased air capacity. engine com partm ent.
The Model 2G and 2GV carburetors have the following 11. Idle m ixture needle limiters are installed on all 2G and
changes for 1971: 2GV model carburetors except 1 1/2" truck. The cor
1. C alibration for 1971 engines. rect engine idle m ixture will be set to a calibration at the
2. New choke shaft lever with increased off-set for remove factory for each engine application. Then, a plastic cap
choke link on 2GV V -8 models. is installed over the head of the m ixture needle. No
3. D am added to air horn on 1 1/4" truck models to adjustm ent will be provided on the vehicle. If the limiter
reduce fuel slosh and improve vapor handling. cap, idle needle and spring are removed for cleaning and
4. Two stage power valve to provide additional fuel at inspection, follow the car m anufacturer’s specifications
wide-open throttle on 1 1/ 2 " truck models. for the idle m ixture adjustment. Service replacement
5. Tim ed ported vacuum on all 2GV models to operate idle m ixture needle lim iter caps will be colored red to
purge valve on the vapor canister. indicate a field replacem ent has been made.
6 . Seven short air horn screws changed to self-locking 12. All 2GV models have no provision for transfer of ex
thread type for im proved torque retention. haust manifold heat to the carburetor through a heat
7. External carburetor venting has been eliminated from passage in the throttle body.
all passenger and 1 1/4" truck applications to meet O n 2 G V m o d e ls u sin g th e C .E .C . valve, a 3 /1 6 "
1971 State and Federal requirem ents for Evaporative tu b e h as b een a d d e d to th e th ro ttle b o d y b e tw e en
Emissions. Similar to 1970 California 2GV models, va th e id le need les. T h is su p p lie s v a c u u m to th e
por vent holes, vented throttle body gaskets (where C .E .C . valve fo r full d is trib u to r v a c u u m a d v a n c e
used), and idle vent valves have been eliminated (except d u rin g h ig h g ea r o p e ra tio n . T h e th ro ttle b o d y
on 20 and 30 Series). The float bowl is internally vented castin g has b e e n revised to p ro v id e e x te n d e d p a s
by a large hole or tube which leads from inside air horn sages fo r tra c k in g c ra n k c a se v a p o rs to th e in ta k e
bore to the top of the fuel in the float bowl. The carbu m a n ifo ld fro m th e P o sitiv e C ra n k c a se V e n tila to r
retor is internally balanced through the internal vent so V alve (P .C .V .). A lso, a 1 /4 " p ip e ta p is in c lu d e d
that the same pressure causing air to flow will be acting at th e r e a r o f th e th r o ttle b o d y o n all p a s s e n g e r
upon the top of the fuel in the float bowl causing the ca r 2G V m o d els as a n a cce sso ry v a c u u m so u rc e.
correct fuel to flow. 13. The choke system is changed on 2GV V - 8 models in
8 . A su p p le m e n ta ry fuel feed passag e, called A d ju st that a delayed vacuum break system is used. The system
ab le P a rt T h ro ttle (A .P.T .) is lo c a te d in th e b o tto m operates as follows: W hen the engine is started, vacuum
o f th e flo a t bow l, n e x t to th e m a in m e te rin g je ts, is applied to the choke vacuum diaphragm which opens
o n all 2 G a n d 2G V m odels. F u e l passes dow n the choke valve, against the choke coil tension, to a
th ro u g h th is p assag e, p a s t a c a lib ra tio n screw , o n point where the engine will run without loading or
in to th e p o w e r v alve cav ity a n d th e n p asses on stalling lean. To delay the choke valve from opening too
in to th e m a in fuel w ells to s u p p le m e n t th e fuel fast, an internal check valve is used in the choke
p assin g th ro u g h the c a lib ra te d m a in m e terin g je ts. vacuum diaphragm unit. A fter the engine starts,
T h e c a lib ra tio n screw , lo c a te d in th e s u p p le m e n vacuum is applied through the check valve to the
ta ry fuel feed p assag e, is fa c to ry a d ju ste d a n d vacuum break diaphragm causing the vacuum break
s h o u ld n o t be re a d ju s te d in th e field. diaphragm plunger to move slowly inward. This gives
9. A new g a rte r sp rin g a c c e le ra to r p u m p is u se d o n sufficient time to overcome engine friction and allow
1 W 2G V m o d el c a rb u re to rs. T h e n ew p u m p uses the engine manifold to be wetted to prevent a lean stall.

6M-12 CARBURETOR
ID L E AIR B L E E D S F IL T E R IM TCDM A,
G A S K E T S F |L T E R R E L IE F J mt L
ID L E
R E S T R IC T IO N
O F F ID LE
D ISC H A R G E P O R T S
FLO A T N E E D LE
FLO A T
N EED LE
ID LE D ISC H A R G E H O LE
IDLE S Y S T E M FLOAT SYSTEM
PISTON VACUUM
CHAM BER
M IX T U R E PA SSA G E
MAIN NOZZLE POWER PISTON
BO O ST VEN TURI
MAIN VENTURI
MAIN W E L L T U B E POW ER PISTON
S PRIN G
MAIN W E LL IN S E R T ■THROTTLE VALVE
POW ER VALVE
MAIN METERING
JE T
POWER R ES T R IC T IO N S
M A I N M E TE R IN G S Y S TE M
MAIN W E LL
PO W ER S Y S T E M
CHOKE VALVE
VACUUM
DIAPHRAGM UNIT
DIAPHRAGM
PUMP DISCHARGE
CHECK B A L L
PUMP DISCHARGE
PA SSA G E
PUMP
R ETU R N SPRING
CHOKE
PUMP S Y S T E M SYSTEM
Fig. G4--Rochester 2GV (SAE 1 1/4) Systems

CARBURETOR 6M-13
ID LE
ESTRICTION
ID LE
PASSAGE -
IDLE
TUBE ""
MAIN _
M ETERING
JET S
IDLE
M IXTURE
N E E D LE
FLOAT SYSTEM
IDLE SYSTEM
M ANIFOLD
PISTON VACUUM .VACUUM
CHAMBER VACUUM R E L I E F
PA SSAG E
POWER PISTON
POWER PISTON
SPRING
POWER VALVE
POWER RESTRICTIONS
MAIN METERING SYSTEM

POWER SYSTEM
RETAINER 8 SPRING
PUMP DISCHARGE
CHECK B A LL
PUMP DISCHARGE
PASSAGE
PUMP
R ETU RN SPRING
PUMP SY S T E M
Fig. G 5-R ochester 2G and 2GV (SAE 1 1/2) Systems

6M-14 CARBURETOR
W h en th e v a c u u m b reak d ia p h ra g m is fully seated, sp rin g assists in closing th e ch o k e valve, a lo n g

th e c h o k e v alv e w ill re m a in in th e v a c u u m b re a k w ith te n sio n fro m the re m o te ch o k e th e rm o s ta tic
p o s itio n u n til th e e n g in e b e g in s to w a rm u p a n d coil, fo r im p ro v ed cold starting. T h e c h o k e closing
the e x h a u s t h e a t w arm s th e R e m o te C h o k e T h e r assist sp rin g o n ly e x e rts p re ssu re on th e v a c u u m
m o s ta tic C o il. T h e e x h a u s t h e a t th e n b e g in s to b re a k lin k to assist in closing th e ch oke valve
relax th e te n sio n o f th e choke coil. T his allow s the d u rin g engine starting.
c h o k e v a lv e to o p e n g ra d u a lly th r o u g h a ir flo w W h e n th e e n g in e s ta rts a n d th e c h o k e v a c u u m
a g a in st th e o ff-set ch o k e valve, u n til th e en g in e is b re a k d ia p h ra g m seats, th e closing sp rin g re ta in e r
w arm a n d th e ch o k e valve is fully open. h its a sto p o n th e p lu n g e r stem a n d n o lo n g e r
A c h o k e c lo sin g a ssist s p rin g h a s b e e n a d d e d to exerts p ressu re on th e v acu u m b re a k link.
th e v a c u u m b re a k d ia p h ra g m p lu n g e r ste m . T h e
ROCHESTER 2GV (SAE 1 1 / 4 )

REPAIR PROCEDURES
INDEX
D isassem bly........................................................................6M-14 Assemble Bowl and T hrottle Body ................... 6M-17
Air H orn ................................................................... 6M-14 Assemble A ir H o rn .................................................6M-18
Bowl and T hrottle B o d y ........................................6M-16 Adjust F loat.............................................................. 6M-18
Cleaning and In sp ectio n .................................................6M-17 Assemble Air H orn to Bowl.................................6M-19
Assembly and A d ju stm e n t............................................ 6M-17 Adjust Accelerator Pump R o d ............................ 6M-20
D IS A S S E M B L Y link from the diaphragm plunger. The compression

spring need not be removed from the diaphragm
Removal of the Combination Emission plunger stem.
Control (C.E.C.) Valve Assembly 2 Disconnect vacuum break diaphragm hose from tube
on throttle body, then remove vacuum break dia
1. Remove vacuum hose from the C.E.C. valve (Fig. G 6 ) phragm from air horn by removing two retaining
and vacuum supply tube located between two m ixture screws.
screws on throttle body. Place carburetor on a clean bench, being careful not to
2. Bend back retaining tabs on lock washers; then remove damage throttle valves. Then remove the fuel inlet filter
large C.E.C. valve nut and remove C.E.C. valve from nut, filter, spring and two gaskets.
bracket. 4. Remove pum p rod retaining clip from the throttle lever
end of rod, and remove rod from throttle lever. Rotate
NOTE: Do not remove C.E.C. valve bracket from the upper pum p lever counterclockwise, then remove the
float bowl assembly unless replacement of the pum p rod from the pum p lever by aligning squirt on rod
bracket is necessary. Complete replacement in with notch in lever.
structions are included in the replacement bracket 5. Using a wide bladed screwdriver, remove the fast idle
kit. cam attaching screw rotate cam and remove from rod.
6. Hold choke valve wide open, then rotate the upper end
CAUTION: Do not immerse the C.E.C. valve assem of choke rod towards pum p lever and remove the rod
bly in any type of carburetor cleaner. from upper choke lever.
Remove ( 8) air horn to float bowl attaching screws, tap
Disassemble Air Horn (Fig. G7)
air horn lightly to loosen from bowl and lift air horn
1. Remove choke coil lever retaining screw from the end from bowl.
of choke shaft and disengage choke lever from vacuum In v e rt air h o rn an d rem ove flo at h inge pin, float,
break diaphragm link. Then remove the vacuum break an d float needle.
1. Pump Rod 7. Power Piston 13. A ir Horn 20. Diaphragm Link

2. Pump Outer Lever 8. A ir Horn to Bowl 14. Vacuum Diaphragm 21. Float Needle and
3. W asher Gasket 15. Choke Lever Seat a
4. A ccelerator Pump 9. Choke Valve 16. Fuel Inlet Nut 22. Float Hinge Pin |
5. Pump Inner Lever 10. Choke Shaft 17. Gaskets 23. Splash Shields
6. Pump Inner Lever 11. Choke Rod 18. Fuel Filter 24. Float
Retainer 12. Choke Kick Lever 19. Filter Spring

CARBURETOR 6M-15
TO VACUUM
ADVANCE ON
DISTRIBUTOR
ELECTRICAL
CONNECTIONS
C.E.C. VALVE
COMBINED EMISSION CONTROL VALVE
Fig. G6-C.E.C. Valve (com bined Emission Control valve)
Fig. G 7 -A ir H orn-Exploded View

6M-16 CARBURETOR
Fig. G 8 -B o w l and T hrottle B ody-E xploded V iew
1. Cluster Assembly 5. Main Jets 10. Pump Discharge

2. Gasket 6. A ir Horn Gasket Check Assem bly
3. Splash S h ield -M ain 7. Bowl Assembly 1 1. A ccelerator Pump
W ell 8. T hrottle Body to Bowl Spring
4. Power Valve Gasket 12. Fast Idle Cam
Assem bly 9. T hrottle Body 13. Idle M ixture Screws
Assem bly 14. Choke Rod
9. Using a wide bladed screwdriver, remove the float nee NOTE: The center cluster screw has a fiber washer
dle seat and gasket. and the two outer screws have lock washers. Also,
10. Remove air horn to float bowl gasket. the center screw is not threaded the full length of
11. Remove power piston by depressing shaft and allowing the body. The smaller diameter is required for pump
spring to snap sharply -thus forcing piston from casting. jet discharge.
12. Remove retaining screw from the inner pum p lever and
remove outer pum p lever and plastic washer from air
horn. Place plunger in gasoline or kerosene to prevent 4. Using a pair of long nose pliers, remove the pum p dis
rubber from drying out. charge spring retainer. Then remove the spring and
13. If the choke shaft or valve need replacement, remove check ball from the pump discharge cavity.
two choke valve screws, then remove choke valve and 5. Invert carburetor and remove three large throttle body
slide shaft and lever from air horn. to bowl attaching screws. T hrottle body and gasket may
now be removed.
NOTE: The two choke valve screws are staked in
place, remove the staking before removing screws NOTE: Do not tamper with the idle mixture needles
with limiter caps unless performing an overhaul or
due to needle damage. This has been set to test re
quirements by the manufacturer.
Disassemble Bowl and Throttle Body
6. F urther disassembly of the throttle body is not recom
(Figure G8)
mended. If parts are damaged, replace the throttle body
1. Remove pump plunger return spring from pump well. assembly. The idle mixture needles have plastic limiter
caps installed. They should not be removed unless it is
2. Remove main m etering jets and power valve and gas necessary to replace the m ixture needles or clean the
kets. idle m ixture channels. If removal is necessary, new li
3. Remove three screws on top of cluster; then remove the m iter caps are provided in the repair kits. They should
cluster and gasket from the float bowl. not be installed until after the idle m ixture has been

CARBURETOR 6M-17
adjusted on the engine per instructions provided in the CAUTION: Do not force the idle mixture needle
service manual. against the seat or damage will result.
IMPORTANT: If CO Reading equipment is not avail New Part Replacement

able, before removing idle mixture needle, be certain
to count number of turns to bottom this old idle mix If a new throttle body is being replaced, install and bottom
ture needle. This is required so that when it is neces the new idle m ixture needle and back off four turns. Do not
sary to install a new needle, you may bottom the install plastic lim iter cap at this time until proper screw
new needle and then back off the same number of settings have been made.
turns it took to bottom the old needle. After completing assembly of the carburetor, and when
installed in the vehicle, adjust the m ixture screw to achieve
7. Remove idle mixture needle and spring, if required. the required percent of "CO" in the exhaust gas (see Service
M anual under, "A dditional External Settings and A djust
m ents") - which is the recommended method; however, if
Cleaning and Inspection equipment for a "CO" reading is not available, you may set
the idle speed and idle m ixture settings as outlined also under
The carburetor should be cleaned in a cold immersion "A dditional External Settings and Adjustm ents".
type cleaner. 2. Invert bowl, place new throttle body gasket in position
1. Thoroughly clean carburetor castings and metal parts aligning holes in gasket with holes in the float bowl, and
in an approved carburetor cleaner. attached throttle body to bowl with the attaching
screws. Tighten screws evenly and securely.
CAUTION: Any rubber parts, plastic parts, dia
phragms, pump plunger, electric parts and solenoids NOTE: A new red plastic idle mixture needle limiter
should not be immersed in carburetor cleaner. How cap is provided in the carburetor repair kit and also
ever, the air horn which has the pressure relief valve in the idle mixture needle and limiter cap kit. This
will withstand normal darning in carburetor cap must be installed after the idle mixture needle
cleaner. Make sure the cleaning solution is has been set on engine by the CO reading (see
thoroughly removed from pressure relief valve area. Specifications), or another method may be used, by
backing off the new mixture needle the same num
ber of turns after bottoming, as was required to bot
2. Blow out all passages in castings with compressed air. tom the original needle which was pre-set and
D o not pass drills through jets or passages. sealed by the manufacturer before it left the factory.
3. Inspect idle m ixture needle for damage. (See Note in disassembly procedures).
4. Examine float needle and seat assembly for wear. Install
a new factory m atched set if worn.
5. Inspect upper and lower casting sealing surfaces for 3. D rop pum p discharge check ball into discharge hole.
damage. Ball is 3/16" diam eter steel. Install pump discharge
6. Inspect holes in levers for excessive wear or out of spring and retainer. (Top of pump discharge spring
round condition. If levers or rods are worn they should retainer should be flush with top of float bowl casting).
be replaced.
7. Exam ine fast idle cam for excessive wear or damage.
8. Check throttle and choke levers and valves for binds
and other damage.
place as necessary.
A S S E M B L Y AND A D JU S T M EN TS
Assemble Bowl and Throttle Body

1. If it was necessary to remove the idle mixture adjusting
needles and springs, install them into the throttle body
until finger tight. Back out screw four turns as a
prelim inary idle m ixture adjustm ent.
D o n o t in s ta ll th e id le m ix tu re lim ite r c a p s u n til

th e id le m ix tu re h as b e e n re s e t w ith th e c a r b u r
e to r in s ta lle d o n th e e n g in e p e r in s tr u c tio n s i n
c lu d e d in the service m an u al. Fig. G9--Bowl Assembly--Parts Location

6M-18 CARBURETOR
4. Install main well inserts, gasket and cluster assembly, 6. Install power piston into vacuum cavity. M ake sure
tighten screws evenly and securely. M ake certain that that piston travels freely in cavity. Lightly stake re
the center screw is fitted with fiber gasket. tainer in place.
5. Install main m etering jets, power valve gasket and 7. Install the float needle seat and gasket into air horn
power valve. Figure G9 shows the bowl and throttle casting. Tighten securely with a wide blade screw
body at the stage of assembly. Install pum p return driver. Place the float needle into needle seat.
spring, apply pressure with finger to center it in pump 8. Install air horn to float bowl gasket. Align position
well and to m ake sure th at is properly seated. cut-out in float tow ard power piston and align float
hanger with holes in the links on air horn casting; then
install retaining pin.
9. Install fuel filter spring, fuel filter, filter gasket, fuel
Assemble Air Horn (Figure G10) inlet nut gasket and fuel inlet nut. Torque inlet nut
1. Install choke kick lever on choke shaft with tang on sufficiently to seat gasket. Install vacuum break dia
kick lever tow ards lever on shaft. phragm assembly on to air horn with the part number
2. Install choke shaft into air horn--insert shaft left to on bracket facing outward. Install two attaching screws
right. and tighten securely. Insert off-set and vacuum break
3. Center choke valve on choke shaft with letters "R P" diaphragm rod into plunger on vacuum break dia
facing upward. Install choke valve screws. Before tight phragm. Then install other end of rod to hole in choke
ening the choke valve screws, make sure th at there is coil lever. Install choke coil lever on to end of choke
.0 2 0 " clearance between the choke kick lever on the air shaft aligining flats on lever with flats on shaft. Install
horn casting. Then tighten the choke valve screw se retaining screw into the end of choke shaft and tighen
curely and stake in place to eliminate any possibility of securely. Part num ber on choke coil lever face outward
their coming loose. when installed correctly.
4. Install accelerator pum p plunger and rod to the inner
pum p lever - end of pum p plunger rod points inward Installation of the Combined Emission
tow ards air horn bore.
5. Install outer accelerator pum p lever with plastic washer Control Valve on Float Bowl.
partially through air horn and align flats on lever with
inner lever. Then install and secure levers with retaining 1. Install C.E.C. valve into bracket on float bowl. Install
screw. lock washer, large retaining nut and tighten securely.
Then, bend retaining ears on lock washer over flats of
nut so that nut is locked securely in place.
2. Install vacuum hose on tube located between the idle
m ixture needles and the throttle body and to the outer
tube on the C.E.C. valve. (Figure G 6 ).
NOTE: Refer to the adjustment section for the cor

rect procedure when adjusting the C.E.C. valve as
sembly.
Adjust Float
Brass-Type
1. W ith air horn inverted and air horn gasket installed
measure the distance from the air horn gasket to the
lower edge (sharp edge) of the float seam at the outer
end of the float pontoon. To adjust, bend the float arm
at rear, as shown in inset (Fig. G il) .
2. W ith the air horn assembly held upright and float sus
pended freely, measure dimension from air horn gasket
to bottom of float pontoon at toe, adjust to specified
dimension by bending tang which contacts seat at rear
of float arm (fig. G 12).
Nitrophyl-Type
1. W ith air horn inverted, gasket in place and needle
seated measure distance from lip at toe of float to air
horn gasket. Adjust float to specifications by bending
Figure G 1 0 -A ir Horn A ssem bly-P arts Location tang (fig. G13).

CARBURETOR 6M-19
Fig. G 1 4 -F lo a t Drop A djustm en t (N itrophyl)
2. W ith air horn right side up so that float can hang free,
Fig. G1 1 -F lo at Level A djustm en t (Brass) measure distance from lip at toe of float to air horn
gasket. Adjust float to specifications by bending tang
(Fig. G14).
Assemble Air Horn To Bowl

1. Place air horn on bowl, making certain that accelerator
pum p plunger is positioned properly and that it will
move freely. Raise air horn, index power piston with
spring and lower it straight down to ensure proper in
stallation.
2. Install and tighten air horn screws evenly and securely
GAUGE FROM
GASKET SURFACE in sequence shown in Figure G15. The num ber one
TO BOTTOM screw is the long screw.
OF FLOAT
Fig. G 1 2 -F lo a t Drop A djustm en t (Brass)
Fig. G 1 3 -F lo a t Level A djustm en t (N itrophyl) Fig. G 1 5 -A ir Horn T igh te nin g Sequence

6M-20 CARBURETOR
3. Install fast idle rod in choke kick lever, then install

opposite end into fast idle cam. R otate rod and cam and
secure cam to bowl with the shouldered bolt letters GAUGE FROM TOP
OF AIR HORN RING
"R P" on fast idle cam face outward.
TO TOP OF PUMP ROD
NOTE: The rod offset end connects to fast idle cam.
4. Install accelerator pum p rod and secure at throttle lever

with "H air-pin" type clip.
5. Connect vacuum diaphragm at fitting on throttle body.
Adjust Accelerator Pump Rod (Fig. G16)

Back out idle stop screw and completely close throttle
valves in bore. Place gauge on top of air horn ring. Bend the
pum p rod at lower angle to obtain specified dimension, to top
of pum p rod.
IM PORTANT: After carburetor overhaul, throttle THROTTLE VALVES ( —

body part replacem ent, m ixture needle part FULLY CLOSED ]
replacement, or limiter cap and needle rem oval, to
the procedures in Section 6M , 1971 Chassis

Service M anual, under “ A d d ition al External
Settings and Adjustm ents,” must be follow ed. Fig. G 16 -A cce le ra to r Pump Rod A djustm en t
ROCHESTER 2G AND 2G V (SAE 1 Vi\

REPAIR PROCEDURES
INDEX
D isassem bly........................................................................ 6M-20 Assemble Bowl ........................................................ 6M-24

A ir H o r n ................................................................... 6M-21 Assembly Air H o rn ................................................. 6M-24
Bowl and T hrottle B o d y ........................................ 6M-23 Adjust Float Level ........................................... . 6M-25
Cleaning and In sp ectio n................................................. 6M-23 Adjust Float D rop ................................................... 6M-25
Assembly and A d ju stm e n t............................................ 6M-24 Assemble A ir Horn to Bowl................................. 6M-25
Assembly T hrottle B o d y ........................................ 6M-24
D IS A S S E M B L Y 2. Bend back retaining tabs on lock washers; then remove

larger C.E.C. valve nut and remove C.E.C. valve from
bracket.
NOTE: Do not remove C.E.C. valve bracket from the
Removal of the Combination Emission float bowl assembly unless replacement of the
bracket is necessary. Complete replacement in
Control (C.E.C.) Valve Assembly. structions are included in the replacement bracket
kit.
1. Remove vacuum hose from the C.E.C. valve and
vacuum supply tube located between two mixture CAUTION: Do not immerse the C.E.C valve assem
screws on throttle body. bly in any type of carburetor cleaner.

CARBURETOR 6M-21
TO V A C U U M
ADVANCE ON
D IS T R IB U T O R
E LE C TR IC A L
C O N N E C T IO N S
C.E.C. VALVE
COMBINED EMISSION CONTROL VALVE
Fig. V1-C.E.C. Valve (Combined Emission C ontrol Valve)
Disassemble Air Horn (Figure V2) 7. Place choke valve in wide open position, rotate choke
rod towards pum p lever and remove the choke rod from
1. On 2GV models, remove choke coil lever retaining upper choke lever on choke shaft.
screw from end of choke shaft and remove choke coil 8. Remove air horn to bowl attaching screws and choke
lever from choke vacuum diaphragm rod. cable bracket on 2G models. Tap air horn lightly to
2. Remove the choke vacuum break diaphragm rod from loosen from bowl and lift air horn from float bowl.
the vacuum diaphragm plunger by rotating off-set end 9. Place air horn top-down on a flat surface and remove
of rod out of slot in diaphragm plunger. float hinge pin, float, air horn gasket, splash shield and
3. Remove choke vacuum diaphragm supply hose from float needle.
tube on throttle body, then remove vacuum diaphragm 10. Using a wide bladed screwdriver, remove the float nee
assembly by removing two retaining screws. dle seat and gasket.
4. Place carburetor on a proper holding fixture being care 11. Remove power piston by depressing shaft and allowing
ful not to damage the throttle valve or components. spring to snap sharply thus forcing piston from casting.
Then remove the fuel inlet filter nut, filter, spring, and 12. Remove screw retaining pump inner lever to outer lever
filter nut gasket. and withdraw lever and plastic washer from air horn.
Place plunger in gasoline or kerosene to prevent rubber
NOTE: The paper fuel inlet filter has its own sealing from drying out.
gasket so there is no extra gasket required between 13. If choke shaft or valve needs replacement, remove two
the filter element and fuel inlet nut. choke valve screws:
a. On 2GV Models, remove choke valve, and slide
5. Remove pump rod retaining clip from throttle lever end shaft and kick lever from air horn.
o f rod, and remove rod from throttle lever, depress b. On 2G Models, disconnect choke spring from lever,
pum p and rotate the pum p rod out of upper pum p lever. and remove shaft and lever assembly from air horn.
6. Using a wide bladed screwdriver, remove the fast idle c. On 2G Models, remove retaining ring from annular
cam attaching screw-rotate cam and remove cam from groove in casting, then remove choke lever and
rod. swivel and spring.

6M-22 CARBURETOR
Fig. V 2~A ir Horn Exploded View
1. Pump Rod 7. Power Piston 13. A ir Horn 20. Filter Spring

2. Pump O uter Lever 8. A ir Horn-to-Bowl 14. Vacuum Diaphragm 21. Float Needle and
3. A ccelerato r Pump Gasket 15. Choke Lever Seat
4. W asher 9. Choke Valve 16. Diaphragm Link 22. Float Hinge Pin
5. Pump Inner Lever 10. Choke Rod 17. Fuel Inlet Nut 23. Splash Shield
6. Pump Inner Lever 11. Choke Shaft 18. Gasket 24. Float
Retainer 12. Choke Kick Lever 19. Fuel Filter
Fig. V 3~B ow l and T hrottle B ody-E xploded V iew

CARBURETOR 6M-23
Disassembly of Float Bowl and Throttle NOTE: Do not tamper with the idle mixture needle
with a limiter cap unless performing an overhaul or
Body (Figure V3)
1. Remove the pum p plunger return spring from pump quirements by the manufacturer.
well.
2. Remove main metering jets and power valve and gas 7. F urther disassembly of the throttle body is not recom
ket. mended. If the idle mixture needles are damaged, or
3. Remove three screws on top of cluster after which clus need replacement or the idle mixture channels have to
ter and gasket may be removed. be cleaned, the plastic limiter cap should be broken
away from m ixture screws as new ones are provided in
NOTE: The cluster center screw has two fiber wash
the repair kit.
ers and a baffle located just above the main well air
bleeds. The two outer screws have lock washers.
IMPORTANT: If CO Reading equipment is not avail
Also, the center screw is not threaded the full length
able, before removing idle mixture needle, be certain
of the body -- smaller diameter is required for pump
to count number of turns to bottom this old idle mix
jet discharge. The high speed bleed baffle must be
ture needle. This is required so that when it is neces
installed between the two fiber gaskets underneath
sary to install a new needle, you may bottom the
the head of center cluster screw.
new needle and then back off the same number of
4. Using a pair of long nose pliers, remove the pum p dis turns it took to bottom the old needle.
charge spring retainer (Figure V4). Then the pump dis
charge spring and check ball may also be removed. 8. Remove idle mixture needle and spring, if required.
CAUTION: Do not immerse the C.E.C. valve in any

type of carburetor cleaner or solvent.
The carburetor should be cleaned in a cold immersion type

cleaner.
1. Thoroughly clean carburetor castings and metal parts
in an approved carburetor cleaner.
CAUTION: Any rubber parts, plastic parts, dia

phragms, pump plungers, electric parts and solen
oids, should not be immersed in carburetor cleaner.
However, the air horn which has the pressure relief
valve will withstand normal cleaning in carburetor
cleaner. Make sure the cleaning solution is
thoroughly removed from pressure relief valve area.
2. Blow out all passages in castings with compressed air.

Do not pass drills through jets or passages.
3. Inspect idle m ixture needle for damage.
Fig. V 4-R em o ving Pump Discharge Spring Retainer a new factory m atched set if worn.
Inspect upper and lower casting sealing surfaces for
5. R em ove tw o screw s re ta in in g h o t idle co m p e n sato r damage.
a n d rem o v e c o m p e n s a to r asse m b ly a n d g a sk et Inspect holes in levers for excessive wear or out of
fro m v e n tu ri area. (A ir c o n d itio n e d m odels only.) round condition. If levers or rods are worn they should
6. In v e rt c a rb u re to r a n d re m o v e th re e la rg e th ro ttle be replaced.
b o d y to bow l a tta c h in g screw s. T h ro ttle b o d y an d Examine fast idle cam for excessive wear or damage.
g ask et m ay now be rem o v ed .
1. C luster Assem bly 6. Bowl Assem bly 10. Choke Rod

2. C luster Gasket 7. T hrottle Body-to-Bowl 1 1. Idle M ixture Screws
3. Hot Idle C om pensator Gasket 12. Fast Idle Cam
4. Power Valve 8. T hrottle Body 13. A ccelerato r Pump
Assem bly Assem bly Spring
5. Main Jets 9. Idle Speed Screw 14. Pump Discharge
Check Assem bly

6M-24 CARBURETOR
8. Check throttle and choke levers and valves or binds and 3. D rop steel pum p discharge ball into pum p discharge
other damage. cavity. Ball is 3/16" diam eter steel. Install pump dis
9. Replace filter element. charge spring and retainer.
place as necessary. NOTE: The top of retainer should be flush with top
of float bowl casting beneath venturi cluster.
A S S E M B L Y AND A D JU S T M EN T S 4. Install gasket and venturi cluster assembly, tighten

screws evenly and securely. M ake certain that the high
speed bleed baffle is installed under the center cluster
Assembly of Float Bowl and Throttle screw with a fiber gasket on each side of the baffle. The
notches on the high speed bleed baffle point downward
Body tow ards venturi area.
5. On air conditioned models, install the hot idle compen
1. If removed, install the idle m ixture adjusting needles sator assembly and gasket. Tighten screws evenly and
and springs into throttle body until finger tight. Back securely.
out screws four turns as a prelim inary idle adjustm ent. 6. Install main metering jets, power valve gasket and
power valve. Tighten securely.
7. Install pump return spring into pum p well, apply pres
New Part Replacem ent sure with finger to center it in pump well. Figure V5
shows the float bowl and throttle body at this stage of
If a new throttle body is being replaced, install and bottom assembly.
the new idle mixture needle and back off four turns. Do not
install plastic lim iter cap at this time until proper screw
Assembly of Air Horn (Figure V6)
settings have been made.
A fter completing assembly of the carburetor, and when 1. On 2GV Models, install choke kick lever on choke shaft
installed in the vehicle, adjust the m ixture screw to achieve with tang on kick lever towards lever on shaft.
the required percent of "CO" in the exhaust gas (see Service 2. On 2GV Models, install choke shaft into up ended air
M anual under, "A dditional External Settings and A djust h o rn -in sert shaft left to right.
m ents") -which is the recom m ended method; however, if 3. On 2G Models, install torsion spring and choke lever
equipment for a "CO" reading is not available, you may set and swivel assembly on air horn. Install retain annular
the idle speed and idle m ixture settings as outlined also under ring in groove.
"A dditional External Settings and A djustm ents". 4. Center choke valve on choke shaft with letters "RP"
facing upward. Install choke valve screws and tighten
NOTE: Do not install the new plastic limiter caps securely. Stake screws to eliminate any possibility of
provided until the idle mixture has been adjusted
with the carburetor installed on the engine, per in
structions in the Service Manual.
NOTE: A new red plastic idle mixture needle limiter cap

is provided in the carburetor repair kit and also in the
idle m ixture needle and lim iter cap kit. This cap must
be installed after the idle mixture needle has been set
on engine by the CO reading (See Specifications), or
another method m ay be used, by backing off the new
mixture needle the same number of turns, after bottom
ing, as was required to bottom the original needle
which was pre-set and sealed by the m anufacturer
before it left the factory. (See “ Note” in disassem bly
procedures). Install new limiter cap.
CAUTION: Do not force the idle mixture needle

against the seat or damage will result.
2. Invert the float bowl, and place new throttle body gas
ket in position over locating dowels and attach throttle
body to bowl with three attaching screws. Tighten
screws evenly and securely. Fig. V 5~Bow l A ssem bly-P arts Location

CARBURETOR 6M-25
Float Drop Adjustment

W ith air horn right side up so that float can hang free,
measure distance from lip at toe of float air horn gasket.
A djust float to specifications by bending tang (Fig. V 8).
Fig. V 6—A ir Horn Assembiy--Parts Location
Assembly of Air Horn to Float Bowl

their coming loose. (On 2G Models, connect torsion
spring to idle cam lever). 1. Place air horn on bowl, making certain that accelerator
5. Install accelerator pum p plunger and rod to pump inner pum p plunger is properly positioned and that it will
lev er-en d of plunger rod points inward. move freely. Raise air horn, index power piston with
6. Position accelerator pum p outer lever with plastic spring, and lower it straight down to insure proper
w asher partially through air horn and align flats on installation.
inner lever and outer lever shaft install and secure levers 2. Install and tighten air horn screws evenly and securely
with retaining screw. in sequence shown in Figure V9. The num ber one screw
7. Install power piston in vacuum cavity. M ake sure that is the long screw.
piston travels freely in cavity. Lightly stake retainer in
place. NOTE: The choke cable retaining bracket is retained
8. Install float needle seat gasket into casting, then install by number seven and eight screws.
needle seat and tighten securely with a wide bladed
screwdriver. Position float needle into seat. 3. Install fast idle rod in choke kick lever, then install
9. Install splash shield to float retainer legs--notch in opposite end into fast idle cam. Rotate rod and cam and
shield tow ard accelerator pump. secure cam to bowl with the shouldered b o lt-letters
10. Install air horn-to-bowl gasket m aking sure gasket is "R P" on fast idle cam face outward.
indexed with locating dowel.
11. Position cut out in float tow ard power piston and align NOTE: The rod offset end connects to fast idle cam.
float with legs, then install retainer pin through splash
shield and float.
12. Install fuel filter spring, fuel filter, fuel inlet nut gasket,
and fuel inlet nut. Tighten fuel inlet nut securely.
13. Install vacuum break diaphragm onto air horn with
part num ber on diaphragm bracket facing away from
casting or outward. Position vacuum break diaphragm
rod into slot in diaphragm plunger and attached to
choke coil lever. Then install the choke coil lever on
flats on the end of choke shaft; tang on choke coil lever
faces outward. Install choke coil lever retaining screw
and tighten securely.
Float Level Adjustment

W ith air horn inverted, gasket in place and needle seated
measure distance from lip at toe of float to air horn gasket.
Adjust float to specifications by bending tang (fig. V7). Fig. V8--Float Drop A djustm en t

6M-26 CARBURETOR
4. Install accelerator pump rod and secure at throttle lever

with "hair pin" type clip.
5. Connect vacuum diaphragm at fitting on throttle body.
Assembly of C.E.C. Valve to Bracket on

Float Bowl
1. Install C.E.C. valve into bracket on float bowl. Then
install lock washer and large retaining nut and tighten
securely. Then, bend retaining ears of lock washer on
flats of nut so that the nut is locked securely in place.
2. Install vacuum hose from tube on throttle body located
between the idle m ixture screws to outer tube on the
C.E.C. valve. (Figure V10).
NOTE: Refer to the adjustment section for proper

adjustment of the C.E.C. valve on the engine.
IM PO RTANT: After carburetor overhaul, throttle

body part replacem ent, m ixture needle part
replacement, or limiter cap and needle rem oval,
the procedures in Section 6M , 1971 Chassis
Fig. V 9~ A ir Horn T igh te nin g Sequence Settings and Adjustm ents,” must be follow ed.
TO V A C U U M
ADVANCE ON
D IS T R IB U T O R
E LE C T R IC A L
C O N N E C T IO N S
Fig. V10--C.E.C. Valve (Combined Emission C ontrol Valve)

CARBURETOR 6M-27
ROCHESTER 4 MV (QUADRAJET)
INDEX
G eneral D e sc rip tio n ........................................................ 6M-27 Cleaning and In sp ec tio n .........................................6M-32

R epair Procedures............................................................ 6M-29 Assembly and A d ju stm e n t................................... .6M-32
D isassem bly............................................................... 6M-29 Throttle Body A ssem bly.........................................6M-32
A ir H orn Rem oval ........................................ 6M-30 Float Bowl A sse m b ly ............................................ .6M-32
A ir H orn Disassem bly................................... 6M-30 Float A djustm ent ................................................... .6M-33
Float Bowl D isassem b ly ............................... 6M-30 A ir H orn A ssem bly..................................................6M-33
T hrottle Body D isassem bly.......................... 6M-31 A ir H orn to Bowl In sta lla tio n ............................ .6M-33
GENERAL DESCRIPTION
The Rochester 4M V C arburetor (fig. Q l), used in con The model 4MV for Chevrolet has the following major
junction w ith a tem perature sensing choke coil (m ounted on changes for 1971:
the intake manifold), is used w ith 350 cu. in. and larger 1. Calibration for 1971 engines.
displacem ent engines.
2. New accelerator pum p for greater capacity on 350"
This is a four barrel, two stage carburetor with versatility
truck engines.
and principles of operation th at m ake it adaptable for small
3. Vacuum break diaphragm restriction increased to .020"
to larger engines w ithout design changes. for faster choke valve opening on cold starts.
The fuel bowl is centrally located to avoid problems of fuel 4. Heavier choke closing assist spring for improved engine
slosh, causing engine tu rn cut-out, and delayed fuel flow to starting.
the carburetor bores. 5. The choke unloader mechanism is changed in that the
The prim ary side has small bores and a triple venturi for separate wide open kick lever is removed. A tang has
fine fuel control in the idle and economy ranges. The second
ary side has larger bores and an air valve for high air capacity
(fig. Q2).
C H O K E LEVER C HOKE ROD

A IR H O R N
PUMP FAST
PLU N GER IDLE
CAM
IDLE SPEED
SCREW
C.E.C.
S O L E N O ID
(VALVE)
FUEL INLET
NUT A N D
FILTER
CHOKE VACUUM
BREAK
S E C O N D A R Y THROTTLE TH E R M AC
PUMP R O D L O C K O U T LEVER TUBE
A N D LEVER
IDLE M IXTURE LIMITER
C A P A N D NEEDLE THROTTLE LEVER
Fig. Q 1-R ochester 4M V (Q uadrajet) C arburetor

6M-28 CARBURETOR
PULL CLIP
■FLOAT NEEDLE
FLOAT NEEDLE
•SEAT , , INTERNAL VENTS
FIXED IDLE AIR

BY-PASS
)LE CHANNEL
SIDE IDLE AIR RESTRICTION
B L EED
THROTTLE
IDLE SVALVE
DISCHARGE HOLE
IDLE SYSTEM FLOAT SYSTEM
SECONDARY MAIN ACCELERATOR

WELL AIR BLEED WELL 8 TUBE
METERNG
ROD LEVER
PRIMARY MAIN
METERING ROD
POWER PISTON
POWER PISTON
SPRING
ENGINE "SECONDARY
MANIFOLC THROTTLE VALVE
VACUUM
y
VACUUM CHANNEL POWER SYSTEM
MAIN METERING MA|N METER|NQ SYSTEM
AS PLUNGER MOVES UP
FUEL FLOWS PAST CUP
INTO PUMP WELL.
PUMP SUCTION BREAKER
PUMP JETS
DISCHARGE BALL RETAINER
DISCHARGE PASSAGE
PUMP ROD.
PUMP RETURN
SPRING
AIR VALVE DASHPOT OPERATION ACCELERATING PUMP SYSTEM
Fig. Q 2-R ochester 4M V (Q uadrajet) Systems

CARBURETOR 6M-29
been added to the faster idle lever. This contacts a tang DISASSEMBLY
on the fast idle cam and through the interm ediate choke
shaft forces the choke valve slightly open to adm it more
air to the carburetor bores and intake m anifold should NOTE: Place carburetor on proper holding fixture.
the engine become flooded or loaded during starting. Care should be used so as not to damage the throttle
Except for certain truck applications, a combination valves as they are a precision fit.
Emission Control Valve (C.E.C. Valve) is used. The valve,
when energized through the transmission, acts as a throttle
stop by increasing idle speed during high grear operation of
the engine which helps in controlling overrun hydrocarbons Removal of the Combination Emission
during deceleration. The C.E.C. Valve also provides full
spark vacuum advance during high gear operation but is Control (C.E.C.) Valve Assembly
de-energized in the lower gears and at idle for retarded spark
tim ing during this period. N orm al idle speed setting is made 1. Remove vacuum hose or hose assembly from vacuum
with the idle stop screw. Idle speed settings should be made tube on float bowl. Then remove the hose from the
following vehicle emission control inform ation on the label outer tube on C.E.C. valve assembly. (Fig. Q3)
located in the engine com partm ent. 2. Bend back retaining tabs on lock washer; then remove
The idle m ixture screws on all 4MV models except for larger C.E.C. valve nut and remove valve from bracket.
some truck applications, will have a plastic lim iter cap in
stalled to prevent idle fuel over-enrichm ent. N o adjustm ent NOTE: Do not remove C.E.C. valve bracket from the
will be provided on the vehicle. The idle m ixture screw will air horn unless replacement of the bracket is neces
be pre-set at the factory and capped, and no further adjust sary. Complete replacement instructions are in
ment should be required except during cleaning and over cluded in the replacement bracket kit.
haul. If the lim iter cap, idle needle and spring are removed
for cleaning and inspection, follow the specifications for idle
m ixture adjustm ent.
In conjunction with the use of idle needle limiters in 1971, CAUTION: Do not immerse the C.E.C. valve assem
the throttle body casting has been revised to provide stop lugs bly in any type of carburetor cleaner.
for the lim iter caps.
Fig. Q3--C.E.C. Valve-Com bined Emission Control Valve

6M-30 CARBURETOR
Air Horn Removal

1. Remove larger C.E.C. valve bracket retaining screw
from float bowl. Do not remove the bracket from air
horn assembly.
2. Remove clip from upper end of choke rod, disconnect
choke rod, disconnect choke rod from upper choke
shaft lever and remove choke rod from lower lever in
bowl.
3. Remove roll pin at pum p lever pivot by driving pivot
inw ard with proper fitting punch. Then remove pump
lever from air horn and upper end of pump rod by
rotating lever from rod.
4. Remove nine (9) air horn to float bowl attaching
screws. Two attaching screws are located next to the Fig. Q -4 -A ir Horn Exploded V iew
prim ary venturi. (Two long screws, five short screws,
two counter-sunk screws). A ir Horn-to-Bowl Choke Valve
5. Remove vacuum break hose at diaphragm and remove Gasket Counter-sunk A ir
A ir Horn Assembly Horn Retaining
diaphragm unit from retaining bracket.
A ir Horn-to-Bowl Screws
6 . Disconnect choke assist spring at diaphragm plunger
Retaining Screws (2 7. Secondary M etering
and remove air valve to dashpot rod at air valve lever. long, 5 short, 2 Rods
counter-sunk--ltem 8. M etering Rod Hanger
7. Remove small screw at top of secondary m etering rod No. 6)
hanger, then remove metering rod hanger and second 4. Choke S haft and
ary rods as an assembly. Lever
8. Remove air horn by lifting straight up. A ir horn gasket
should rem ain on bowl for removal later. 3. Remove pum p return spring from pum p well.
4. Remove plastic filler over float valve.
CAUTION: Care must be taken not to bend the main 5. R em ove pow er pisto n by pressing th e p isto n dow n
well air bleed tubes or accelerating well tubes pro a n d re lea sin g it. R em ove p o w er sp rin g fro m well.
truding from the air horn. These are permanently
pressed into the casting. Do not remove. NOTE: Never remove power piston with pliers, if
unable to remove, repeat step 5.
Air Horn Disassembly (Figure Q4) NOTE: The power pistong assembly is held in place
for ease in assembly of the air horn, by a plastic
retainer at top of power piston bore.
NOTE: Further disassembly of the air horn is not
required for cleaning purposes.
Remove metering rods from power piston by discon
necting tension spring from top of each rod then rotat
ing rod to remove from hanger.
7. Remove float assembly by pulling up slightly on retain
NOTE: If part replacement is required, proceed as
ing pin until pin can be removed by sliding toward
follows:
pum p well. After pin is removed, slide float assembly
tow ard front of bowl to disengage needle pull clip being
1. Remove choke valve attaching screws, then remove
careful not to distort pull clip.
choke valve and shaft (Figure Q4).
Remove pull clip and fuel inlet needle.
REmove fuel inlet needle seat with wide blade screw
CAUTION: Air valves and air valve shaft are cali driver. Remove needle seat gasket and discard.
brated and should not be removed. 10. Remove prim ary metering jets. No attem pt should be
made to remove secondary metering discs.
There is an air valve shaft spring repair kit which includes 11. Remove pum p discharge check ball retainer and check
the plastic cam, torsion spring, spring and retaining screw. If ball.
replacem ent is necessary, instructions are provided in kit. 12. Remove baffle from secondary side of bowl.
13. Remove retaining screw from choke assembly and
remove assembly from float bowl then remove second
Float Bowl Disassembly (Fig. Q5) ary lock out line from bowl.
1. Remove pum p plunger from pum p well. 14. Remove fast idle cam from choke assembly.
2. Remove air horn gasket from dowels on secondary side
of bowl, then remove gasket from around power piston CAUTION: Do not place vacuum break assembly in
and prim ary metering rods. carburetor cleaner.

CARBURETOR 6M-31
Fig. Q5~Float Bowl Exploded V iew
1. Fuel Inlet Nut 10. Secondary T hrottle 18. Power Piston Spring 26. Float Needle Pull
2. Gasket Lockout 19. Primary M etering Clip
3. Fuel Filter 11. T hrottle Body-to-Bowl Rods 27. Float Needle
4. Fuel F ilter Spring Gasket 20. Power Piston 28. Float Needle Seat
5. Vacuum Break Hose 12. Float Bowl Assem bly 21. M etering Rod 29. Needle Seat Gasket
6. Vacuum Diaphragm 13. Idle Speed Screw Retainer 30. Discharge Ball
7. A ir Valve Dashpot 14. Primary Jets 22. Float Retainer
8. Choke Control 15. Pump Discharge Ball 23. Secondary A ir Baffle 31. Choke Rod
Bracket 16. Pump Return Spring 24. Float Bowl Insert 32. Choke Lever
9. Fast Idle Cam 17. A ccelerato r Pump 25. Float Hinge Pin
15. Remove interm ediate choke rod and actuating lever m ixture needles, destroy plastic limiter caps as new
from inside of float bowl well. ones are provided in the overhaul kit.
16. Remove fuel inlet filter nut gasket, filter and spring.
17. Remove throttle body by removing throttle body to IMPORTANT: If CO Reading equipment is not avail
bowl attaching screws. able before removing idle mixture needle, be certain
18. Remove throttle body to bowl instulator gaskets. to count number of turns to bottom this old idle mix
ture needle. This is required so that when it is neces
sary to install a new needle, you may bottom the
Throttle Body Disassembly (Figure Q6) new needle and then back off the same number of
turns it took to bottom the old needle.
NOTE: Do not tamper with the idle mixture needle
Remove idle m ixture needle and spring, if required.
with a limiter cap unless performing an overhaul or
quirements by the manufacturer. NOTE: No further disassembly of the throttle body
is required.
1. Remove pum p rod from throttle lever by rotating rod
out of prim ary lever.
2. No further disassembly of the throttle body is necessary
unless the idle m ixture needles are damaged or the idle CAUTION: Extreme care must be taken to avoid
channels need cleaning. If necessary to remove the idle damaging secondary throttle valves.

6M-32 CARBURETOR

place as necessary.
A S S E M B L Y AND A D JU STM EN TS
New Part Replacement

If a new throttle body is being replaced, install and bottom
the new idle mixture needle and back off four turns. Do not
install plastic limiter cap at this time until proper screw
settings have been made.
A fter completing assembly of the carburetor, and when
installed in the vehicle, adjust the m ixture screw to achieve
the required percent of "CO" in the exhaust gas (see Service
Fig. Q 6 -T h ro ttle Body Exploded View M anual under, "A dditional External Settings and A djust
m ents") which is the recommended method; however, if
equipment for a "CO" reading is not available, you may set
1. S houldered R etaining 6. Fast Idle Screw the idle speed and idle m ixture seettins as outlined also under
Screw 7. T hrottle Body-to-Bowl
"A dditional External Settings and A djustm ents".
2. Torsion Spring Screws
(3-to-4) 8. Idle M ixture Needle
3. Fast Idle A djusting 9. A ccelerator Pump
Lever Rod Throttle Body Assembly
4. Fast Idle Cam Lever 10. Throttle Body
5. Choke Unloader Assem bly 1. If removed, install the idle m ixture needles and springs
Lever until lightly seated. Back out idle m ixture needles two
turns as a prelim inary idle adjustment.
Cleaning and Inspection NOTE: Do not install the new plastic limiter caps
until the idle mixture has been set with the carbu
CAUTION: Do not immerse the C.E.C. valve in any retor installed on the engine. Instructions for adjust
type of carburetor cleaner or solvent. ment are included in the service manual.
The carburetor should be cleaned in a cold immersion type

cleaner.
1. Thoroughly clean carburetor castings and m etal parts NOTE: A new red plastic idle mixture needle limiter
in an approved carburetor cleaner. cap is provided in the carburetor repair kit and also
in the idle mixture needle and limiter cap kit. This
CAUTION: Any rubber parts, plastic parts, dia cap must be installed after the idle mixture needle
phragms, pump plungers, electric parts and solen has been set on engine by the CO reading (see
oids, should not be immersed in carburetor cleaner. Specifications), or another method may be used, by
However the air horn which has the pressure relief backing off the new mixture needle the same num
valve will withstand normal cleaning in carburetor ber of turns, after bottoming, as was required to
cleaner. Make sure the cleaning solution is bottom the original needle which was pre-set and
sealed by the manufacturer before it left the factory.
thoroughly removed from pressure relief valve area.
(See iNotei in disassembly procedures). Install new
limiter cap.
2. Blow out all passages in castings with compressed air.
2. Install pum p rod in hole of throttle lever by rotating rod
D o not pass drills through jets or passages.
into lever.
a new factory m atched set if worn. Float Bowl Assembly
damage. 1. Install new throttle body to bowl insulator gasket being
6 . Inspect holes in levers for excessive wear or out of certain the gasket is properly installed over two locating
round condition. If levers or rods are worn they should dowels on bowl.
be replaced. 2. Install throttle body making certain throttle body is
7. Exam ine fast idle cam for excessive wear or damage. properly located over dowels on float bowl then install
8 . Check throttle and choke levers and valves or binds and throttle body to bowl screws and tighten evenly and
other damage. securely. Place carburetor on proper holding fixture.

CARBURETOR 6M-33
NOTE: Make sure retaining pin is held firmly in

place and tang of float needle is seated on float nee
dle.
b. Bend float up or down for proper adjustment.

14. Install power piston spring in power piston well. If
prim ary main m etering rods were removed from hanger
reinstall m aking sure th at tension spring is connected to
3. Install fuel inlet filter spring, filter, new gasket and inlet top of each metering rod. Install power piston assembly
n u t and tighten nut securely. in well with m etering rods properly positioned in m eter
4. Install fast idle cam on choke shaft with cam pick-up ing jets. Press down firmly on power piston retainer to
lever on underside of cam. insure engagement of retaining clip.
5. Connect choke rod to choke rod actuating lever (plain 15. Install plastic filler over float needle, pressing down
end) then holding choke rod, with grooved end pointing ward until seated properly.
inward, position choke rod actuating lever in well of 16. Install pum p return spring in pum p well.
float bowl and install choke assembly engaging shaft 17. Install air horn gasket around prim ary metering rods
with hole in actuating lever (fig. Q7). Install retaining and piston. Position gasket over two dowels on second
screw and tighten securely. Remove choke rod from ary side of bowl. Press power piston down firmly to
lever for installation later. assure correct alignment engagement of pin.
6. Install vacuum hose to tube connection on bowl and 18. Install pum p plunger in pum p well.
vacuum break assembly.
7. Install air deflector in secondary side of bowl with not
ches tow ards top. Air Horn Assembly
8. Install pum p discharge check ball and retainer in pas 1. Install choke shaft, choke valve and two attaching
sage next to pum p well. screws, if removed. M ake sure that the two choke valve
9. Install prim ary m ain metering jets. screws are lightly staked in place.
10. Install fuel inlet needle seat and gasket. Use wide blade
screw driver to avoid distortion. Install fuel inlet needle.
Air Horn to Float Bowl Installation
11. Install pull clip on needle. Pull clip is properly posi
tioned with open end tow ards front of bowl. 1. Place air horn assembly on bowl, carefully positioning
12. Install float by sliding float lever under pull clip from vent tubes and accelerating well tubes to air horn gas
front to back. W ith float lever in pull clip, hold float ket. D o not force air horn assembly on to float bowl as
assembly at toe and install retaining pin from pump distortion of the vent tubes may result.
well side. Be careful not to distort pull clip (D o N O T 2. Install two long air horn screws, five short screws and
install pull clip th ru hole in float arm .) two countersunk screws in prim ary venturi area. All
13. Float level adjustm ent (fig. Q 8) screws m ust be tightend evenly and securely (Figure
Q9).
a. W ith an adjustable T-scale, measure from top of 3. Connect pum p lever to upper pum p rod by rotating
float bowl gasket surface (gasket removed) to top of lever into rod. (Pum p rod should be in inner hole). Then
float at toe (located gauging point 3/16" back from install pum p lever into air horn casting and push pump
toe). lever pin back through casting until flush with casting.

6M-34 CARBURETOR
Fig. Q 1 0 -ln s ta llin g Secondary M etering Rods
Fig. Q 9 -A ir Horn T ightening Sequence
4. Connect choke rod into lower choke lever in float bowl IM PO RTANT: After carburetor overhaul, throttle
cavity and retain in upper lever with retaining clip.
5. Install air valve to dashpot rod into air valve shaft lever
and into the hole in the dashpot plunger; then position replacement, or limiter cap and needle rem oval,
dashpot into retaining bracket and connect choke assist the procedures in Section 6M , 1971 Chassis
spring and finally the choke vacuum hose.
6. Install secondary metering rod and hanger. Rod should Service M anual, under “ A d d ition al External
be positioned with upper ends through hanger holes and Settings and Adjustm ents,” must be followed.
tow ards each other. (Figure Q10). Install hanger re
tainer screw and tighten securely.
HOLLEY 4150
INDEX
General D e sc rip tio n ........................................................ 6M-35 Cleaning and In sp ectio n .......................................... 6M-40
Repair Procedures............................................................ 6M-35 Assembly and A d ju stm e n t................................... .. 6M-41
D isassem bly............................................................... 6M-35 Assemble T hrottle B o d y ................................. 6M-41
Disassemble into Sub-assemblies................. 6M-35 Assemble M ain Body ................................... .. 6M-41
Disassemble Fuel Bowls ............................... 6M-35 Assemble Secondary Throttle Operating
Disassembly M etering B odies...................... 6M-38 Assem bly........................................................... .. 6M-41
Disassemble Secondary T hrottle Assemble M etering Bodies .......................... ..6M-41
Operating A ssem bly............................................... 6M-39 Assemble Fuel Bowls ................................... ..6M-41
Disassemble M ain Body ............................... 6M-39 A djust Floats (Preliminary) ........................ ..6M-42
Disassemble T hrottle B o d y .......................... 6M-40 Assemble Subassemblies ................................. 6M-42

CARBURETOR 6M-35
GENERAL DESCRIPTION
The Holley 4150 center inlet carburetor fig. SI is used a n d se c o n d a ry fu el bow ls, p rim a ry a n d se c o n d a ry
on 350 and 454 cu. in. engines. See C arburetor identification, m e te rin g b o d ie s a n d th e se c o n d a ry th ro ttle o p e ra tin g
fig. S2. This carburetor is used in conjunction with a tem per assem bly. T h e se c o n d a ry m eterin g bo d y o n th e M odel
ature sensing choke coil m ounted on the intake manifold over 4150 C a rb u re to r is sim ilar to the p rim a ry m ete rin g
the exhaust crossover passage. bo d y . T h e se c o n d a ry th ro ttle o p e ra tin g a sse m b ly is
T h is fo u r b a rre l c a rb u re to r co n sists o f seven sub- v acu u m o p e ra te d (Fig. S3).
assem b lies; th e th ro ttle b o d y , th e m a in b o d y , p rim a ry
Fig. S 1 -H o lle y M odel 4 1 5 0 - Center Inlet C a rburetor
3. Remove prim ary fuel bowl screw (4) and remove fuel
DISASSEMBLY
bowl, metering body, baffle and gaskets.
4. Remove secondary fuel bowl screws (4) then remove
Disassemble Into Subassemblies (Fig. bowl and metering body and gasket.
S4) 5. Disconnect secondary throttle operating rod at throttle
lever.
NOTE: Before disassembly, loosen the fuel inlet fit 6. Remove secondary throttle operating diaphragm as
ting, fuel bowl sight plugs and needle and seat as sembly and gasket from main body.
sembly lock screws. 7. Remove secondary diaphragm rod retaining clip.
8. Remove throttle body to main body screws, then
1. Remove vacuum hose from the C.E.C valve and timed remove throttle body and gasket.
spark tube.
2. Bend back retaining tabs on lock washer; then remove
large C.E.C. valve nut and remove valve from bracket.
Disassemble-Fuel Bowls (Fig. S5)
NOTE: Do not remove C.E.C. valve bracket from the 1• Loosen inlet needle and seat lock screw, then turn ad
float bowl assembly unless replacement of the justing nut counter-clockwise to remove the needle and
bracket is necessary. seat assembly.
Remove float hinge pin retainer and slide float from
Com plete replacem ent instructions are included in the bowl; note position and remove spring and hinge pin
replacem ent bracket kit. from float assembly. Remove bowl filler from primary
bowl after float is removed.
CAUTION: Do not immerse the C.E.C. valve assem- 3. Remove sight plug and gasket.
bly in any type of carburetor cleaner. 4. Remove inlet fitting, fuel filter, spring and gaskets.

6M-36 CARBURETOR
CHEVROLET
OVERHAUL MANUAL
Fig. S 2 -C a rb u re to r Id e n tific a tio n

LOCK PRIMARY
SCREW VENTURI
MAIN JET- PICK-UP
ADJUSTING MAIN WELL
NUT MAIN WELL'
FLOAT AIR BLEED
MAIN METERING SYSTEM (TYPICAL)
DIAPHRAGM
SECONDARY
FILTER DIAPHRAGM THROTTLE
SPRING INLET ROD
PLATE
VALVE
FUEL INLET SYSTEM (END INLET)
SECONDARY THROTTLE OPERATING SYSTEM
DISCHARGE
PASSAGE IDLE TRANSFER
IDLE AIR BLEEDf AIR BLEED
DIAPHRAGM ^ — ^DIAPHRAGM IDLE TRANSFER
RESTRICTION PUMP INLET RETURN FEED RESTRICTION!
CHECK BALL SPRING
PUMP SYSTEM
DISCHARGE
NOZZLE
BOOSTER
VENTURI
SECONDARY SECONDARY
IDLE ADJUSTING/
FUEL BOWL THROTTLE
N EEDLE jU ^ in 'OLE
IDLE T R A N S F E R ^ L y S p ^ DISCHARGE
POWER VALVE
RESTRICTION
IDLE PLATE
SECONDARY TRANSFER
PASSAGE > C _Jr PASSAGE MAIN JET SLOT
IDLE TRANSFER IDLE DISCHARGE
SLOT HOLE
SECONDARY SYSTEM (IDLE & LOW SPEED)
IDLE SYSTEM
M AIN JET
MAIN WELL { f lN J j X D
POWER SYSTEM
6M-38 CARBURETOR
M A IN BODY
FUEL
METERING BOW L
BODY
SEC O N DAR Y THROTTLE THROTTLE

OPER ATING ASSEMBLY BODY
Fig. S4--Subassemblies
1. Fuel Inlet Nut 10. Inelt Nut Lock Screw

2. Inlet Nut Gasket 1 1. Float
3. Fuel Filter 12. Flaot Hinge Pin
4. Fuel F ilter Spring 13. Fuel D isplacem ent
5. Fuel Bowl Block
6. Inlet Needle and Seat 14. Pump Diaphragm
Assem bly Spring
7. A dju stin g Nut Gasket 15. Pump Diaphragm
8. Fuel Inlet A djusting (Prim ary Only)
Nut 16. Pump Cover
9. Inlet Nut Lock Screw
Gasket
5. P R IM A R Y BOW L ONLY--
• R e m o v e p u m p d ia p h ra g m screw s a n d lift p u m p
housing, d ia p h rag m an d spring fro m fuel bow l.
• C h eck p u m p in let b all for free m o v e m e n t a n d d a m
ag e. D a m a g e to ball, p a ssa g e o r r e ta in e r r e q u ir e s
new bow l assem bly.
fl
Disassemble Metering Bodies (Fig. S6)
1. On prim ary metering body remove the metering body
filler block.
2. Remove main metering jets with a jet wrench or a wide
blade screw driver (a small screw driver will damage the
jets). Remove the power valves using a 1" 12pt. socket.
Remove Idle mixture screws and seals (prim ary side
Fig. S5~Fuel Bowl Assem bly o n ly ).

CARBURETOR 6M-39
y*~— 8
Fig. S6~M etering Body Assem bly
1. M etering Body 4. Fuel Displacem ent

2. Idle M ixture Needle Block
(Prim ary Block Only) 5. Main M etering Jets
3. Idle M ixture Needle 6. Power Valve Gasket
Seal 7. Power Valve
Fig. S 8 -M a in Body Assembly

Disassemble Secondary Operating
Diaphragm Assem bly (Fig. S7)
1. Main Body Assem bly 8. Screw-Choke Valve
2. Pump Discharge 9. Choke Rod
1. Remove D iaphragm cover. Needle 10. Choke S haft and
2. Remove spring and diaphragm . 3. Gasket-Pump Lever
Discharge Nozzle 11. Seal-Choke Rod
4. Pump Discharge (Nylon)
Nozzle 12. Vacuum Break
5. Gasket Pump 13. Link-Vacuum Break
Discharge Nozzle 14. Choke Lever
Screw 15. Fast Idle Cam
6. Screw-Pump 16. Retainer-Choke Lever
Discharge Nozzle 17. Screw-Vacuum Break
7. Choke Valve
Disassemble Main Body (Fig. S8)

ft ... . ,
1. Remove choke vacuum break retaining screws; remove

choke vacuum break disconnecting link at choke lever.
2. Remove choke lever retaining clip and fast idle cam

retaining clip; remove choke lever and fast idle cam.
3. REmove pum p discharge nozzle screw, nozzle and gas
kets; up-end the body assembly to remove pum p dis
charge check valve.
NOTE: The choke rod seal will withstand normal

1. Screw 4. Diaphragm cleaning in carburetor cleaner, therefore, further
2. Cover 5. Housing disassembly of the main body is not required for
3. Spring 6. Gasket
cleaning purposes. If parts replacement is required,
proceed as follows:

6M-40 CARBURETOR
Fig. S 9 -T h ro ttle Body Assem bly
1. S crew Fast Idle Cam 10. T hrottle 17. Screw A ccelerator

Lever Plate-Secondary Pump Cam
2. Fast Idle Cam Lever 11. Throttle 18. Pump O perating
3. Screw -Secondary Shaft-Secondary Lever
T hrottle Lever 12. T h orttle Plate-Primary 19. Screw Pump Lever
4. Lever-Secondary 13. T hrottle A dju stin g
T h ro ttle O perating Shaft-Prim ary Spring Pump
5. T hrottle Body 14. C otter Pin-Throttle Lever A djusting
6. Screw -Idle Speed Link Screw
7. S pring-Idle Speed 15. Link-Throttle Nut-Pump Lever
8. Bushing T hrottle C onnector A djusting
Shaft 16. C am -Accelerator
9. S crew -Throttle Plate Pump
• F ile o ff th e sta k e d en d s o f sh a ft screw s th e n rem o v e 4. Remove cotter key and disconnect throttle connecting
screws. link (secondary lockout) from shaft levers.
• R em ove choke ro d (u p w ard th ro u g h p lastic seal) an d 5. File off the staked ends of the throttle plate attaching
rem o v e seal fro m m a in body. screws, then remove the screws and throttle plates.
• R e m o v e v a lv e fro m sh a ft slo t a n d slid e s h a ft fro m 6. Remove burrs from throttle shaft and slide the shafts
m ain body. out of flange.
7. Remove accelerator pump cam from throttle lever.
8. Remove vacuum break hose from fitting.
Disassemble Throttle Body (Fig. S9)
NOTE: Ordinarily the throttle body need not be dis Cleaning and Inspection
assembled for cleaning and inspection purposes.
The carburetor should be cleaned in a cold immersion
type cleaner.
NOTE: If necessary, diassemble for part replace
ment as follows: NOTE: The most frequent causes of carburetor mal
function are gum, carbon, and water. Carefully
1. Remove pum p operating lever assembly. Disassemble clean and inspect all parts and castings as the car
spring, bolt and nut if needed. buretor is being serviced as follows:
2. Remove idle speed screw and spring.
3. Remove diaphragm lever from secondary thorttle shaft 1. Thoroughly clean carburetor castings and metal parts
and fast idle cam lever from prim ary throttle shaft. in an approved carburetor cleaner.

CARBURETOR 6M-41
CAUTION: Any rubber parts, plastic parts, dia 6. Install the throttle connecting link (secondary lockout)
phragms, pump plungers, electric parts, including to the throttle shaft levers.
solenoids, should not be immersed in carburetor 7. Install fast idle cam lever on prim ary throttle shaft and
cleaner. However the air horn which has the pres diaphragm lever on secondary throttle shaft.
sure relief valve will withstand normal cleaning in 8. Install idle speed screw and spring. T urn idle speed
carburetor cleaner. Make sure the cleaning solution screw clockwise until contact with throttle lever is
is thoroughly removed from pressure relief valve made and turn 1 1/ 2 " additional turns for preliminary
area. adjustm ent.
9. Install accelerator pum p cam on throttle lever.
10. Assemble and install pum p operating lever assembly.
11. Install vacuum break hose on fitting.
NOTE: Secondary throttle shaft bushings and accel
erator pump cam are plastic. Assemble Main Body
1. Install pum p discharge valve.
2. Install pum p discharge nozzle. Use new gaskets.
2. Check secondary throttle operating diaphragm for free 3. Install choke rod seal and choke rod in main body.
operation and leakage by moving diaphragm rod to the 4. Install choke shaft in main body and connect upper end
up position then covering vacuum passage opening in of choke rod.
housing with thum b. The diaphragm should hold up 5. Install choke valve on choke shaft (do not tighten re
ward. Remove thum b from vacuum passage and dia taining screws).
phragm rod should move down readily. 6. Center choke valve on shaft by holding valve closed
3. Blow out all passages in castings with compressed air. while tightening screws.
D o not pass - drills through jets or passages. 7. Stake screw ends with pliers.
5. Exam ine flaot needle and seat assembly for wear. Install NOTE: The choke valve is offset and should fall
a new factory m atched set if worn. freely to wide open position from its own weight.
damage. 8. Install choke lever and fast idle cam; then retainer.
7. Inspect holes in levers for excessive wear or out of 9. Connect vacuum break link to choke lever, then install
round condition. If levers or rods are worn they should vacuum break with two retaining screws.
be replaced.
8. Exam ine fast idle cam for excessive wear or damage. Assemble Secondary Throttle Operating
9. Check throttle and choke levers and valves for binds
and other damage. Assembly
11. Check all springs for distortion or loss in tension re 1. Install diaphragm assembly and spring in housing.
place as necessary. 2. Install diaphragm cover and tighten securely.
NOTE: Diaphragm may be checked for leaks by

ASSEMBLY AND ADJUSTMENTS pushing in on rod then holding finger over vacuum
hole. Rod should remain in.
Assemble Throttle Body Assemble Metering Bodies

1. Install secondary throttle stop screw (if removed). 1. Using a new gasket, install power valve and tighten
2. Install throttle shafts in throttle body. secure. (Use a 1" 12 pt. socket.) Install main metering
jets with a wide blade screw driver.
NOTE: The throttle shafts have plastic bushings. P R IM A R Y ONLY--
Roll new bushing between thumb and first finger to Using new seals, install idle mixture screws and make
help shape the bushing on the shaft for easier instal preliminary adjustm ent of idle m ixture screws by turning
lation. lightly to seat and back out one turn.
3. Install the throttle valves on the shaft (do not tighten CAUTION: Do not turn screw tightly against seal.
retaining screws).
4. C enter the throttle valves on the shafts by holding the 2. On prim ary metering body install filler block.
valves closed while tightening the screws.
NOTE: The throttle valves are installed with identifi Assemble Fuel Bowls
cation numbers down (to manifold side).
1. P R IM A R Y A N D SEC O N D A R Y BOW L
5. Support the throttle shafts and stake the throttle valve • O n p rim a ry bow l install bow l filler before float
screws. in stallatio n (Fig. S10).

6M-42 CARBURETOR
CARBURETOR BODY BQWL p|LLER
METERING BODY , ICTC

M AIN JETS
Fig. S10--Fuel Bow l Assem bly
• A sse m b le s p rin g to flo a t, slid e flo a t in to b o w l a n d

in sta ll flo a t r e ta in e r screw s.
• In s ta ll in le t n e e d le a n d seats le a v in g lo c k n u ts loose.
U se new gask ets.
• In s ta ll in le t fittin g , fuel filter, sp rin g a n d g ask et
(new).
• In stall sight plugs in new gaskets.
2. P R IM A R Y B O W L O N L Y
• In stall p u m p spring an d d iap h rag m in fuel bow l.
Fig. S 12-A ssem bly of Main Body to T h ro ttle Body
Assemble Subassemblies
A d ju s t F lo a ts (Fig. S 1 1)
1. Invert the main body, align new throttle body to main
1. M ake a prelim inary float adjustm ent by inverting pri body gasket, then position throttle flange assembly and
m ary fuel bowl and turning adjustable needle-seat until install the screws and tighten securely. (Fig. S I2).
top of float is specified distance from top of fuel bowl.
2. Using a new gasket, install secondary throttle operating
2. R ep e a t Stop one fo r seco n d ary float. assembly on main body and tighten securely.
3. Lay flange and main body on prim ary side then install
NOTE: Final adjustment of the float is made on the new fuel bowl gasket and secondary m etering body as
vehicle. Refer to Section 6M of the Chassis Service sembly onto main body algining dowel pins and holes.
Manual. 4. Install secondary fuel bowl and retaining screws with
new gaskets under heads.
5. Lay assembly on secondary bowl then install prim ary
metering body and gasket on main body.
6. Install splash shield, new gasket and prim ary fuel bowl.
CENTER IN BOWL
7. Align pum p lever under operating lever duration

spring, then install fuel bowl retaining screws with new
gaskets under heads and tighten securely.
IM PO RTANT: After carburetor overhaul, throttle

replacement, or limiter cap and needle rem oval,
the procedures in Section 6M, 1971 Chassis
Settings and Adjustm ents,” must be follow ed.
Fig. S 11 -P re lim in a ry Float A djustm en t

CARBURETOR 6M-43
SPECIAL TOOLS
Fig. S 13 -E ng ine Fuel Special Tools
1. J-1 137 Choke Rod 5. J-9 7 8 9 Universal

Bending C arburetor Kit
2. J-4 5 5 2 Choke Rod 6. J-101 76 Fast Idle
Bending (1 2 b b l.) W rench
J-5 1 9 7 Unloader 7. J-2 2 9 7 3 Ther-Mac
3.
Therm om eter
Bending
4. J-83 28 Carburetor
Holding Tool

. •
V
SECTION 6Y
ENGINE ELECTRICAL
CONTENTS OF SECTION
Starting M otor................................................................... 6Y-1 Charging S y stem s........................................................ 6 Y -8

Starting Solenoid............................................................... 6Y-7 Special T o o ls ................................................................. 6Y-17
STARTING MOTOR
INDEX
D isassem bly........................................................................ 6Y-2 Loose Electrical C onnections..................................... ..6Y-4

Cleaning and In sp ectio n ................................................. 6Y-3 Turning the C o m m u ta to r............................................ ..6Y-5
Testing and Repairs ................ ....................................... 6Y-3 Brush H older Replacem ent ..........................................6Y-5
A rm ature Test for S h o rts ............................................ 6Y-3 A ssem bly............................................................................ ..6Y-5
Field Coil Test for Open C irc u it............................... 6Y-4 Pinion C learance.................................................................6 Y -6
Field Coil Test for G round ........................................ 6Y-4
CONTACT SOLENOID
FINGER PLUNGER RETURN SPRING
SHIFT
LEVER
GROMMET
SPIRAL
BUSHING SPLINES
BUSHING
PINION
STOP
OVERRUNNING
BRUSH INSULATED BRUSH HOLDER FIELD COIL ASSIST CLUTCH
BRUSH SPRING ARMATURE SPRING
GROUNDED BRUSH HOLDER
Fig. 1S~Starting M otor Section

ENGINE ELECTRICAL 6 Y -2
Fig. 2S--Starting M otor Parts Layout
1. Drive Housing 7. Solenoid Case 15. O verrunning Clutch 22. G rounded Brush
2. S hift Lever B olt 8. Screw and Lock Assem bly Holders
3. S hift Lever Nut and W asher 16. A rm ature 23. Brushes
Lock W asher 9. Grom met 17. Braking W asher 24. Screws
4. Pin 10. Field Frame 18. Com m utator End 25. Field Coils
5. S hift Lever 11. Through Bolts Frame 26. Insulators
6. Solenoid Plunger 12. T hrust Collar 19. Brush Springs 27. Pole Shoes
6A. Solenoid Return 13. Snap Ring 20. W asher 28. Screws
Spring 14. Retainer 21. Insulated Brush
Holders
D IS A S S E M B L Y (Figs. 1S and 2S)
1. D isconnect the field coil connector(s) from the m otor a. Slide two piece thrust collar off end of arm ature
solenoid Terminal. shaft.
2. Remove through bolts. b. Slide a standard half-inch pipe coupling or other
metal cylinder of suitable size (an old pinion of
3. Remove C om m utator end frame, field frame assembly
suitable size can be used if available) onto shaft so
and arm ature assembly from drive housing.
end of coupling or cylinder butts against edge of
4. Remove overrunning clutch from arm ature shaft as fol retainer (fig. 3S). Tap end of coupling with hammer,
lows: driving retainer towards arm ature end of snap ring.

they have not been chipped, cracked, or excessively

worn. Check the spring for normal tension and drive
collar for wear. If necessary the spring or collar can be
replaced by forcing the collar toward the clutch and
removing lock ring from end of tube.
3. Check brush holders to see that they are not deformed
or bent, but will properly hold brushes against the com
m utator.
4. Check the condition of the brushes and if pitted or worn
to one- half their original length, they should be re
placed.
5. Check fit of arm ature shaft in bushing of drive housing.
Shaft should fit snugly in the bushing. If the bushing is
worn, it should be replaced. Apply a silicone lubricant
to this bushing before reassembly. Avoid excessive lu
brication.
6. Check fit of bushing in com m utator end frame. If this
bushing is damaged or worn excessively, the end frame
assembly m ust be replaced. Apply a silicone lubricant
to this bushing before reassembly. Avoid excessive lu
brication. Lubricant forced onto the com m utator would
gum and cause poor com m utation with a resulting de
crease in cranking m otor performance.
7. Inspect arm ature com m utator. If com m utator is rough
or out of round, it should be turned down and undercut.
Inspect the points where the arm ature conductors join
the com m utator bars to make sure that it is a good firm
connection. A burned com m utator bar is usually evi
Fig. 3S--Driving Retainer O ff Snap Ring
dence of a poor connection. See "Turning the Com
c. Remove snap ring from groove in shaft using pliers m utator," described under Testing and Repairs.
or other suitable tool. If the snap ring is too badly
distorted during removal, it may be necessary to use CAUTION: Some starter motor models use a molded
a new one when reassembling clutch. armature commutator design and no attempt to un
d. Slide retainer and clutch from arm ature shaft. dercut the insulation should be made or serious dam
5. Disassemble brush rigging from field frame. age may result to the commutator. Undercutting
a. Release "V" spring from slot in brush holder sup reduces the bonding of the molding material which
port. holds the commutator bars and since the molding
b. Remove support pin. material is softer than the copper bars, it is not
c. Lift brush holders, brushes and spring upward as a necessary to undercut the material between the
unit. bars of the molded commutator.
d. Disconnect leads from each brush.
e. Repeat operation for other set of brushes.
Cleaning and Inspection TESTIN G AND R EP A IR S

W ith the starting m otor completely disassembled except
for removal of field coils, the com ponent parts should be Armature Test For Shorts
cleaned and inspected as described below. Field coils need be
removed only where defects in the coils are indicated by the Check the arm ature for short circuit by placing on
tests described in this section, in which case the pole shoe growler and holding hack saw blade over arm ature core
screws should be removed and the pole shoes and field coils while arm ature is rotated (fig. 4S). If saw blade vibrates,
disassembled. Any defective parts should be replaced or re arm ature is shorted. Recheck after cleaning between the
paired (see Repairs). com m utator bars. If saw blade still vibrates, replace the ar
1. Clean all starting m otor parts, but do not use grease mature.
dissolving solvent for cleaning the overrunning clutc-
h,arm ature, and field coils since such a solvent would
dissolve the grease packed in the clutch mechanism and
Armature Test For Ground
would dam age arm ature and field coil insulation.
2. Test overrunning clutch action. The pinion should turn Place one lead on the arm ature core or shaft and the other
freely in the overrunning direction and must not slip in on the com m utator (fig. 5S). If the lamp lights, the arm ature
the cranking direction. Check pinion teeth to see that is grounded and must be replaced.

Fig. 4S--Arm ature Short C ircuit Text
Field Coil Test For Open Circuit Fig. 6S--Field Coil Open C ircu it Test
Place one lead on the insulated brush and the other to the
field connector bar (fig. 6 S). If the lamp does not light, the
field coils are open and will require replacement.
Loose Electrical Connections
W hen an open soldered connection of the arm ature to
com m utator leads is found during inspection, it may be resol
dered provided resin flux is used for soldering.
Field Coil Test For Ground
Place one lead on the connector bar and the other on the CAUTION: Acid flux must never be used on electri
grounded brush (fig. 7S). If the lamp lights, the field coils are cal connections.
grounded.
W hen inspection shows com m utator roughness, it should

be cleaned as follows:
NOTE: Be sure to disconnect the shunt coil before
performing this test (when applicable).
Fig. 5S--Armature Ground Test

Turning The Com m utator

1. Turn down com m utator in a lathe until it is thoroughly
cleaned.
CAUTION: Do not cut beyond section pre vio u sly

turned. See caution under “ clea n in g and insp ection .”
2. U ndercut insulation between com m utator bars 1/32".

This undercut m ust be the full width of insulation and
flat at the bottom; a triangular groove will not be satis
factory. A fter undercutting, the slots should be cleaned
out carefully to remove any dirt and copper dust.
3. Sand and the com m utator lightly with No. 00 sandpa
per to remove and slight burrs left from undercutting.
4. Recheck arm ature on growler for short circuits.
Brush Holder Replacement

If brush holders are dam aged, they can be replaced by
special service units which are attached with screws and nuts.
Fig. 9S--Forcing Snap Ring Over Shaft
Overrunning Clutch
d. Repeat for other set of brushes.
The overrunning clutch (roll clutch design) used in the 2. Assemble overrunning clutch assembly to arm ature
various starting m otors is (fig. 8 S) designed to be serviced as shaft.
a complete unit. a. Lubricate drive end of arm ature shaft with silicone
lubricant.
b. Slide clutch assembly onto arm ature shaft with pin
A SSEM BLY ion outward.
c. Slide retainer onto shaft with cupped suraface facing
A fter all parts have been thoroughly tested and inspected end of shaft (away from pinion).
and worn or damaged parts replaced, the starter should be d. Stand arm ature on end of wood surface with com
reassembled. m utator down. Position snap ring on upper end of
1. Assemble brush rigging to field frame. shaft and hold in place with block of wood.
a. Assemble brushes to brush holders. end of shaft (fig. 9S). Slide snap ring down into groove.
b. Assemble insulated and grounded brush holder
together with the "V" spring and position as unit on
the support pin. Push holders and spring to bottom
of support and rotate spring to engage the "V" in
slot in support.
c. A ttach ground wire to grounded brush and field
lead wire to insulated brush.
Fig. 8 S— RolI Type Clutch Cross-Section Fig. 10S--Forcing Snap Ring Into Retainer

3. Assemble thrust collar on shaft with shoulder next PINION C LEA R A N C E C H EC K

to snap ring.
f. Place arm ature flat on work bench, and position 1. Connect a battery, of the same voltage as the solenoid,
retainer and thru st collar next to snap ring. Then from the solenoid switch term inal to the solenoid frame
using two pair of pliers at the same time (one pair or ground term inal (fig. 11S).
on either side of shaft), grip retainer and thrust
collar and squeeze until snap ring is forced into
retainer (fig. 10S).
NOTE: Disconnect the motor field coil connector for
3. Lubricate the drive housing bushing with a silicone
this test.
lubricant. M ake sure th ru st collar is in place against
snap ring and retainer and slide arm ature and clutch
assembly into place in drive housing engaging shift
lever with clutch.
2. M om entarily flash a jum per lead from the solenoid
4. Position field frame over arm ature and apply special m otor term inal to the solenoid frame or ground term i
sealing com pound between frame and solenoid case. nal. The pinion will now shift into cranking position
and will remain there until the battery is disconnected.
Position frame against drive housing using care to pre
vent dam age to the brushes.
5. Lubricate the bushing in the com m utator end frame 3. Push the pinion back towards the com m utator end to
with a silicone lubricant. Place leather brake washer on eliminate slack movement.
arm ature shaft and slide com m utator end frame onto
shaft.
4. M easure the distance between the pinion and pinion

6. Reconnect the field coil connectors to the "m otor" so stop (fig. 12S). If clearance is not within specified limits
lenoid terminal. (.010-. 140) it may indicate excessive wear of solenoid
7. A fter overhaul is completed, perform "Pinion Clear linkage shift lever yoke buttons or im proper assembly
ance Check". of the shift lever mechanism. W orn or defective parts
should be replaced.
Fig. 11S--Circuit fo r Checking Pinion Clearance Fig. 1 2S--Checking Pinion Clearance

STARTING SOLENOID
INDEX
R em oval.............................................................................. 6Y-7 Installation.......................................................................... 6Y-7

Replacement of C o n ta c ts ............................................... 6Y-7
Removal Installation
1. Remove the outer screw and washer from the m otor 1. W ith solenoid return spring installed on plunger, posi
connector strap terminal. tion solenoid body to drive housing and turn counter
2. Remove the two screws retaining solenoid housing to clockwise to engage the flange key in the keyway slot.
end frame assembly. 2. Install two screws retaining solenoid housing to end
3. Twist solenoid clockwise to remove flange key from frame.
keyway slot in housing; then remove solenoid assembly. 3. Install outer screw and washer securing m otor connec
tor strap terminal.
4. Install starter m otor as previously described.
Replacement of Contacts (fig. 13S)
1. W ith solenoid removed from m otor, remove nuts and
washers from switch and m otor connector strap term i
nals. S O LEN O ID
BO D Y TO HOLD-IN
2. Remove the two solenoid end cover retaining screws C O IL C O N TA C T C O N TA C T
R IN G S FINGER
and washers and remove end cover from solenoid body. SW ITCH
TERMINAL
3. Remove nut and washer from battery terminal on end FIBER
W ASHER
cover and remove battery terminal. Remove resistor
by-pass term inal and contactor.
4. Remove m otor connector strap term inal and solder new BATTERY
TERMINAL
term inal in position.
TO PULL-IN
5. Using a new battery term inal, install term inal washer C O IL PLUNGER
and retaining nut to end cover. Install by-pass terminal
and contactor. M OTOR C O N N E C T O R
STRAP TERMINAL
6. Position end cover over switch and m otor terminals and
install end cover retaining screws. Also install washers
and nuts on the solenoid switch and starting m otor
terminals.
7. Bench test solenoid for proper operation. Fig. 13S--Exploded V iew of Solenoid

CHARGING SYSTEMS
5.5" Series ID D e lc o tro n ............................................... 6 Y -8 10-SI Series Type 100 D elco tro n ................................. 6Y-11
5.5" SERIES 10 DELCOTRON

INDEX
fi Y 8
D isassem bly........................................................................ Test Lam p M e th o d ........................................................ 6Y-10
Cleaning and In sp ectio n ................................................. 6Y-9 O hm m eter M e th o d ........................................................ 6Y-10
Testing R otor ................................................................... 6Y-9 R epairs................................................................................. 6Y-11
G ro u n d s............................................................................ 6Y-9 Diode R eplacem ent........................................................ 6Y-11
Open C ir c u it................................................................... 6Y-9 Heat Sink Replacement ............................................... 6Y-11
Short C irc u it................................................................... 6 Y ‘9 Brush R eplacem ent........................................................ 6Y-11
Testing Stator ................................................................... 6Y-10 End Fram e Replacement ............................................ 6 Y -11
G ro u n d s............................................................................ 6Y-10 Drive End Fram e ........................................................ 6Y-11
Open C ir c u it................................................................... 6Y-10 Slip Ring End F r a m e ................................................. 6Y-12
Short C irc u it................................................................... 6Y-10 A ssem bly............................................................................ 6Y-12
Testing Diodes................................................................... 6Y-10
2. Remove 4 thru bolts then break loose the end frames by

D IS A S S EM B LY (fig. 1C) prying at bolt locations.
1. Hold generator in a vise, clamping the mounting flange 3. Remove the slip-ring end frame and stator (as an assem
lengthwise. bly) from drive end and rotor assembly.
R E LA Y T E R M IN A L F” T E R M IN A L
SLIP RING DRIVE END
END FRAME FRAME
" G R D ” T E R M IN A L THRU BEARING

BRUSH AND BOLT
TERMINAL
ASSEMBLY
SLIP RINGS
BEARING
PULLEY
DIODES FAN
ROTOR STATOR
ASSEMBLY
Fig. 1C --5.5” Series I D D e lcotron

4. Place a piece of tape over the slip ring end frame bearing (CHECK FOR GROUNDS)
to prevent entry of dirt or other foreign m atter. OHMMETER
CAUTION: Brushes may drop onto rotor shaft and

become contaminated with bearing lubricant. Clean
brushes prior to installing with a non toxic cleaner
such as trichlorethylene.
5. Remove the three stator lead attaching nuts and sepa

rate stator from end frame.
6. Remove screws, brushes and holder assembly.
7. Remove heat sink from end frame by removing "BAT"
and "G R D " term inals and one attaching screw (fig.
1C).
8. Remove slip ring end frame bearing (if necessary). Re
fer to bearing replacem ent included in this section.
9. Remove pulley retaining nut and slide washer, pulley
and fan from shaft.
a. Single Groove Pulley—Place 15/16" box wrench on
retaining nut and insert a 5/16" alien wrench into OHMMETER
(CHECK FOR SHORTS A N D OPENS)
shaft to hold shaft while removing nut (fig. 2C).
b. Double Groove P ulley-P lace a 15/16" socket (with
wrench flats on the drive end or use A dapter J- Fig. 3C--Checking Rotor fo r Grounds or Opens
21501 and a box wrench) on retaining nut, insert a
5/16" alien wrench through socket and adapter into
4. Slip rings which are out of round may be trued in a lathe
hex on shaft to hold the shaft while removing the
to .001" maxim um indicator reading. Remove only
nut.
enough material to make the rings smooth and concen
10. Remove rotor and spacers from end frame assembly.
tric. Finish with 400 grain polishing cloth and blow dry.
11. Remove drive end frame bearing retainer plate and
bearing assembly from frame. 5. Slip rings are not replaceable-excessive damage will
require rotor assembly replacement.
6. Inspect brushes for wear. If they are worn halfway,
CLEAN IN G AND IN SPECTIO N replace. Inspect brush springs for distortion or weaken
ing. If brushes appear satisfactory and move freely in
W ith D elcotron completely disassembled, except for re brush holder, springs may be reused.
moval of diodes, the com ponents should be cleaned and in
spected. Be sure testing equipm ent is in good working order
before attem pting to check the generator. TESTIN G ROTOR (fig. 3C)
1. W ash all m etal parts except stator and rotor assemblies.
The rotor may be checked electrically with a 110-volt test
2. Clean bearings and inspect for sealing, pitting or rough lamp or an ohmmeter.
ness.
3. Inspect rotor slip rings, they may be cleaned with 400
grain polishing cloth. R otate rotor for this operation to
Grounds
prevent creating flat spots on slip rings. Connect one test lamp or ohm m eter from either slip ring
to the rotor shaft or to the rotor poles. If the lamp lights or
if the ohm m eter reading is low, the field windings are
grounded.
Open Circuit
Connect one test lamp or ohm m eter lead to each slip ring.
If the lamp fails to light or if the ohm m eter reading is high,
the windings are open.
Short Circuit
The windings are checked for shorts by connecting a
12-volt battery and an am m eter in series with the two slip
rings. Note the am m eter reading. An am m eter reading above
the specified field amperage draw indicates shorted windings.
Fig. 2C~Pulley Removal Refer to Specifications at the end of this manual.

ENGINE ELECTRICAL 6 Y -1 0
OHMMETER
OHMMETER OHMMETER
TEST LAMP TEST LAMP
(Check for Opens) (Check for Grounds)
Fig. 4C--Checking Stator Fig. 5C--Checking Diodes
TESTIN G STA TO R (Fig. 4C) Test Lamp Method
Grounds
Diode in Heat Sink
Connect a 110-volt test lamp or an ohm m eter from any
stator lead to the stator frame. If test lamp lights or if ohm m W ith the stator previously disconnected connect one of
eter reads low, the windings are grounded. the lamp leads to the heat sink and other lead to the light in
only one of the test directions. If lamp lights in both direc
tions or fails to light at all, the diode is defective.
Open Circuit
If lamp fails to light of if ohm m eter reads high when
successively connected between each pair of stator leads, the Diode in the End Frame
windings are open.
Connect one lamp lead to the end frame and the other
lamp lead to the diode lead, and observe lamp condition.
Short Circuit Reverse the lamp lead connections and observe the lamp
A short in the stator windings is difficult to locate without condition. A good diode will allow lamp to light in only one
special test equipm ent due to the low resistance of the wind direction. If lamp lights in both directions or fails to light at
ings. However, if all other electrical checks are norm al and all, the diode is defective.
the generator fails to supply rated output, shorted stator
windings are indicated. Also, look for heat discoloration on
the windings.
Ohmmeter Method
TESTIN G DIO D ES (Fig. 5C) Use an ohm m eter with a 1-1/2 volt cell and use the lowest
range scale.
Two m ethods may be used to check diodes for shorts or Connect the ohm m eter leads at each diode as previously
opens, a test lam p of not more than 12 volts or an ohmmeter. described using a test lamp first in one direction and then the
other. N ote the readings. If both readings are identical (very
CAUTION: Do not use a 110-volt test lamp to test high or very low), the diode is defective. A good diode will
diodes. give one high and one low reading.

J9600-2 Heat Sink Replacement (Fig. 7C)

1. D etach heat sink from end frame by removing the two
attaching bolts. N ote carefully the proper stack up of
parts so the "BAT" and "G R D " term inal bolts can be
reassembled in the same manner.
2. Replace diodes, if necessary, as outlined in Diode Re
placement.
3. Assemble heat sink to the end frame, following care
fully the proper stack up of parts as noted in Step 1.
Brush Replacement (fig. 8C)

1. A fter through bolt removal and Delcotron separation,
remove stator lead nut that also holds relay term inal
connector.
Fig. 6C --lnstalling Diodes w ith Press Tools 2. Remove 2 m ounting screws and brush holder assembly.
R EP A IR S
3. Position new brush holder assembly and install retain
Diode Replacement (fig. 6C) ing screws.
4. Connect relay term inal wire lead and install stator lead
1. Support end frame with support Tool J-9717-2 and nut.
press out diode with diode removal Tool J-9717-1 and
an arbor press or vise. End Frame Replacement
CAUTION: Do not strike diode as shock may dam 1. Remove heat sink as outlined in H eat Sink Replace
age other diodes. ment.
2. A ttach brush holder assembly to the new end frame and
2. Select diode with proper color marking. insert pin or wire through the hole to hold the brushes
in the holder. After the D elcotron unit has been com
NOTE: Diodes in the heat sink are positive (red pletely assembled, w ithdraw the pin or wire from the
markings) and those in the end frame are negative end frame hole to allow the brushes to drop down onto
(black markings). the slip rings.
3. Replace heat sinks to end frame as outlined in Heat
3. Support outside end frame around diode hole on a flat, Sink Replacement.
sm ooth surface and press diode into position with J-
9600-2 and an arbor press or vise. M ake sure diode is
square with end fram e and started straight.
Bearing Replacement-Drive End Frame
1. The drive end frame bearing can be removed by detach
CAUTION: Avoid bending or moving diode stem as ing the retainer plate bolts and separating retainer plate
excessive movement can cause internal damage and seal assembly from end frame, and then pressing
and result in diode failure. bearing out using suitable tube or pipe on inner race.
2. Refill bearing one-quarter full with Delco-Remy No.
1948791 grease or equivalent. Do not overfill.
3. Press bearing into end frame using tube or pipe that fits
over outer race.

4. Install retainer plate. Use new retainer plate if felt seal

is hardened or excessively worn.
NOTE: Stake retainer plate bolts to plate.
Bearing Replacement--Slip Ring End

Frame 15/16
SOCKET
1. Replace the bearing if the grease supply is exhausted.
M ake not attem pt to re-lubricate and reuse the bearing.
2. Press bearing from outside of housing tow ard inside,
using suitable tool that just fits inside the end frame.
3. To install, place a flat plate over the bearing and press
in from outside of housing until bearing is flush with the
outside of the end frame. Support, inside of end frame
around bearing bore with a suitable tool to prevent 5/16 ALLEN
distortion. Use extreme care to avoid misalignment.
4. Saturate felt seal with S.A.E. 20 engine oil and install
seal and steel retainer at inner end of bearing assembly.
Fig. 9C --T o rquing Pulley N u t
A SSEM BLY
1. Install stator assembly in slip ring end frame and locate 3. Install fan, spacer, pulley washer and nut.
diode connectors over the relay, diode and stator leads, 4. Place torque wrench and A dapter (J-21501) on shaft
and tighten term inal nuts. nut and insert alien wrench into opening at end of drive
2. Install rotor in drive end frame. shaft. Tighten shaft nut to 40-50 ft. lbs. (fig. 9C).
10-SI SERIES TYPE 100 DELCOTRON

INDEX
D ISA SSE M B L Y ............................................................... 6Y-12 Short C irc u it.................................................................6Y - 14

Cleaning and In sp ectio n................................................. 6Y-14 Diode Trio C h e c k s........................................................6Y-15
T esting ................................................................................. 6Y-14 Rectifier Bridge C h e c k .................................................6Y-15
R otor Field W inding C h e c k s...................................... 6Y-14 Voltage Regulator B rush/L ead Check......................6Y-15
G ro u n d s.......................................................................... 6Y-14 R epairs.................................................................................6Y-16
Open Circuit ................................................................. 6Y-14 Brush Holder and Regulator R eplacem ent.............6Y-16
Short C irc u it................................................................. 6Y-14 Slip Ring Servicing.................. .....................................6Y-16
Stator Checks ................................................................. 6Y-14 Drive End Bearing Replacement and Lubrication 6Y-16
G ro u n d s.......................................................................... 6Y-14 Slip Ring End Bearing Replacement and
Open C ir c u it................................................................. 6Y-14 L u b rication .............................................................. 6Y-17
D IS A S S EM B LY (fig. 10C) NOTE: A scribe mark will help locate the parts in the
same position during assembly.
1. Hold generator in a vise, clamping the m ounting flange
lengthwise.
2. Remove the four thru-bolts and separate te slip ring end
frame and stator assembly from the drive end and rotor 3. Place a piece of tape over the slip ring end frame bearing
assembly by prying apart with a screwdriver at the to prevent entry of dirt and other foreign material, and
stator slot. also a piece of tape over the shaft at the slip ring end.

Fig. 10C--10-SI Series Delcotron
CAUTION: Brushes may drop onto the rotor shaft

NOTE: Two insulators are assembled over the top of
and become contaminated with bearing lubricant.
the brush retaining clips and the two screws have
Clean brushes prior to installing with a non-toxic
special insulating sleeves over the screw body.
cleaner such as trichlorethylene.
4. Remove the stator lead attaching nuts and separate

stator from end frame.
NOTE: At this point with the two end frames sepa

rated the stator disconnected and the rotor removed
electrical checks of the rotor, rectifier bridge, stator
and diode trio brush lead clip may be made without
further disassembly. Refer to the specific checks as
outlined in this section.
5. Remove screw attaching diode trio to brush holder as

sembly and remove diode trio from end frame (fig.
15C).
NOTE: Diode trio may be checked for a grounded

brush lead clip at this point. Refer to diode trio
checks.
6. Remove the rectifier bridge attaching screw and the OHMMETER

(CHECK FOR SHO RTS A N D O PE N S )
"BAT" term inal screw, and disconnect the capacitor
lead. Remove rectifier bridge from the end frame.
7. Remove two attaching screws, and remove brush
holder and regulator assemblies. Fig 1 1 0 -C h eckin g Rotor

8. Remove retaining screw and capacitor from end of

(CHECK FOR OPENS)
fram e (fig. 15C). OHMMETER
9. Remove slip ring end frame bearing (if necessary). Re
fer to bearing replacem ent covered in this section.
10. Remove pulley retaining nut and slide washer, pulley,
fan and spacer from shaft.
a. Single groove pulley-place 15/16" box wrench on
the shaft nut and insert a 5/16" alien wrench into
the shaft end hole to hold the shaft while removing
the nut (fig. 2C).
b. Double groove pulley-place a 15/16" socket (with
wrench flats on the drive end or use adapter J -2 1501
and a box w rench) on the pulley retaining nut, insert
a 5/16" alien wrench through the socket and
adapter into hex hole in the shaft to hold the shaft
while removing the nut.
11. Remove rotor and spacers from the drive end frame
assembly.
12. R em ove drive en d fram e b earin g re ta in e r p late
screw s, p late, b earin g , a n d slinger fro m e n d fram e
(if necessary ).
OHMMETER OHMMETER
(CHECK FOR OPENS) (CHECK FOR GRO U N D S)
CLEAN IN G AND IN SPECTIO N Fig. 12C--Checking Stator
Open Circuit
W ith generator completely disassembled the com ponents
should be cleaned and inspected. Be sure testing equipment Connect one test lamp or ohm m eter lead to each slip ring.
is in good working order before attem pting to check the If the lamp fails to light or if the ohm m eter reading is high,
generator. the windings are open.
1. W ash all metal parts except stator and rotor assemblies.
Short Circuit
2. Clean bearings and inspect for sealing, pitting or rough
ness. The windings are checked for shorts by connecting a 12
3. Inspect rotor slip rings, they may be cleaned with 400 volt battery and an ammeter in series with the two slip rings.
grain polishing clot. R otate rotor for this operation to Note the am m eter reading. An am m eter reading above the
prevent creating flat spots on slip rings. specified field amperage draw indicates shorted windings.
4. Slip rings which are out of round may be trued in a lathe Refer to Specifications at the end of this manual.
to .001" maximum indicator reading. Remove only
enough m aterial to m ake the rings sm ooth and concen
tric. Finish with 400 grain polishing clot and blow dry.
Stator Checks (fig. 12C)
Grounds
5. Slip rings are not replaceable-excessive damage will
require rotor assembly replacement. Connect a 110-volt test lamp or an ohm m eter from any
6. Inspect brushes for wear. If they are worn halfway, stator lead to the stator frame. If test lamp lights or if ohm m
replace. Inspect brush springs for distortion or weaken eter reads low, the windings are grounded.
ing. If brushes appear satisfactory and move freely in
brush holder, springs may be reused.
Open Circuit
If lamp fails to light or if ohm m eter reads high when
TESTIN G successively connected between each pair of stator leads, the
windings are open.
W here specified, conduct the following tests using an

ohm m eter with a 1- 1/2 volt cell and use the lowest range Short Circuit
scale for the readings.
A short in the stator windings is difficult to locate without
special test equipment due to the low resistance of the wind
Rotor Field Winding Checks (fig. 11C) ings. However, if all other electrical checks are norm al and
the generator fails to supply rated output, shorted stator
The rotor may be checked electrically with a 110-volt test windings are indicated. Also, look for heat discoloration on
lamp or an ohmmeter. the windings.

EN G IN E ELECTRICAL 6 Y -1 5
BRUSH
HOLDER REGULATOR
SINGLE CONNECTOR
INSULATED
Fig. 13C--Diode Trio Checks
HEAT SINK INSULATING
WASHER
GROUNDED
Diode Trio (fig. 13C) HEAT SINK
W ith the diode trio unit remove from the end frame, OHMMETER
connect an ohm m eter to the single connect and to one of the
three connectors. Observe the reading, then reverse the
ohm m eter leads to the same connectors. A good diode trio Fig. 14C--Rectifier Bridge Checks
will give one high and one low reading. If both readings are
the same, replace the diode trio. Repeat this test between the and between the insulated heat sink and each of the three
single connector and each of the other two connectors. terminals. W hen this is done all six diodes are checked with
two readings taken for each diode.
NOTE: There are two diode trio units differing in
appearance used in the generator but they are com
pletely interchangeable.
NOTE: The diodes are not replaced individually. The
The diode trio may also be checked for a grounded brush entire rectifier ridge is replaced if one or more diodes
lead while still installed in the end frame. Connect an ohm m are defective.
eter from the brush lead clip to the end frame as shown in
Step 2, Figure 15C, then reverse the lead connection. If both CAUTION: Do not use high voltage to check the
readings are zero, check for a grounded brush lead clip rectifier bridge, such as a 110 volt test lamp.
caused by omission of the insulating washer, of the insulating
sleeve over the screw, or dam aged insulating sleeve. Remove
the screw to inspect the sleeve. If sleeve or screw are not
grounded, replace regulator. Voltage Reg./Brush Lead Clip Check
CAUTION: Do not use high voltage to check the (fig. 15C)

diode trio, such as 110 volt test lamp.
Connect an ohm m eter from the brush lead clip to the end
Rectifier Bridge Check (fig. 14C) frame as shown in Step 1, Figure 15C. Then reverse lead
connections. If both readings are zero, either the brush lead
Connect an ohm m eter to the grounded heat sink and one clip is grounded or the regulator is defective.
of the three terminals. Then reverse the lead connections to A grounded brush lead clip can result from omission of the
the grounded heat sink and same terminal. If both readings insulating washer, omission of the insulating sleeve on the
are the same, replace the bridge. A good rectifier bridge will screw, or a damaged insulating sleeve. Remove the screw and
give one high and one low reading. Repeat this same test inspect the sleeve. If it is satisfactory, replace the regulator
between the grounded heat sink and the other two terminals, unit.

ENG INE ELECTRICAL 6 Y -1 6
Slip Ring Servicing

OHMMETER OHMMETER
INSULATING If the slip rings are dirty, they may be cleaned and fin
WASHERS ished with 400 grain or finer polishing cloth. Spin the rotor,
and hold the polishing cloth against the slip rings until they
are clean.
CAUTION: The rotor must be rotated in order that

the slip rings will be cleaned evenly. Cleaning the
slip rings by hand without spinning the rotor may
result in flat spots on the slip rings, causing brush
noise.
Slip rings which are rough or out of round should be trued

in a lathe to .002 inch maximum indicator reading. Remove
only enough m aterial to make the rings sm ooth and round.
Finish with 400 grain or finer polishing cloth and blow away
all dust.
Bearing Replacement-Drive End Frame

1. The drive end frame bearing can be removed by detach
ing the retainer plate bolts and separating retainer plate
and seal assembly from end frame, and then pressing
bearing out using suitable tube or pipe on outer race.
2. Refill bearing one-quarter full with Delco-Remy No.
CAPACITOR DIODE 1948791 grease or equivalent. Do not overfill.
ATTACHING TRI° 3. Press bearing into end frame using tube or pipe as in
RECTIFIER NUTS Step 1 with bearing and slinger assembled as shown in
BRIDGE Figure 16C.
4. Install retainer plate. Use new retainer plate if felt seal
Fig. 15C~Brush Lead Clip Checks is hardened or excessively worn.
R EP A IR S NOTE: Stake retainer plate bolts to plate.
Brush Holder and Regulator Replacement (fig.

15C)
1. If not previously removed, remove the three stator lead

attaching nuts, the stator, diode trio brush lead screw
and diode trio from the end frame.
2. Remove the rem aining two screws from the brush
holder and regulator and remove these units from the
end frame.
NOTE: The two screws retaining the brush clips

have insulating washers over the tops of the brush
clips and special insulating sleeves over the screw
body above the threads. If they are damaged or miss
ing a ground will result causing uncontrolled or no
output.
3. Replace defective unit and reassemble using reverse of

removal procedures.
NOTE: The screw nearest regulator terminals does

not have an insulating washer, but may or may not
have an insulating sleeve. Fig. 16C--Drive End Bearing Cross Section

EN GIN E ELECTRICAL 6 Y -1 7
Bearing Replacem ent-Slip Ring End NOTE: The two screws retaining the brush clips
have insulating washers over the top of the brush
Frame clips and special insulating sleeves over the screw
body above the threads. If the third screw does not
1. Replace the bearing if the grease supply is exhausted. have an insulating sleeve, it must not be inter
M ake no attem pt to re-lubricate and reuse the bearing. changed with either of the other two screws.
2. Press out from outside of housing, using suitable tool
over outer race of bearing.
3. To install, place a flat plate over the bearing and press 5. Position rectifier bridge to end frame. Install attaching
in from outside of housing until bearing is flush with the screw and the "BAT" term inal screw. Connect capaci
outside of the end frame. Support inside of end frame tor lead to bridge.
around bearing bore with a suitable tool to prevent 6. Position diode trio on rectifier bridge term inal and in
distortion. Use extreme care to avoid misalignment. stall screw attaching brush lead clip to brush holder.
4. Install new seal whenever bearing is replaced. Lightly
coat the seal lip with oil and press seal into the end
frame with the seal lip tow ard the inside of the end
frame. CAUTION: Insulating washer on the screw must be
assembled over top of the connector.
R E A S S E M B LY
1. Install rotor in drive end frame and attach spacer, fan, 7. Position stator in end frame. Connect stator leads to
pulley, washer, and nut. rectifier bridge term inals and install attaching nuts.
2. Using adapter J-2 1501, insert an alien wrench into hex 8. Position slip ring end frame to drive end frame and
shaped hole at end of shaft and torque the shaft nut to install four thru bolts.
40-50 ft. lbs. (fig. 9C).
3. Install capacitor and retaining screw in slip ring end
frame. NOTE: Remove tooth pick from brush holder at
4. Position brush holder and regulator assemblies in end opening in slip ring end frame before operating ma
fram e and install two retaining screws. chine on vehicle.

EN G IN E ELECTRICAL 6Y -1 8
SPECIAL TOOLS
J 9 7 1 7 -2 J 9 7 1 7 -1 J-9 6 0 0 -2 J - 2 1 501
SUPPORT PRESS SHOULDERED PULLY
TO O L TO O L INSTALLER ADAPTER
Fig. 17C -S pe cial Tools

SECTION 7
CLUTCHES AND TRANSM ISSIONS

CONTENTS
Single Plate D iaphragm Spring C lu tc h ...................... 7- 1 4-Speed New Process Transmission (Model 435).... 7- 49
D ual Plate D iaphragm Spring C lu tc h ........................ 7 -3 D ana Model 20 Transfer C a se ...................................... 7- 60
Single Plate Coil Spring C lu tc h ................................... 7- 4 New Process M odel 205 Transfer C ase...................... 7-66
3-Speed Saginaw T ransm ission...................................... 7 -8 A dapter Assemblies ........................................................ 7-74
3-Speed M uncie Transm ission ...................................... 7-14 A lum inum Powerglide ................................................... 7-77
4-Speed Saginaw T ransm ission...................................... 7-20 Turbo H ydra-M atic.......................................................... 7-99
4-Speed M uncie Transm ission (Passenger C ar)........ 7-29 Special T o o ls..................................................................... 7-192
4-Speed M uncie Transm ission (M odel 465) ............. 7-37
SINGLE PLATE DIAPHRAGM CLUTCH
INDEX
D isassem bly........................................................................ 7- 2 A ssem bly............................................................................ 7-3

Inspection and R epair...................................................... 7- 2 Pilot Bearing Replacem ent............................................... 7- 3
Fig. 1—Flat Finger Clutch Cross-Section (Typical)
1. Flywheel 5. Pressure Plate 9. Fork

2. Dowel-hole 6. Diaphragm Spring 10. Retracting Spring
3. Pilot Bushing 7. Cover 11. Drive Straps
4. Driven Disc 8. T hrow ou t Bearing

CLUTCHES AND TRANSMISSIONS 7-2
Fig. 2~Bent Finger Clutch Cross-Section (Typical)
1. Flywheel 5. Pressure Plate 8. T h ro w o u t Bearing

2. Dowel-hole 6. Diaphragm Spring 9. Fork
3. Pilot Bushing 7. Cover 10. Retracting Spring
4. Driven Disc
NOTE: When disassembling, mark edge of pressure 1. Remove three drive-strap to pressure plate bolts and
plate and cover. These marks must be aligned in retracting springs and remove pressure plate from
assembly to maintain balance. clutch cover.
2. The clutch diaphragm spring and two pivot rings are
riveted to the clutch cover. Spring, rings and cover
Disassembly (Fig. 3) should be inspected for excessive wear or damage and
if there is a defect, it is necessary to replace the complete
cover assembly.
Inspection and Repair

1. Check drive straps for looseness at the clutch cover and
evidence of looseness at pressure plate bolt holes.
2. W ash all parts, except driven disk and throw out bear
ing, in cleaning solvent.
NOTE: The throwout bearing is permanently packed

with lubricant and should not be soaked in cleaning
solvent as this will dissolve the lubricant.
Inspect pressure plate and flywheel for scores on the

contact surfaces. Use a straight-edge and check for flat
ness of contact surfaces.
Check throw out bearing for roughness and free fit on
the sleeve of the transmission clutch gear bearing re
tainer. Replace retainer if rough.
Inspect clutch disc for worn, loose or oil soaked facings,
Fig. 3 -R e tra ctin g Spring Location (Typical) broken springs, loose rivets, etc. Replace if necessary.

6. Exam ine splines in hub and m ake sure they slide freely
on splines of transm ission clutch shaft. If splines are
worn, the clutch disc or clutch gear should be replaced
as necessary.
7. Inspect clutch fork ball socket and fingers for wear and
ball retaining spring for damage. Spring should hold
fork tightly to ball stud.
NOTE: Ball spring on fork may be bent in toward

fork if necessary.
8. Inspect ball stud for wear. Replace if scored.

9. Check run out of transm ission pilot hole in clutch hous
ing by removing a flywheel bolt and installing a dial
indicator. The run out should be within .000-.015".
10. Lubricate ball stud before reassembly.
Assembly
1. Install the pressure plate in the cover assembly, lining
up the punch m arks on the edge of the pressure plate
with the punch m arks on the edge of the cover. Fig. 4 -C lu tch Pilot Bearing Removal (Typical)
2. Install pressure plate retracting springs and drivestrap
to pressure plate bolts and lock washers and tighten to tion when the clutch is removed from the vehicle, at which
11 ft. lbs. torque. The clutch is now ready to be in time it should be cleaned and inspected for excessive wear or
stalled. damage and should be replaced if necessary.
To remove, install Tool J-1448 and remove bearing from
Pilot Bearing Replacement crankshaft (fig. 4). In replacing this bearing, use Tool J-1522.
Place bearing on pilot of tool with radius in bore of bearing
T he clutch pilot bearing is an oil im pregnated type bear next to shoulder on tool and drive into crankshaft. Lubricate
ing pressed into the crankshaft. This bearing requires atten- with several drops of machine oil.
DUAL PLATE DIAPHRAGM SPRING CLUTCH

INDEX
D is a s s e m b ly .................................................................... 7-3 A sse m b ly .......................................................................... 7-4
In sp e c tio n a n d R e p a ir ................................................ 7-3 Pilot B earing (R efer to Single P late C lu tc h ). . . . 7-3
Disassembly (Fig. 5)
CAUTION: Assembly should be handled with pres- 2. Remove front pressure plate and rear driven disc from
sure plate face up to prevent movement of the plate the cover assembly.
and distortion of the retracting spring. 3. The rear pressure plate, clutch diaphragm spring, and
pivot rings are riveted to the clutch cover. These items
1. W ith assembly resting on flywheel side of cover, remove and the front pressure plate should be inspected for
drive strap-to-front pressure plate bolts and washers. wear or damage and if there is any defect, it is necessary
Care should be taken to support the front pressure plate to replace the complete cover and pressure plates as
to prevent bending o f the drive straps. sembly.
NOTE: Before disassembling, note location of A0'

marks on edge of intermediate pressure plates and
cover stamping. These parts must be aligned in reas Inspection and Repair
sembly to maintain the balance of the assembly.
Scribe alignment marks, if "0* marks cannot be Refer to inspection and repair procedures covered under
located. single plate clutch assemblies.

Assembly
1. Install clutch disc and front pressure plate in the cover
assembly, aligning the reference " 0 " m ark on the edge
of the pressure plate with the " 0 " m ark on the edge of
the cover.
2. Install lock washers and bolts retaining front pressure
plate to the cover. Torque bolts to 18 ft. lbs.
Fig. 5 -D u a l Plate Clutch Assem bly
1. Flywheel 6. Rear Pressure Plate

2. Front Driven Disc 7. Cover
3. Front Pressure Plate 8. Retracting Spring
4. Dowel Hole 9. Fork
5. Rear Driven Disc
SINGLE PLATE COIL SPRING CLUTCH
INDEX
D isassem bly........................................................................ 7-5 A ssem bly............................................................................ 7-6

Inspection (Refer to D iaphragm C lutch es)............... 7-2 Adjusting L evers............................................................... 7-7

TRUCK CLUTCHES AND TRANSMISSIONS 7-5
Fig. 3E -D isassem bly of Clutch
Disassembly
1. Place the cover assembly on the bed of an arbor or drill
press with a block under the pressure plate so arranged
that the cover is left free to move down.
2. Place a block or bar across the top of the cover with the
spindle. H old compressed while the adjusting nuts are
removed as shown in Figure 2E, then slowly release
pressure to prevent springs flying out.
3. Lift off cover and all parts will be available for inspec
tion. N ote carefully the location of all parts including
Fig. 1 E -C oil Spring C lutch Cross-Section (Single Plate) arrangem ent of springs, see (fig. 3E).
1. Release Lever
2. Eyebolt 8. Pressure Plate
4. To remove levers grasp lever and eyebolt between
3. S trut 9. A nti-R attle Spring thum b and fingers as shown in Figure 4E, so that inner
4. Cover 10. T h ro w o u t Bearing end of lever and upper end of eyebolt are close together,
6. Coil Spring 1 1. Flywheel keeping eyebolt pin seated in its socket in lever.
Fig. 4E-R em oving Levers (Step 1)
1. Release Lever
2. Eyebolt
Fig. 2E--Compressing Clutch 3. Strut

Fig. 7 E— Installing Lever
Fig. 5E -R em oving Levers (Step 2)
1. Release Lever NOTE: If there are spaces for more springs than
2. Eyebolt
specified for the particular assembly, or if two differ
3. S trut
ent colors of springs are used. Figure 8E shows the
5. Lift stru t over ridge on end of lever, (fig. 5E). proper sequence. It is very important that each
group be arranged in like sequence.
6. Lift lever and eyebolt off pressure plate.
7. Assemble anti-rattle springs in cover as shown in Fig
NOTE: It is important to replace all parts which ure 9E. The spring to the left is in operating position.
show wear. 8 . Lower the cover on top of the assembled parts, (fig.
10E) being sure that the anti-rattle springs are in correct
Assembly position and also th at the punch m arks m ade before
dism antling are m atched to insure retaining the original
1. Lay the pressure plate on the block in the press and coat balance.
the lugs with a thin film of approved lubricant such as 9. Place a bar across the cover and slowly compress, guid
lubriplate as shown in Figure 6 E. ing the holes in the cover over the pressure plate lugs
2 . Assemble lever, eyebolt and pin, holding eyebolt and and all springs into their spring seats in the cover.
lever as close together as possible and with the other 10. Assemble adjusting nuts on the eyebolts and screw
hand grasp strut as shown in figure 7E. them down until their tops are flush with the tops of the
3. Insert Strut in the slots in the pressure plate lug, drop eyebolts. Slowly release pressure of spindle and remove
slightly and tilt the lower edge until it touches vertical cover assembly from press.
milled surface of lug.
4. Insert lower end of eyebolt in hole in pressure plate. The
short end of the lever will then be under the hook of the Adjusting Levers
pressure plate and near the strut, (fig. 5E).
W hile no wear adjustm ent is needed because of the coil
5. Slide the stru t upw ard in the slots of the lug, lifting it
spring design, it is imperative that the clutch release levers
over the ridge on the short end of the lever and drop it
are each set to exactly the same height at the time of m anu
into the groove in the lever, (fig. 4E).
facture or rebuild to insure uniform clutch application. To
6. Assemble the pressure springs, on the small bosses of
obtain exactly the same adjustm ent at each release lever, use
the pressure plate in accordance with Figure 8 E in or
gauge plate J-1048 and release lever height gauge J-6456 as
der to retain original balance.
follows:
6 S P R IN G S
3 SPRINGS P A IN T E D
UNPAINTED B LA C K
A D JAC E N T
T O LEVERS
6 S P R IN G S
9 SPRINGS U N P A IN T E D
PAINTED
3 9 6 -V 8
ORANGE
3 5 0 V -8 ADJACENT
TO LEVERS
Fig. 6E-G reasing Lug Fig. 8 E -S p ring A rrangem ent Diagram

Fig. 1 1 E-Gauge Plate Position
Fig. 9E— Installing A nti-R attle Spring
3. Depress each lever several times with a ham m er handle

to settle all parts into working position.
1. Place gauge plate J-1048 (fig. 11E) on the flywheel in
position norm ally occupied by driven plate.
4. Position height gauge J-6456 on the hub of the gauge
plate and the bearing surface of one lever (fig. 13E).
NOTE: It is recommended that a spare flywheel be T urn adjusting nut until lever is flush with proper step
obtained so that this operation may be performed at of height gauge. A djust remaining levers in same m an
the bench. ner. The height gauge (insert) has three steps for use
with the five basic coil spring clutches currently availa
2. Bolt cover on flywheel w ith gauge plate center. ble. One step is used for the 10" clutch, one step for the
13" clutch, while the third step is used for 10-1/2", 11",
NOTE: On assemblies with three levers, the three and 12" clutches. Each side is identified accordingly,
flat machined lands of the gauge plate must be with the step of the gauge contacting the bearing surface
located directly under the levers. On the larger 13" of the lever identified by "Lever". Use the 10-1/2, 11
clutch with four levers, any position is satisfactory. step for 12 " clutches.
Fig. 10E -A ssem bling Cover and Pressure Plate Fig. 1 2E-D epressing Lever

J-6456
ADJUSTING
NUT
Fig. 1 4E--Staking Nut
6. Loosen the cover to flywheel bolts a turn or two at a

time and in rotation until spring pressure is relieved to
allow clutch and gauge plate to be removed.
Fig. 1 3 E—Coil S pring Clutch A djustm en t
5. Stake adjusting n u t (fig. 14E) to eyebolt with a dull

punch to lock adjustm ent.
3-SPEED SAGINAW TRANSMISSION

INDEX
SUBJECT PAGE
Disassembly of T ran sm issio n ........................................ 7- 8 Countergear A nti-Lash P la te ..........................................7-11

Disassembly o f M ainshaft............................................... 7-10 R epairs.....................................................................................7-11
Cleaning and In sp ectio n................................................. 7-10 Clutch Keys and S p rin g ...................................................7-11
Transm ission C a s e ........................................................ 7-10 Extension Oil Seal or B u sh in g ................................... ... 7-11
F ront and R ear B e a rin g s............................................. 7-10 Clutch Bearing Retainer Oil Seal.................................. 7-11
Bearing R o lle rs ............................................................... 7-10 Assembly of M ainshaft................................................... ... 7-11
G e a r s ................................................................................. 7-11 Assembly of T ran sm issio n ............................................ ... 7-14
Reverse Idler G ear B u shing........................................ 7-11
D IS A S S E M B L Y OF TRA N SM ISSIO N 6. Remove clutch gear, m ainshaft and extension assembly

together through the rear case opening. Remove clutch
1. Remove side cover attaching screws and remove side drive gear, needle bearings and synchronizer ring from
cover assembly and shift forks. m ainshaft assembly.
2. Remove clutch gear bearing retainer. 7. Using snap ring pliers, expand the snap ring in the
3. Remove clutch gear bearing to gear stem snap ring, extension which retains the m ainshaft rear bearing (fig.
then remove clutch gear bearing by pulling outw ard on 2A) and remove the extension.
clutch gear until a screw driver of other suitable tool 6. Using J-22246 at the front of the countershaft, drive the
can be inserted between bearing large snap ring and case shaft and its w oodruff key out the rear of the case. Tool
to complete removal. The clutch gear bearing is a slip J-22246 will now hold the roller bearings in position
fit on the gear and into the case bore. (This provides within the countergear bore. Remove the gear and bear
clearance for removal o f clutch gear and m ainshaft as ings.
sembly.) 9. Use a long drift or punch through the front bearing case
4. Remove extension to case attaching bolts. bore and drive the reverse idler shaft and w oodruff key
5. Remove the reverse idler shaft "E" ring. through the rear of the case (fig. 3A).

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21
30 31 32 33 34 35 36 37 38 39 40

Fig. 1 A -S a g in a w 3-Speed T ransm ission C ross-Section (Pass. Car)
31. A nti-Lash Plate
A ssem bly
1. C lutch Gear 10. 1st Speed Gear 16. Snap R in g -B e a rin g 24. Clutch Gear Bearing 32. M agnet
2. B earing Retainer 11. 1st Speed B locker to M a in sh a ft 25. Snap R ing-B earing 33. 2-3 Synch. Sleeve
3. P ilo t B earings Ring 17. Extension to Case 34. C o untergear
CHEVROLET
4. Case 12. 1st Speed Synch. 18. V en t 26. Thrust W a sh e r-F ro n t 35. C ounter S haft
5. 3 rd Speed B locker Hub 19. Speedom eter Drive 27. Thrust W asher-R ear 36. Reverse Id le r S haft
Ring 13. 1st Speed Synch. Gear and Clip 28. Snap R ing-B earing 37. 1st Speed Synch.
OVERHAUL MANUAL
6. 2-3 Synch. Snap Ring Snap Ring 20. M a in sh a ft to Extension Sleeve

7. 2-3 Synch. Hub 14. Reverse Gear 21. Rear Oil Seal 29. Rear Bearing 38. "E " Ring
8. 2nd Speed B locker 15. Reverse Gear T hrust 22. Retainer Oil Seal 30. Countergear Roller 39. Reverse Idle r Gear
Ring and S pring W ashers 23. Snap R in g -B e a rin g Bearings 40. W o o d ru ff Key
9. 2nd Speed Gear to Gear
2. Depress speedometer retaining clip and slide gear from

mainshaft.
3. Remove rear bearing snap ring from m ainshaft groove.
4. Support reverse gear with press plates and press on rear

of m ainshaft to remove reverse gear, th ru st washer,
spring washer, rear bearing, and snap ring from rear of
mainshaft.
CAUTION: When pressing rear bearing be careful to

center gear, washers, bearings and snap ring on
mainshaft
5. Remove the 1st and Reverse sliding clutch hub snap

ring from the m ainshaft and remove the clutch assem
bly, 1st speed blocker ring and first speed gear from rear
Fig. 2A -E xtension to Rear Bearing Snap Ring of the mainshaft.
This completes the disassembly of the mainshaft.
CLEAN IN G AND IN SPECTIO N
Transmission Case
1. W ash the transmission thoroughly inside and outside
with cleaning solvent, then inspect the case for cracks.
2. Check the front and rear faces for burrs, and if present,
dress them off with a fine mill file.
3. Check bearing bores in case and, if damaged, replace

Fig. 3A -R em oving Reverse Idler S haft case.
Front and Rear Bearings

1. W ash the front and rear ball bearings thoroughly in a
NOTE: The truck 3-speed Saginaw manual trans
cleaning solvent.
mission uses a different reverse idler gear shaft
than passenger car models. The passenger car
2. Blow out bearings with compressed air.
model idler shaft has the retaining ring groove at the
center of the shaft whereas the truck model shaft
has the groove relocated off-center and further
CAUTION: Do not allow the bearings to spin, turn
away from the gear. A spacer is released in conjunc
them slowly by hand. Spinning bearings will dam
tion with the truck model shaft to fit between the
age the race and balls.
retaining ring and idler gear to keep the gear from
moving axially. The truck model shaft and spacer
unit will be used to service all models.
3. M ake sure bearings are clean, then lubricate with light
engine oil and check them for roughness by slowly tu rn
ing the race by hand.
D IS A S S E M B L Y OF M AIN SH AFT Bearing Rollers

1. Using snap ring pliers, remove the 2nd and 3rd speed All clutch gear and counter gear bearing rollers should
sliding clutch hub snap ring from m ainshaft and be inspected closely and replaced if they show wear. Inspect
remove clutch assembly, second speed blocker ring and counter shaft and reverse idler shaft at the same time, replace
second speed gear from front of mainshaft. if necessary. Replace all worn washers.

TRUCK CLUTCHES AND TRANSMISSIONS 7-11
Gears
1. Inspect all gears for excessive wear, chips or cracks and
replace any th at are worn or damaged.
2. Inspect reverse gear bushing and if worn or damaged
replace the entire gear.
NOTE: Reverse gear bushing is not serviced sepa

rately.
3. Check both clutch sleeves to see th at they slide freely

on their hubs.
Reverse Idler Gear Bushing

The bushing used in the idler gear is pressed into the gear
and finished bored in place. This insures the positive align
m ent of the bushing and shaft as well as proper meshing of
the gears. Because of the high degree of accuracy to which
these parts are machined, the bushing is not serviced sepa
rately.
Fig. 4 A -S yn chro nize r Assem bly

Countergear Anti-Lash Plate
Inspect the plate teeth for wear or other damage. The
plate and two dam per springs are retained to the countergear
Extension Oil Seal or Bushing i
by three rivets. Disassembly is not recomm ended (fig. 6 A). If bushing in rear of extension requires replacement,
remove seal and use Tool J-5778 to drive bushing into exten
sion housing. Using the same tool, drive new bushing infrom
R E P A IR S the rear. Coat I.D . of bushing and seal with transmission
lubricant, then install new oil seal using Tool J-5154.
Clutch Keys and Springs

Replacem ent Clutch Bearing Retainer Oil Seal
If the lip seal in the retainer needs replacement; pry the
NOTE: The clutch hubs and sliding sleeves are a old seal out and replace with a new seal using Installer Tool
selected assembly and should be kept together as J-23096, or similar tool, until seal seats in its bore.
originally assembled, but the keys and two springs
may be replaced if worn or broken. A S S E M B L Y OF M AIN SH AFT (Fig. 5A)
Turn the front of the m ainshaft upward. Install the follow

ing com ponents of the mainshaft:
1. M ark hub and sleeve so they can be m atched upon 1. Install the second speed gear with clutching teeth up
reassembly. ward; the rear face of the gear will butt against the
2. Push the hub from the sliding sleeve, the keys and the flange on the mainshaft.
springs m ay be easily removed. 2. Install a blocking ring with clutching teeth downward
3. Place the three keys and two springs in position (one on over the synchronizing surface of the second speed gear.
each side of hub), so all three keys are engaged by both All three blocker rings used in this transmission are
springs (fig. 4A). The tanged end of each synchronizer identical.
spring should be installed into different key cavities on 3. Install the second and third synchronizer assembly with
either side. Slide the sleeve onto the hub aligning the the fork slot downward; press it onto splines on the
m arks m ade before disassembly. m ainshaft until it bottom s out. Both synchronizer as
semblies used in this transmission are identical. (If
sleeve becomes removed from 2-3 hub; notches on hub
NOTE: A groove around the outside of the synchro O.D. face forward end of mainshaft).
nizer hub identifies the end that must be opposite
the fork slot in the sleeve when assembled. This
groove indicates the end of the hub with a .07" CAUTION: Be sure the notches of the blocker ring
greater recess depth. align with the keys of the synchronizer assembly.

Fig. 5A~Clutch Gear and M ainshaft Assem bly
1. Clutch Gear 6. 2-3 Synchronizer 11. 1st Speed Blocker 15. Reverse Gear Thrust
2. Clutch Gear Bearing Assem bly Ring W asher
3. 3rd Speed B locker 7. 2nd Speed blocker 12. 1st Speed 16. Spring W asher
Ring Ring Synchronizer 17. Rear Bearing
4. M ainsha ft Pilot 8. 2nd Speed Gear Assem bly 18. Snap Ring
Bearings (14) 9. S houlder (Part of 13. Snap Ring 19. Speedo Drive Gear
5. Snap Ring M ain Shaft) 14. Reverse Gear and Clip
10. 1st Speed Gear 20. M ainshaft
4. Install synchronizer hub to m ainshaft snap ring. Both

synchronizer snap rings are identical.
T urn the rear of the m ainshaft upward. Install the follow
ing com ponents on the mainshaft:
5. Install the first speed gear with clutching teeth up
ward ; the front face of the gear will bu tt against the
flange on the mainshaft.
6 . Install a blocker ring w ith clutching teeth downward
over synchronizing surface of the first speed gear.
7. Install the first and reverse synchronizer assembly with
fork slot downward; press it onto splines on the m ain
shaft.
CAUTION: Be sure the notches of the blocker ring

align with the keys of the synchronizer assembly.
8. Install synchronizer hub to m ainshaft snap ring.

9. Install reverse gear with clutching teeth downward.
10. Install reverse gear th ru st washer (steel).
11. Install reverse gear spring washer. Fig. 6 A -L o a d in g Countergear Bearings w /T o o l J-2 2 2 4 6

Fig. 7A--3-Speed Transm ission Explode
1. T hrust W asher - Front 19. 3rd Speed Blocker 33. 1-2 S ynchronizer Hub 47. Gasket
2. Bearing W asher Ring Assem bly 48. 2-3 S hift Fork
3. Needle Bearings 20. "E " Ring 34. 1-2 S ynchronizer 49. 1st and Reverse S hift
4. C ountergear 21. Reverse Idler Gear Sleeve Fork
5. Needle Bearings 22. Reverse Idler Shaft 35. Snap Ring - Hub to 50. 2-3 S hifter Shaft
6. Bearing W ahser 23. W o o d ru ff Key Shaft Assem bly
7. T hrust W asher - Rear 24. Snap Ring - Hub to 36. Reverse Gear 51. 1st and Reverse
8. Counter Shaft Shaft 37. T hrust W asher S hifter Shaft
9. W o o d ru ff Key 25. 2-3 Synchronizer 38. Spring W asher Assem bly
10. Bearing Retainer Sleeve 39. Rear Bearing 52. " 0 " Ring Seal
1 1. Gasket 26. Synchronizer Key 40. Snap Ring - Bearing 53. "E " Ring
12. Oil Seal Spring to Shaft 54. Spring
13. Snap Ring - Bearing 27. 2-3 Synchronizer Hub 41. Speedom eter Drive 55. 2nd and 3rd Detent
to Case A ssem bly Gear Cam
14. Snap Ring - Bearing 28. 2nd Speed Blocker 42. Retaining Clip 56. 1st and Reverse
to Gear Ring 43. Gasket Detent Cam
15. Clutch Gear Bearing 29. 2nd Speed Gear 44. Snap Ring - Rear 57. Side Cover
16. Case 30. M ainshaft Bearing to Extension 58, TCS S w itch and
17. Clutch Gear 31. 1st Speed Gear 45. Extension Gasket
18. Pilot Bearings 32. 1st Speed Blocker 46. Oil Seal 59. Lip Seal
Ring

12. Install rear ball bearing w ith snap ring slot downward; 6. Pilot the clutch gear, pilot bearings and 3rd speed
press onto m ainshaft. blocker ring assembly over the front of the mainshaft
13. Install rear bearing to m ainshaft snap ring. assembly. D o not assemble bearing to gear yet.
14. Install speedom eter drive gear and retaining clip.
CAUTION: Be sure the notches in the blocker ring
align with the keys in the 2-3 synchronizer assem
bly.
A S S E M B L Y OF TRA N SM ISSIO N
1. Using Tool J-22246 load a row of roller bearings (27) 7. Place extension to case gasket at rear of case holding in
and a bearing th ru st w asher at each end o f the counter place with grease and, from the rear of case, assemble
gear. Use heavy grease to hold them in place (fig. 6 A). the clutch gear, m ainshaft and extension to case as an
2. Place countergear assembly through case rear opening assembly.
along w ith a tanged th ru st washer (tang away from
gear) at each end and install countergear shaft and CAUTION: Be sure the clutch gear engages the
w oodruff key from rear of case. countergear anti-lash plate.
8. Install extension to case retaining bolts.

CAUTION: Be sure countershaft picks up both 9. Install front bearing outer snap ring to bearing and
thrust washers and that the tangs are aligned with position bearing over stem of clutch gear and into front
their notches in the case. case bore.
10. Install snap ring to clutch gear stem, and clutch gear
bearing retainer and gasket to case.
3. Install reverse idler gear and shaft with its w oodruff key
from the rear of case. D o not install idler shaft "E" ring NOTE: The retainer oil return hole should be at the
yet. bottom.
4. Using snap ring pliers, expand the snap ring in the
extension and assemble extension over rear of main- 11 - Install reverse idler gear retainer "E" ring to shaft.
shaft and onto rear bearing. Seat snap ring in rear bear- 12. Shift synchronizer sleeves to neutral positions and
ing groove (fig. 2A). install cover, gasket and fork assembly to case. Be sure
5. Load the m ainshaft pilot bearings (14) into the clutch forks align with their synchronizer sleeve grooves.
gear cabity and assemble the 3rd speed blocker ring 13. Tighten all bolts to specified torque.
onto the clutch gear clutching surface with its teeth 14. R otate clutch gear shaft and shift transmission to free
tow ard the gear. rotation in all gears.
THREE-SPEED MUNCIE TRANSMISSION

INDEX
SUBJECT PA G E
Disassembly of Transm ission ..........................................7-14 C ountergear A nti-Lash P la te .......................................... 7-17

Disassembly of M ainshaft...................................................7-16 R epairs..................................................................................... 7-17
Cleaning and In sp ectio n ................................................. ....7-16 C lutch Keys and Springs-
Transm ission Case.......................................................... ....7-16 Replacem ent ................................................................... ....7-17
F ront and R ear B earings..................................................7-16 Extension Oil Seal or B u sh in g ................................... .... 7-17
Bearing R o lle rs ...................................................................7-16 C lutch Bearing Retainer Oil Seal...................................7-17
G e a r s ................................................................................. ....7-17 Assembly of M ainshaft................................................... ....7-17
Reverse Idler G ear B u sh in g ............................................7-17 Assembly of T ran sm issio n ............................................ ....7-18
D IS A S S E M B L Y OF TRA N SM ISSIO N 3. Remove clutch gear bearing to gear stem snap ring,
then remove clutch gear bearing by pulling outw ard on
(Fig. 1G) clutch gear until a screw driver or other suitable tool
can be inserted between bearing, large snap ring and
1. Remove side cover attaching bolts, side cover assembly, case to complete removal. The clutch gear bearing is a
slip fit on the gear and into the case bore. (This provides
gasket and shift forks.
2. Remove clutch gear bearing retainer bolts, retainer and clearance for removal of clutch gear and mainshaft as
gasket. sembly.)

Fig. 1G ~Transm ission Cross S ection
1. C lutch Gear 8. 1st Speed 15. Rear Bearing-to-S haft 21. Reverse Idler Shaft
2. C lutch Gear Bearing Synchronizer Ring Snap Ring 22. C ountergear
Retainer 9. 1st Reverse Clutch 16. Rear Bearings
3. 3rd Speed Assy. Bearing-to-Extension 23. C ountergear
S ynchronizer Ring
CHEVROLET
10. Reverse Gear Snap Ring 24. Case M agnet

4. 2 n d-3 rd Speed Clutch 11. V ent 17. C ountergear 25. A nti-Lash Plate Assy.
Assy. 12. S peedom eter Gear W o o d ru ff Key (Pass. Only)
5. 2nd Speed and Clip 18. T hrust W asher 26. T hrust W asher
OVERHAUL MANUAL
S ynchronizer Ring 13. Rear Extension Seal 19. Reverse Idler S haft 27. Clutch Gear Bearing
6. 2nd Speed Gear 14. Rear Extension W o o d ru ff Key 28. Snap Ring
7. 1st Speed Gear 20. Reverse Idle r Gear 29. C lutch Gear Retainer
Lip Seal
4. Remove extension to case attaching bolts.

5. R otate extension to left until groove in extension hous
ing flange lines up w ith the reverse idler shaft. Using a
drift or other suitable tool, drive reverse idler shaft out
of gear and case (fig. 2G).
6 . Remove clutch gear, m ainshaft and extension assembly
together through case rear opening. Remove reverse
idler gear from case.
7. Remove clutch gear from mainshaft.
8 . Using snap ring pliers, expand the snap ring in the
extension which retains the m ainshaft rear bearing (fig.
3G). Tap gently on end m ainshaft and remove exten
sion from m ainshaft.
D IS A S S E M B L Y OF M A IN SH AFT (Fig.
4G)
1. Depress speedom eter gear retaining clip and slide gear
from m ainshaft.
2. Remove rear bearing snap ring from m ainshaft groove.
Fig. 3G~Removing Rear Extension From M ainshaft
3. Support reverse gear w ith press plates and press on rear
of m ainshaft to remove reverse gear, thrust washer and
rear bearing from shaft. 7. Support 2nd speed gear with press plates and press on
front of mainshaft to remove clutch assembly, second
speed blocker ring and second speed gear from shaft.
CAUTION: When pressing rear bearing be careful to This completes the disassembly of mainshaft.
center gear, washers, and bearing on shaft.

4. Remove 1st and reverse sliding clutch hub snap ring
from the m ainshaft.
5. Support 1st gear w ith press plates and push on rear of
m ainshaft to remove the clutch assembly, blocker ring Transmission Case
and 1st speed gear. 1. W ash the transmission thoroughly inside and outside
with cleaning solvent, then inspect the case for cracks.
CAUTION: Exercise care to prevent distortion of 2. Check the front and rear faces for burrs, and if present,
snap rings during expansion. dress them off with a fine mill file.
3. Check bearing bores in case and, if damaged, replace
6. Using snap ring pliers, remove the 2nd and 3rd speed case.
sliding clutch hub snap ring from mainshaft.

1. W ash the front and rear ball bearings, thoroughly in a
cleaning solvent.


Bearing Rollers
All clutch gear and countergear bearing rollers should be
inspected closely and replaced if they show wear. Inspect
counter shaft and reverse idler shaft at the same time, replace
Fig. 2G--Removing Reverse Idler Shaft if necessary. Replace all worn washers.

CLUTCHES AND TRANSMISSIONS 7-1 7
Fiq. 4G--Clutch Gear and M ainshaft Assem bly
1. Clutch Gear 7. Retaining Clip 14. Snap Ring 18. S ho ulder (Part o f
2. Snap Ring 8. M ainsha ft 15. 1st Speed M ain sh a ft)
3. Clutch Gear Bearing 9. Speedo Drive Gear Synchronizer 19. 2nd Speed Gear
4. Oil Slinger 10. Snap Ring Assem bly 20. 2nd Speed B lo cker
5. 3rd Speed Blocker 11. Rear Bearing 16. 1st Speed B locker Ring
Ring 12. Reverse Gear T hrust Ring 21. 2-3 S yn ch ro n ize r
6. M ainshaft Pilot W asher 17. 1st Speed Gear Assem bly
Bearings (16) 13. Reverse Gear 22. Snap Ring
Gears Countergear Anti-Lash Plate

1. Inspect all gears for excessive wear, chips or cracks and Inspect the plate teeth for wear or other damage. The
replace any that are w orn or damaged. plate and dam per spring is retained to the countergear by
2. Inspect reverse gear bushing and if worn or damaged three rivets. Disassembly is not recommended.
replace the entire gear.
NOTE: Reverse gear bushing is not serviced sepa R EP A IR S

rately.
Clutch Keys and Springs Replacement
3. Check both clutch sleeves to see th at they slide freely
on their hubs. NOTE: The clutch hubs and sliding sleeves are a
selected assembly and should be kept together as
Reverse Idler Gear Bushing
may be replaced if worn or broken.
and finish bored in place. This insures the positive alignment 1. M ark hub and sleeve so they can be m atched upon
of the bushing and shaft as well as proper meshing of the reassembly.
gears. Because of the high degree of accuracy to which these 2. Push the hub from the sliding sleeve, the keys and the
parts are m achined, the bushing is not serviced separately. springs may be easily removed.

3. Place the three keys and two springs in position (one on

each side of hub), so all three keys are engaged by both
springs (fig. 5G). Slide the sleeve onto the hub aligning
the m arks m ade before disassembly. SLEEVE
Extension Oil Seal or Bushing

If bushing in rear o f extension requires replacement,
remove seal and use Tool J-5778 to drive bushing into exten
sion housing. Using the same tool, drive new bushing in from
the rear. C oat I.D . of bushing and seal with transm ission
lubricant, then install new oil seal using Tool J-5154.
Clutch Bearing Retainer Oil Seal

If the lip seal in the retainer needs replacement; pry the
old seal out and replace w ith a new seal using Installer Tool SPRING
J-23096 or sim ilar tool, until seal seats in its bore.
Fig. 5G~Synchronizer Assem bly
A S S E M B L Y OF M A IN SH AFT (Fig. 4G)
T urn the front of the m ainshaft upward. Install the follow 8. Install synchronizer hub to m ainshaft snap ring.
ing com ponents on the m ainshaft: 9. Install reverse gear with clutching teeth downward.
1. Install the second speed gear with clutching teeth up 10. Install reverse gear steel thrust washer (align flats).
ward; the rear face of the gear will b u tt against the 11. Install rear ball bearing with snap ring slot downward;
flange on the mainshaft. press onto mainshaft.
2. Install a blocking ring with clutching teeth downward 12. Install rear bearing to mainshaft snap ring.
over the synchronizing surface of the second speed gear. 13. Install speedometer drive gear and retaining clip.
All three blocker rings used in this transm ission are This completes the assembly of the mainshaft.
identifcal.
3. Install the second and third synchronizer assembly with
the fork slot downward; press it onto splines on the A S S E M B L Y OF TRA N SM ISSIO N (Fig.
m ainshaft until it bottom s out. Both synchronizer as
semblies are identical but assembled differently. The
6G)
2 nd-3rd speed hub and sleeve is assembled with the fork 1. Load a double row of roller bearings (29) and the bear
slot in the sleeve tow ard the thru st face of the hub. The ing thrust washers in the countergear (Fig. 6 g). Use
1st- reverse hub and sleeve is assembled with the fork heavy grease to hold them in place.
slot in the sleeve opposite the thrust face (fig. 4G). 2. Place countergear assembly through case rear opening
along with a tanged thrust washer (tang away from
CAUTION: Be sure the notches of the blocker ring gear) at each end and install countergear shaft and
align with the keys of the syncrhonizer assembly.
w oodruff key from rear of case. End of shaft m ust be
4. Install synchronizer hub to m ainshaft snap ring. Both flush with case.
synchronizer snap rings are identical.
T urn the rear of the m ainshaft upward. Install the follow CAUTION: Be sure countershaft picks up both
ing com ponents on the mainshaft: thrust washers and that the tangs are aligned with
5. Install the first speed gear with clutching teeth upward; their notches in the case.
the front face o f the gear will butt against the flange on
the m ainshaft. 3. Position reverse idler gear in case.
6 . Install a blocker ring with clutching teeth downward 4. Using snap ring pliers, expand the snap ring in the
over synchronizing surface of the first speed gear. extension and assemble extension over rear of m ain
7. Install the first and reverse synchronizer assembly with shaft and onto rear bearing. Seat snap ring in rear bear
fork slot up; press it onto splines on the mainshaft. ing groove (fig. 3G).
5. Load the mainshaft pilot bearings (16) into the clutch
gear cavity and assemble the 3rd speed blocker ring
onto the clutch gear clutching surface with its teeth
CAUTION: Be sure the notches of the blocker ring tow ard the gear.
align with the keys of the synchronizer assembly 6. Pilot the clutch gear, pilot bearings and 3rd speed
and that both synchronizer sleeves face the front of blocker ring assembly over the front of the m ainshaft
the mainshaft. assembly. D o not assemble bearing to gear yet.

Fig. 6G--Transmission Exploded V iew
1. Bearing Retainer 18. C ountergear 35. S ynchronizer Keys 50. Gasket

2. B olt and Lock 19. Countershaft 36. 1st and Reverse 51. 2nd and 3rd S hifter
W asher 20. W o o d ru ff Key S ynchronizer Hub Fork
3. Gasket 21. B olt Assem bly 52. 1st and Reverse
4. Oil Seal (Extension-to-Case) 37. Snap Ring S hifter Fork
5. Snap Ring 22. Reverse Gear 38. 1st and Reverse 53. 2-3 S hifter Shaft
(Bearing-to-M ain 23. T hrust W asher S ynchronizer Collar Assem bly
Drive Gear) 24. Rear Bearing 39. M ain Drive Gear 54. 1st and Reverse
6. Main Drive Gear 25. Snap Ring 40. Pilot Bearings S hifter Shaft
Bearing 26. Speedom eter Drive 41. 3rd Speed B locker Assem bly
7. Snap Ring Bearing Gear Ring 55. Spring
8. Oil S linger 27. Retainer Clip 42. 2nd and 3rd 56. O-Ring Seal
9. Case 28. Reverse Idler Gear Synchronizer C ollar 57. 1st and Reverse
10. Gasket 29. Reverse Idler 43. Snap Ring Detent Cam
11. Snap Ring (Rear Bushing 44. Synchronizer Key 58. 2nd and 3rd Detent
Bearing-to-Extension) 30. Reverse Idler Shaft Spring Cam
12. Extension 31. W o o d ru ff Key 45. Synchronizer Keys 59. Side Cover
13. Extension Bushing 32. 1st Speed Gear 46. 2nd and 3rd 60. Bolt and Lock
14. Oil Seal 33. 1st Speed Blocker Synchronizer Hub W asher
15. T hrust W asher Ring 47. 2nd Speed B locker 61. TCS S w itch and
16. Bearing W asher 34. Syncrhonizer Key Ring Gasket
17. Needle Bearings Spring 48. 2nd Speed Gear 62. Lip Seal
49. M ainshaft

CAUTION: Be sure the notches in the blocker ring 10. Install front bearing outer snap ring to bearing and
align with the keys in the 2-3 synchronizer assem install bearing on stem of clutch gear and into front case
bly. bore.
7. Place extension to case gasket on extension holding it bearing retainer and gasket to case.
in place with grease and, from the rear of case, assemble
the clutch gear, m ainshaft and extension to case as an NOTE: The retainer oil return hole should be at the
assembly. bottom.
CAUTION: Be sure the clutch gear engages the 12. Shift synchronizer sleeves to neutral positions and in
teeth of the countergear anti-lash plate and that the stall cover, gasket and fork assembly to case. Be sure
oil slinger is in place on the clutch gear. forks align with their synchronizer sleeve grooves.
13. Tighten all bolts to specified torque.
8. R otate extension and install reverse idler shaft and
woodruff key. NOTE: Apply sealer to all through bolts.
9. Install extension to case retaining bolts.
14. R otate clutch gear and shift transmission through gears
NOTE: Apply sealer to all through bolts. to check free rotation of gears.
FOUR-SPEED SAGINAW TRANSMISSION

INDEX
SUBJECT PA G E
Disassembly of transm ission.......................................... ....7-20 C ountergear Anti-Lash P la te ........................................7-25

Disassembly of M ainshaft...................................................7-20 R epairs...................................................................................7-25
Cleaning and In sp ectio n ................................................. ....7-25 Clutch Keys and Springs R eplacem ent................... ..7-25
Transmission Case.......................... ............................... ....7-25 Extension Oil Seal or B u sh in g ................................... ..7-26
B earings............................................................................ ....7-25 Clutch Bearing Retainer Oil Seal............................... 7-26
Bearing R o lle rs ...................................................................7-25 Assembly of M ainshaft................................................... 7-27
G e a r s .....................................................................................7-25 Assembly of Transmission ............................................ 7-28
Reverse Idler G ear B u sh in g ............................................7-25
D IS A S S E M B L Y OF TRA N SM ISSIO N 6. Using snap ring pliers, expand the snap ring in the
extension which retains the m ainshaft rear bearing (fig.
(Figs. 1X and 2X) 5X) and remove the extension.
1. Remove side cover attaching screws and remove side 7. Using J-22246 at the front of the countershaft, drive the
cover assembly and shift forks. shaft and its woodruff key out the rear of the case. Tool
J-22246 will now hold the roller bearings in position
within the countergear bore. Remove the gear and bear
2. Remove clutch gear bearing retainer.
ings (fig. 6 X).
3. Remove clutch gear bearing to gear stem snap ring,

8. Remove reverse idler gear stop ring. Use a long drift or
then remove clutch gear bearing by pulling outw ard on
punch through the front bearing case bore and drive the
clutch gear until a screwdriver or other suitable tool can
reverse idler shaft and woodruff key through the rear of
be inserted between bearing, large snap ring and case to
the case (fig. 7X).
complete removal. The clutch gear bearing is a slip fit
on the gear and into the case bore. This provides clear
ance for removal of clutch gear and mainshaft assem
bly (Fig. 3X). D IS A S S EM B LY OF M AINSH AFT
1. Using snap ring pliers, remove the 3rd and 4th speed
4. Remove extension to case attaching bolts. sliding clutch hub snap ring from m ainshaft and
remove clutch assembly, third gear blocker ring and
5. Remove clutch gear, m ainshaft and extension assembly third speed gear from front of m ainshaft (figs. 8X and
together through the rear case opening (fig. 4X). 9X).

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Fig. 1X ~Transm ission-C ross S ection
1. C lutch Gear 1 1. 2nd Speed B locker 18. Extension 27. Thrust W asher-Front 35. C ountergear
2. B earing Retainer Ring 19. V en t 28. Thrust W asher-Rear A ssem bly
3. P ilo t B earings 12. 1-2 Speed Synch. 20. Speedom eter Drive 29. Snap Ring-Bearing to 36. C ounter S haft
4. Case Hub Gear and Clip Extension 37. Reverse Idler S haft
5. 4th Speed B locker 13. 1-2 Speed Synch. 21. M a in sh a ft 30. Rear Bearing 38. 1-2 Speed Synch.
Ring Snap Ring 22. Rear Oil Seal 31. C ountergear Roller Sleeve and Reverse
6. 4-3 Snych. Snap Ring 14. 1st Speed B locker 23. R etainer Oil Seal Bearings Gear
7. 4-3 Synch. Hub Ring 24. Snap Ring-Bearing to 32. Anti-Lash Plate 39. Reverse Idler Gear
8. 3rd Speed B locker 15. First Gear Gear Assem bly (S liding)
Ring 16. Reverse Gear T hrust 25. C lutch Gear Bearing 33. Magnet 40. C lutch Key
9. 3rd Speed Gear and S pring W ashers 26. Snap R ing-Bearing to 34. 4-3 Snych. Sleeve 41. W o o d ru ff Key
10. 2nd Speed Gear 17. Snap R ing-Bearing to Case
M a in sh a ft
Fig. 2X ~ T ransm ission -E xplo de d V ie w
1. Bearing Retainer 15. T hrust W asher-Front 29. 3rd Speed Blocker 42. Gasket-Extension to 55. D etent Spring
2. G asket-Retainer to Gear Ring Case 56. 3-4 D etent Cam
Case 16. Needle Retainer 30. 3rd Speed Gear 43. Snap Ring-Extension 57. 1-2 D etent Cam
3. Oil Seal W asher 31. Needle Bearings to Rear Bearing 58. 3-4 S h ifte r Shaft
4. Snap R ing-Bearing to 17. Needle Bearings 32. Second Speed Gear 44. Extension 59. G asket-Cover to Case
Shaft 18. C o untergear 33. 2nd Speed B locker 45. Vent 60. Cover
5. Snap R ing-Bearing to 19. Needle Retainer Ring 46. Bushing 61. TCS S w itch and
Case W asher 34. M a in sh a ft 47. Oil Seal Gasket
6. C lutch Gear Bearing 20. T hrust W asher-Rear 35. 1st Speed B locker 48. 1-2 S ynchronizer 62. Lipseal
7. C lutch Gear Gear Ring Sleeve and Reverse 63. Detent Cam Retainer
8. M a in sh a ft P ilot 21. C o un te rshaft 36. First Speed Gear Gear 64. 1-2 S h ift Fork
Bearings 22. W o o d ru ff Key 37. T hrust W asher 49. Key Retainer 65. " 0 " Ring
9. 4th Speed B locker 23. Synchronizer Sleeve 38. W ave W asher 50. 1-2 Synchronizer Hub 66. 1-2 S h ift S haft
Ring 24. Snap Ring-Hub to 39. Rear Bearing 51. Clutch Keys 67. S pring
10. Case S haft 40. Snap R ing-Bearing to 52. Key Retainer 68. Ball
1 1. Filler Plug 25. Key Retainer Shaft 53. Snap Ring-Hub to 69. " 0 " Ring
12. Reverse Idle r Gear 26. 3-4 S ynchronizer Hub 41. Speedo Drive Gear Shaft 70. Reverse S h ifte r S haft
13. Reverse Idler S haft 27. C lutch Keys and C lip 54. 3-4 S hift Fork and Fork
14. W o o d ru ff Key 28. Key Retainer
J . 22246 COUNTER
SHAFT
Fig. 6X--Removing C ountershaft
PULL MAIN
DRIVE GEAR
FORWARD
Fig. 3X -R em oving Clutch Gear Bearing
Fig. 7X~Removing Reverse Idler Gear S haft
Fig. 4X -R em oving Clutch Gear and M ainshaft Assem bly
Fig. 8X--Third and Fourth Synchronizer Snap Ring
Fig. 5X~Extension to Rear Bearing Snap Ring

Fig. 9X~Rem oving 3-4 S ynchronizer and T hird Speed Gear Fig. 1 1X--Removing Rear Bearing and First Speed Gear
2. Depress speedom eter retaining clip and slide gear from

mainshaft.
3. Remove rear bearing snap ring from m ainshaft groove
(fig. 10X).
4. Support first gear with press plates and press on rear of CAUTION: When pressing rear bearing be careful to
m ainshaft to remove first gear, thrust washer, spring center gear, washers, bearings and snap ring on
washer, rear bearing and snap ring from rear of m ain mainshaft.
shaft (fig. 11X).
5. Remove the 1st and second sliding clutch hub snap ring
from the m ainshaft and remove the clutch assembly,
2 nd speed blocker ring and second speed gear from the
rear of the m ainshaft (figs. 12X and 13X). This com
pletes the disassembly of the mainshaft.
Fig. lO X -R e ar Bearing to M ainsha ft Snap Ring Fig. 12X~First and Second Synchronizer Snap Ring

Reverse Idler Gear Bushings

and finish bored in place. This insures the positive alignment
of the bushing and shaft as well as proper meshing of the
gears. Because of the high degree of accuracy to which these
parts are m achined, the bushing is not serviced separately.
Countergear Anti-Lash Plate

Inspect the plate teeth for wear or other damage. The
plate and two dam per springs are retained to the countergear
by three rivets. Disassembly is not recommended (fig. 23X).
R EP A IR S
Clutch Keys and Springs
NOTE: The clutch hubs and sliding sleeves are a

selected assembly and should be kept together as
may be replaced if worn or broken.
Fig. 13X~Removing 1-2 Synchronizer and Second Speed Gear
1. M ark hub and sleeve so they can be m atched upon
reassembly.
CLEAN IN G AND IN SPECTIO N 2. Push the hub from the sliding sleeve, the keys and the
springs may be easily removed.
3. Place the three keys and two springs in position (one on
Transm ission Case each side of hub), so all three keys are engaged by both
1. W ash the transm ission thoroughly inside and outside springs (fig. 14X). The tanged end of each synchronizer
with cleaning solvent, then inspect the case for cracks. spring should be installed into different key cavaties on
2. Check the front and rear faces for burrs, and if present, either side. Slide the sleeve onto the hub aligning the
dress them off with a fine mill file. m arks m ade before disassembly.

1. W ash the front and rear ball bearings thoroughly in a
cleaning solvent.
2. Blow out bearings with compressed air. SPRING
SLEEVE

Bearing Rollers
All clutch gear and countergear bearing rollers should be
inspected closely and replaced if they show wear. Inspect
counter shaft and reverse idler shaft at the same time, replace
if necessary. Replace all w orn washers.
Gears
1. Inspect all gears for excessive wear, chips or cracks and
replace any th at are worn or damaged.
2. Check both clutch sleeves to see that they slide freely
on their hubs. Fig. 1 4X -T hree-F our Synchronizer Assem bly

SCREWDRIVER
Fig. 17X--Removing Bearing Retainer Oil Seal
sion housing (fig. 15X). Using the same tool, drive new bush
Fig. 1 5X -E xtension Bushing Replacement ing in from the rear. Coat I.D . of bushing and seal with
transmission lubricant, then install new oil seal using Tool
J-5154 (fig. 16X).
NOTE: A groove around the outside of the synchro
nizer hub identifies the end that must be opposite
the fork slot in the sleeve when assembled. This Clutch Gear Bearing Retainer Oil Seal
groove indicates the end of the hub with a .07"
greater recess depth. If the lip seal in the retainer needs replacement; pry the
oil seal out and replace with a new seal using Tool J-23096
Extension Oil Seal or Bushing until seal seats in its bore (figs. 17X and 18X).
If bushing in rear o f extension requires replacement,

NOTE: Lip of seal must face rear of bearing retainer.
remove seal and use Tool J-5778 to drive bushing into exten-
J-23096
Fig. 16 X -ln s ta llin g Extension Oil Seal Fig. 1 8X —Installing Bearing Retainer Oil Seal

1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 14 15 15 14 15 14
Fig. 19X--Clutch Gear and M ainsha ft Details
1. Clutch Gear Bearing 8. First Speed Gear

2. Clutch Gear 9. T hrust W asher
3. M ainsha ft Pilot 10. Spring W asher
Bearings 11. Rear Bearing
4. 3-4 Synchronizer 12. Speedo Drive Gear
A ssem bly 13. M ainshaft
5. T hird Speed Gear 14. Snap Ring
6. Second Speed Gear 15. Synchronizing
7. 1-2 S ynchronizer and "B lo c k e r" Ring
Reverse Gear
A ssem bly
Fig. 2 0 X -ln s ta llin g 3-4 Synchronizer and T hird Gear
A S S E M B L Y OF M A IN SH AFT (Fig. 19X)

8. Install synchronizer hub to m ainshaft snap ring (fig.
T urn the front of the m ainshaft upward. Install the follow 12X).
ing com ponents on the mainshaft: 9. Install a blocker ring with notches downward so they
1. Install the third speed gear w ith clutching teeth up align with the keys of the 1-2 synchronizer assembly.
ward; the rear face o f the gear will butt against the 10. Install first gear with clutching teeth downward.
flange on the mainshaft. 11. Install first gear thrust washer (steel).
2. Install a blocking ring with clutching teeth downward 12. Install first gear spring washer.
over the synchronizing surface of the third speed gear. 13. Install rear ball bearing with snap ring slot downward;
All four blocker rings used in this transm ission are press onto m ainshaft (fig. 22X).
identical. 14. Install rear bearing to m ainshaft snap ring (fig. 10X).
3. Install the 3rd and 4th synchronizer assembly with the
shaft until it bottom s out (fig. 20X).

align with the keys of the synchronizer assembly.
4. Install synchronizer hub to m ainshaft snap ring (fig.

8X). Both synchronizer snap rings are identical.
T urn the rear of the m ainshaft upward. Install the follow
ing com ponents on the m ainshaft:
5. Install the second speed gear with clutching teeth up
ward; the front face of the gear will butt against the
flange on the m ainshaft.
6 . Install a blocker ring w ith clutching teeth downward
over synchronizing surface of the second speed gear.
7. Install the first and second synchronizer assembly with
shaft (fig. 2 IX).

align with the keys of the synchronizer assembly. Fig. 21 X—ln sta llin g 1-2 S ynchronizer and Second Speed Gear

2. Place countergear assembly through case rear opening

along with a tanged thrust washer (tang away from
gear) at each end and install countergear shaft and
woodruff key from rear of case.
CAUTION: Be sure countershaft picks up both

thrust washers and that the tangs are aligned with
their notches in the case.
3. Install reverse idler gear and shaft with its woodruff key
from the rear of case.
4. Using snap ring pliers, expand the snap ring in the
extension and assembly extension over rear of m ain
shaft and onto rear bearing. Seat snap ring in rear bear
ing groove (fig. 5X).
5. Load the mainshaft pilot bearings (14) into the clutch
gear cavity and assemble the 4th speed blocker ring
onto the clutch gear clutching surface with its clutching
teeth tow ard the gear (fig. 24X).
6. Pilot the clutch gear, pilot bearings and 4th speed
blocker ring assembly over the front of the mainshaft
assembly. Do not assemble bearing to gear yet.
Fig. 22 X --lnsta llin g Rear Bearing CAUTION: Be sure the notches in the blocker ring
align with the keys in the 3-4 synchronizer assem
15. Install speedometer drive gear and clip. bly.
This completes the assembly of the mainshaft.
7. Place extension to case gasket at rear of case holding in

A S S E M B L Y OF TRA N SM ISSIO N place with grease and, from the rear of the case, assem
ble the clutch gear, mainshaft and extension to case as
1. Using Tool J-22246 load a row of roller bearings (27)
an assembly.
and a bearing th ru st w asher at each end of the counter
8. Install extension to case retaining bolts. Using seal ce
gear. Use heavy grease to hold them in place (fig. 23X).
ment on bottom bolt only.
MAIN DRIVE GEAR
Fig. 23X ~Loading Countergear Bearings Fig. 24X--Loading M ainshaft Pilot Bearings

9. Install front bearing outer snap ring to bearing and 11. Shift synchronizer sleeves to neutral positions and in
position bearing over stem of clutch gear and into front stall cover, gasket and fork assembly to case. Be sure
case bore. forks align with their synchronizer sleeve grooves.
bearing retainer and gasket to case. 12. Tighten all bolts to specified torque.
NOTE: The retainer oil return hole should be at the

bottom.
FOUR-SPEED
MUNCIE TRANSMISSION (PA SS. CAR)
INDEX
SU BJECT PA G E
D isassem bly............................................................................7-29 R epairs................................................................................. ...7-34

Cleaning and In sp ectio n ................................................. ....7-32 Reverse Shifter Shaft and S ea l................................... ...7-34
Transm ission C ase.......................................................... ....7-32 Extension Oil Seal or B u sh in g ................................... ...7-34
F ront and R ear Bearings ............................................ ....7-32 Clutch Keys and S p rin g s ............................................ ...7-34
Bearing Rollers and Spacers............................................7-33 Assembly of M ainshaft................................................... ...7-34
G e a r s ................................................................................. ....7-33 Assembly of C o u n terg ear..................................................7-35
Reverse I d le r ................................................................... ....7-33 Assembly Case C om ponents.......................................... ...7-35
D IS A S S E M B L Y OF TRA N SM ISSIO N NOTE: Slide 3-4 synchronizer clutch sleeve to 4th

speed gear position (forward) before trying to
(figs. IB and 2B) remove mainshaft assembly from case (fig. 6 B).
8. Carefully remove the rear bearing retainer and entire

1. Remove transm ission side cover. mainshaft assembly from the case by tapping bearing
retainer with a soft hammer.
2. Remove four bolts and (2) bolt lock strips from front
bearing retainer and remove retainer and gasket.
9. Unload bearing rollers (17) from main drive gear and
remove fourth speed synchronizer blocker ring.
3. Remove the main drive gear retaining nut (fig. 3B)
using Tool J-0933, after locking up transmission by 10. Lift the front half of reverse idler gear and its tanged
shifting into two gears. thrust washer from case.
4. W ith transm ission gears in neutral, drive lock pin from 11. Press main drive gear down from front bearing (fig.
reverse shifter lever boss, (fig. 4B) and pull shifter shaft 7B).
out about 1/8". This disengages the reverse shift fork
from reverse gear.
12. From inside case, tap out front bearing and snap ring.
5. Remove six bolts attaching the case extension to the

case. Tap extension w ith soft ham m er in a rearw ard 13. From the front of the case, press out the countershaft
(fig. 8 B) using Tool J-22246; then remove the counter
direction to start. W hen the reverse idler shaft is out as
far as it will go, move extension to left so reverse fork gear and both tanged washers.
clears reverse gear and remove extension and gasket.
14. Remove the 112 rollers, six. .070" spacers and roller
spacer from countergear.
6. The rear reverse idler gear, flat thrust washer, shaft and
roll spring pin may now be removed. 15. Remove m ainshaft front snap ring as shown in Figure
9B and slide third and fourth speed clutch assembly,
7. Remove speedometer gear and reverse gear using Tool third speed gear and synchronizing ring from front of
J-5814 (fig. 5B). mainshaft.

1 2 3 4 5 6 7 8 9 10 11 12 13
TOP VIEW OF REVERSE

IDLER GEARS
Fig. 1 B-T ransm ission Cross Section (Std. Ratio Shown)
1. Bearing Retainer 9. First and Second 17. Reverse Idler Gear

2. M ain Drive Gear Speed Clutch (Rear)
3. Fourth Speed Assem bly 18. C ountergear
S ynchronizing Ring 10. First Speed 19. C ountershaft Bearing
4. T hird and Fourth Synchronizing Ring Roller Spacer
Speed Clutch 11. First Speed Gear 20. M agnet
Assem bly 12. First Speed Gear 21. C ountershaft Bearing
5. T hird Speed Sleeve Roller
Synchronizing Ring 13. Reverse Gear 22. C ountershaft
6. Third Speed Gear 14. Speedom eter Drive 23. Oil S linger
7. Second Speed Gear Gear 24. Reverse Idler Shaft
8. Second Speed 15. M ainshaft 25. Thrust W asher
Synchronizing Ring 16. Reverse Idler Shaft 26. Reverse Idler Gear
Roll Pin (Front)

64
Fig. 2B -Four-Speed Transm ission Exploded V iew

1. B e a rin g R e ta in e r 20. C lu tc h H u b 38. R everse Id le r G e a r 61. B ea rin g R o lle rs ( 2 8 )
2. G asket 21. C lu tc h K ey s (R e a r ) 62. S pacer
3. B e a rin g R e ta in in g 22. F irs t a n d S e c o n d 39. F la t T h r u s t W a sher 63. T a n g e d W asher
Nut S p e e d C lu tc h S lid in g 40. R everse Id le r S h a ft 64. C o u n te r s h a ft
4. B e a rin g S n a p R in g S leeve 41. R everse Id le r S h a ft 65. G asket
5. M a in D riv e G e a r 23. F irs t S p e e d G e a r R o ll Pin 66. D e te n t C am s R e ta in e r
B e a rin g S y n c h r o n iz in g R in g 42. R everse S h if t e r S h a ft R ing
6. T ra n s m is s io n Case 24. F irs t S p e e d G e a r L o c k Pin 67. F o rw a r d S p e e d S h ift
7. R e a r B e a rin g R e ta in e r 25. F irs t S pe e d G e a r 43. R everse S h if t e r S h a ft F o rk s
G asket S leeve L ip Seal 68. F irs t a n d S e c o n d
8. M a in D riv e G e a r 26. R e a r B e a rin g S n a p 44. R everse S h if t F o r k S peed G e a r S h if t e r
8a. O il S lin g e r R ing 45. R everse S h if t e r S h a ft S h a ft a n d D e te n t
9. B e a rin g R o lle rs ( 1 7 ) 27. R ea r B ea rin g and D e te n t P la te P la te
a n d Cage 28. R e a r B ea rin g 46. R everse S h if t e r L e v e r 69. T h ir d a nd F o u r t h
10. S n a p R in g R e ta in e r 47. R everse S h if t e r S h a ft Sp«:ed G e a r S h if t e r
11. T h ir d a n d F o u r t h 29. S e le c tiv e F it S n a p D e te n t B all S h a ft a n d D e te n t
S p e e d C lu tc h S lid in g R ing 48. R everse S h if t e r S h a ft P late
S leeve 30. R everse G e a r B all D e te n t S p rin g 70. D e te n t C am s
12. F o u rth Speed G ear 31. S p e e d o m e te r D riv e 49. S p e e d o m e te r D riv e n 71. D e te n t C am S p rin g
S y n c h r o n iz in g R in g G ear G e a r a n d F it t in g 72. L ip Seals
13. T h ir d S p e e d 32. R e a r B ea rin g 50. R e ta in e r a n d B o lt 73. T ra n s m is s io n S id e
S y n c h r o n iz in g R in g R e ta in e r to 51. " O ” R in g Seal C over
14. T h ir d S p e e d G e a r Case E x te n s io n -G a s k e t 52. T a n g e d W a sher 73a. H e a d e d C a m Pin
15. M a in s h a ft 33. Case E x te n s io n 53. Spacer 74. T h ir d a n d F o u r t h
16. Second Speed G ear 34. E x te n s io n B u s h in g 54. B ea rin g R o lle rs ( 2 8 ) S p e e d S h if t e r L e v e r
17. Second Speed G ear 35. R e a r O il Seal 55. Spacer 75. F irs t a n d S e c o n d
S y n c h r o n iz in g R in g 36. R everse Id le r F r o n t 56. B ea rin g R o lle rs ( 2 8 ) S p e e d S h if t e r L e v e r
18. F irs t a n d S e c o n d T h r u s t W asher 57. C o u n te rg e a r 76. T C S S w itc h and
S p e e d C lu tc h (T a n g e d ) 58. C o u n te rg e a r R o lle r Gasket
A s s e m b ly 37. R everse Id le r G e a r Spacer
19. C lu tc h K e y S p rin g (F ro n t) 59. B ea rin g R o lle rs ( 2 8 )
60. S pacer

Fig. 3B--Removing M ain Drive Gear Retaining Nut
Fig. 5B~Removing Speedom eter Gear

16. Spread rear bearing retainer snap ring and press m ain
shaft out of the retainer (fig. 10B).
Inspect the front face which fits against clutch housing for
burrs and if any are present, dress them off with a fine cut
17. Remove the m ainshaft rear snap ring. Support second mill file.
speed gear and press on rear of m ainshaft to remove
rear bearing, 1st speed gear and sleeve, 1st speed syn
chronizing ring, 1-2 speed synchronizer clutch assem
bly, 2 nd speed synchronizer ring and second speed gear. CAUTION: Be sure cleaning solvent does not loosen
case magnet.

Transm ission Case

W ash the transm ission case inside and out, with a clean 1. W ash the front and rear bearings thoroughly in a clean
ing solvent and inspect for cracks. ing solvent.
Fig. 6B~Third and Fourth Speed Synchronizer Clutch Sleeve in

Fig. 4B -R em oving Reverse S hifter Shaft Lock Pin Fourth Gear Position
I
Fig. 9B~Rem oving M ainshaft Front Snap Ring
Fig. 7B~Rem oving M ain Drive Gear

Gears
CAUTION: Do not allow the bearings to spin, but Inspect all gears and replace all that are defective or
turn them slowly by hand. Spinning bearings will damaged. Inspect for loose dam per plate on countergear (if
damage the race and balls. so equipped).
3. M ake sure bearings are clean, then lubricate them with

light engine oil and check them for roughness. R ough Reverse Idler
ness may be determ ined by slowly turning the outer 1. The bushings used in the idler gear are pressed into the
race by hand. gear then peened into holes in the bores, and are bored
in place. This insures the positive alignm ent of the bush
CAUTION: Bearings must be lubricated with light ings and their shafts, as well as proper meshing of gears.
oil before checking for roughness. Because of the high degree of accuracy to which these
parts are m achined, the bushings are not serviced sepa
Bearing Rollers and Spacers rately.
2. Check bushings for excessive wear by using a narrow
All m ain drive gear and countergear bearing rollers feeler gauge between the shaft and the bushing or use
should be inspected closely and replaced if they show wear. a micrometer. The proper clearance is from .003" to
Inspect countershaft at the same tim e and replace if neces .005".
sary. Replace all worn spacers.
Fig. 8B--Removing C ountershaft W ith J-2 2 2 4 6 Fig. 10B~Removing Rear Bearing Retainer
A
R EP A IR S 1. Push the hub from the sliding sleeve. The keys will fall
Reverse Shifter Sh aft and Seal free and the springs may be easily removed.
2. Place the two springs in position (one on each side of
Replacement the hub), so all three keys are engaged by both springs.
Place the keys in position and, holding them in place,
1. W ith case extension rem oved from transm ission the slide the hub into the sleeve.
reverse shifter shaft lock pin will already be removed.
(See Step 4 under Disassembly). NOTE: The sleeve with the large square edge oppo
2. Remove shift fork. site the fork groove identifies the 3-4 synchronizer
3. Carefully drive shifter shaft into case extension, allowing sleeve.
ball detent to drop into case.
4. Place ball detent spring into detent spring hole and from
inside extension install shifter shaft fully into its opening
A S S E M B L Y OF M AIN SH AFT
until the detent plate is butted against inside of extension 1. From the rear of the m ainshaft, assemble the secon
housing. speed gear (with hub of gear tow ard rear of shaft).
5. Place detent ball on spring (fig. 1 IB) and, holding ball 2. Install 1-2 synchronizer clutch assembly to mainshaft
down with your thum b or a suitable tool push the (sliding clutch sleeve taper tow ard the rear, hub to the
shifter shaft back in away from case until it is directly front); together with a synchronizing ring on either side
over the ball and tu rn until the ball drops into detent of clutch assembly so their keyways line up with the
on the shaft detent plate. clutch keys (fig. 12B).
6 . Install shift fork. 3. Press the 1st gear sleeve onto the m ainshaft using a 1
3/4" I.D. pipe cut to a convenient length or other suita
NOTE: Do not drive the shifter shaft lock pin into ble tool.
place until the extension has been installed on the 4. Install the first speed gear (with hub tow ard front) and
transmission case. using 1 5/8" I.D . pipe cut to a suitable length, press on
the rear bearing (fig. 13B).
Extension Oil Seal Or Bushing 5. Choose the correct selective fit snap ring (.087", .090",
.093", or .096") and install it in the groove in mainshaft
If bushing in rear of extension requires replacement,
behind the rear bearing. W ith proper ring, maximum
remove oil seal and use Tool J-5778 to drive bushing into case
distance between snap ring and rear face of bearing will
extension. Using the same tool, drive new bushing in from the
be from zero to .005".
rear. Coat I.D . of bushing with transmission lubricant, then
install new oil seal using Tool J-5154. Prelubricate seal be
tween lips with cup grease. NOTE: Always use new snap rings when reassem
bling transmission and do not expand the snap ring
Clutch Keys and Springs Replacement further than is necessary for assembly.
NOTE: The clutch hubs and sliding sleeves are a

select fit assembly and should be kept together as 6. Install the third speed gear (hub to front of transm is
originally assembled, but the three keys and two sion) and the third speed gear synchronizing ring (not
springs may be replaced if worn or broken. ches to front of transmission).
CLUTCH
mm ■i
Fig. 1 1 B—Installing Reverse S hifter Shaft and Detent Ball Fig. 1 2B— Installing S ynchronizing Ring

I.D. PIPE
SNAP RING
GROOVE
Fig. 13 B -ln s ta llin g Rear Bearing Fjg. 15B--Loading Countergear Bearings Using J -2 2 2 4 6
7. Install the third and fourth speed gear clutch assembly

(hub and sliding sleeve) with both sleeve taper and hub
A S S E M B L Y OF CO U N TERG EA R
tow ard the front, m aking sure the keys in the hub corre 1. Install roller spacer (tube type) in countergear.
spond to the notches in the third speed gear synchroniz 2. Using heavy grease to retain the rollers, install a spacer,
ing ring. 28 rollers, a spacer, 28 more rollers, then another
8. Install snap ring in the groove in m ainshaft in front of spacer. Install in the other end of the countergear, a
the th ird and fourth speed clutch assembly, with ends spacer, 28 rollers, a spacer, 28 more rollers, and another
of snap ring seated behind spline teeth. spacer (fig. 15B).
9. Install the rear bearing retainer (fig. 10B). Spread the 3. Insert Tool J-22246 into countergear.
snap ring in the plate to allow the snap ring to drop
around the rear bearing and press on the end of the
m ainshaft until the snap ring engages the groove in the
A S S E M B L Y OF C A S E CO M PON EN TS
rear bearing.
10. Install the reverse gear (shift collar to rear) and 2 anti 1. Rest the transm ission case on its side with the side cover
rattle springs (R PO M 20 only). opening tow ard the assembler. Put countergear tanged
11. Install retaining clip and speedometer gear. On models thrust washers in place, retaining them with heavy
using the metal gear, press speed. Drive gear onto m ain grease, making sure the tangs are resting in the notches
shaft using a suitable press plate such as J - 1453. Posi of the case.
tion the gear to obtain a m easurem ent of 4 7 /8 " from 2. Set countergear in place in bottom of transm ission case,
the forw ard side o f the gear to the flat surface of the rear making sure that tanged thrust washers are not
bearing retainer (Fig. 14B). knocked out of place.
3. Position the transm ission case resting on its front face.
4. Lubricate and insert countershaft in rear of case. T urn

countershaft so flat on end of shaft is horizontal and
facing bottom of case.
5. Align countergear with shaft in rear and hole in front
of case, and press countershaft into case (pushing as
sembly tool out front of case) until flat on shaft is flush
with rear of case. Be sure thrust washers remain in place
(fig. 16B).
6. A ttach a dial indicator (fig. 17B) and check end plate
of the countergear. If end play is greater than .025" new
thrust washers m ust be installed.
7. Install cage and the seventeen roller bearings into main
drive gear, using heavy grease to hold the bearings in
place. Install oil slinger on main drive gear with con
cave side tow ard gear.
8. Install main drive gear and pilot bearings through the
side cover opening and into position in transmission
Fig. 14B —Installing Speedom eter Gear front bore.

ALIGNMENT
PIN
BOTTOM
OF CASE
NOTCH IN 0
SYNCHRONIZING
I RING MM
Fig. 18 B—I nsta 11i ng M ainshaft Assem bly

Fig. 1 6 B--I nsta 11i ng C ountershaft
CAUTION: Be sure main drive gear engages both
9. Place gasket in position on front face of rear bearing the countergear and anti- lash plate on standard ra
retainer. tion models.
10. Install the fourth speed synchronizing ring on main
drive gear w ith the notches tow ard the rear of the trans 13. W ith the guide pin in rear bearing retainer aligned with
mission. hole in rear of case, tap rear bearing retainer into posi
11. Position the reverse idler gear thrust washer (tanged) tion with a soft hammer.
on the machined face o f the ear cast in the case for the 14. From the rear of the case, insert the rear reverse idler
reverse idler shaft and hold with heavy grease. Position gear, engaging the splines with the portion of the front
the front reverse idler gear next to the thrust washer, gear inside the case.
with the hub facing tow ard rear of the case. 15. Using heavy grease, place gasket in position on rear face
of rear bearing retainer.
16. Install the remaining flat thrust washer on reverse idler
CAUTION: Before attempting to install mainshaft shaft. If new idler shaft is being used, drive out the roll
assembly to case, slide the 3-4 synchronizing clutch
pin and press it into new shaft.
sleeve forward into fourth speed detent position (fig.
17. Install reverse idler shaft, roll pin, and thrust washer
6 B).
into gears and front boss of case. M ake sure to pick-up
front tanged thrust washer.
12. Lower the m ainshaft assembly into the case making NOTE: Roll pin should be in a vertical position.
certain the notches on the fourth speed synchronizing
ring correspond to the keys in the clutch assembly (fig. 18. Pull reverse shifter shaft to left side of extension and
18B). rotate shaft to bring reverse shift fork forward in exten
sion (reverse detent position). Start the extension onto
the transmission case (fig. 19B), while slowly pushing
in on the shifter shaft to engage the shift fork with the
reverse gear shift collar. Then pilot the reverse idler
shaft into the extension housing perm itting the exten
sion to slide onto the transmission case.
19. Install 6 extension and retainer-to-case attaching bolts.
Torque upper 3 bolts and lower 3 bolts to specification.
20. Push or pull reverse shifter shaft to line up groove in the
shaft with the holes in the boss and drive in the lock pin.
Install shifter lever.
21. Press bearing onto main drive gear (snap ring groove to
front) and into case until several main drive gear retain
ing nut threads are exposed.
22. Lock transmission up by shifting into two gears. Install
main drive gear retaining nut on the gear shaft and
draw it up tight using Tool J-0933. Be su~e bearing fully
S3 seats against shoulder on gear. Torque retaining nut to
Fig. 17B--Checking Countergear End Play 40 ft. lbs. and lock in place by staking securely into

main drive gear shaft hole with a center punch. Care

m ust be used to avoid damaging the threads on the
shaft.
Install the main drive gear bearing retainer, gasket, four

attaching bolts and ( 2 ) strip bolt lock retainers, using a
suitable sealer on bolts. Torque to specification.
24. Shift m ainshaft 3-4 sliding clutch sleeve into neutral

position and 1-2 sliding clutch sleeve into second gear
(forward) detent position. Shift side cover 3-4 shifter
lever into neutral detent and 1-2 shifter lever into sec
ond gear detent position.
25. Install side cover gasket and carefully position side

cover into plate. There is a dowel pin in the cover to
assure proper alignment with the case. Install attaching
bolts and tighten evenly to avoid side cover distortion.
Fig. 19B —Installing Case Extension Torque to specification.
4-SPEED MUNCIE TRANSMISSION (MODEL 4 6 5 )

INDEX
SU BJECT PA G E
Disassembly of T ran sm issio n ............................................ 7-37 Clutch G ear Bearing R etainer Oil S eal................... ..... 7 4 3
Subassembly O p e ra tio n s................................................. .... 7 4 0 M ainshaft............................................................................... 7 4 3
Transm ission Cover............................................................ 7 4 0 D isassem bly................................................................... ..... 7 4 3
D isassem bly................................................................... .... 7 4 0 Inspection ..................................................................... ..... 7 4 5
A ssem b ly ............................................................................ 741 A ssem bly............................................................................. 7 4 5
Clutch G e a r.......................................................................... 7 4 2 C ountershaft ................................................................... ..... 7 4 6
D isassem bly................................................................... .... 7 4 2 D isassem bly................................................................... ..... 7 4 6
Inspection ..................................................................... .... 7 4 2 A ssem bly............................................................................. 7 4 7
A ssem b ly ....................................................................... .... 7 4 2 Assembly of T ran sm issio n ............................................ ..... 7 4 7
D IS A S S E M B L Y OF TRA N SM ISSIO N NOTE: On models equipped with 4-wheel drive

transfer case, use Tool J-23070 to remove main
Refer to Figures 1Q and 2Q shaft rear lock nut (fig. 26Q).
1. M ount transm ission in suitable holding fixture and

remove cap screws attaching transm ission cover assem
bly to transm ission case. If required, insert two 5/16 x 3. Remove parking brake and brake flange plate assembly
18 screws in cover flange threaded holes and turn on models equipped with propeller shaft parking brake.
evenly to raise cover dowel pins from case. Refer to Section 5, Truck Service Manual.
4. Remove rear bearing retainer and gasket.
NOTE: Move reverse shifter fork so that reverse 5. Slide speedometer drive gear off mainshaft.
idler gear is partially engaged before attempting to 6. Remove clutch gear bearing retainers and gasket.
remove cover. Forks must be positioned so rear edge 7. Remove countergear front bearing cap and gasket.
of the slot in the reverse fork is in line with the front 8. Pry countergear front bearing out by inserting screw
edge of the slot in the forward forks as viewed drivers into groove at cast slots in case.
through tower opening. 9. Remove countergear rear bearing retaining rings (snap
ring) from shaft and bearing. Using Tool J-22832 and
2. Place transm ission in two gears at once to lock gears. J-8433-1, remove countergear rear bearings (fig. 3Q).
Remove the universal joint flange nut, universal joint This will allow countergear assembly to rest on bottom
front flange and brake drum assembly. of case.

K” MODELS
40 < 1
Fig. 1Q -Transm ission Assem bly-C ross Section
1. Main Drive Clutch 11. Reverse Driven Gear 24. M ainshaft Rear 37. T hrust W asher
Gear 12. Poppet Spring Bearing 38. Snap Ring
2. Drive Gear Bearing 13. Poppet Ball 25. Rear Bearing Snap 39. Front C ountershaft
Retainer 14. S hift Rail Ring Bearing
3. Snap Ring-Outer 15. 1st and 2nd Shift 26. Snap Ring 40. C ountergear Front
4. 3rd and 4th Fork 27. C ountershaft Cover
Synchronizer Ring 16. 1st Speed Gear 28. C ountershaft Rear 41. Pilot Bearing Rollers
5. 3rd and 4th 17. T hrust W asher Bearing 42. Clutch Gear Oil
Synchronizer C ollar 18. Bearing Snap Ring 29. Bearing Snap Ring S linger
6. 3rd and 4th S hift 19. Speedom eter Drive 30. Reverse Idler Gear 43. Snap Ring
Fork Gear 31. Reverse Idler Shaft 44. 3rd Speed Gear
7. 3rd and 4th Speed 20. O utput Yoke 32. Case M agnet Bushing
Synchronizer Ring 21. Flange Nut 33. Snap Ring 45. T hrust W asher
8. 3rd Speed Gear 22. Rear Bearing 34. Snap Ring 46. 2nd Speed Gear
9. 2nd Speed Gear Retainer Oil Seal 35. Damper Assembly Bushing
10. 1st and 2nd 23. Rear Bearing 36. C ountergear 47. 1st Speed Gear
Synchronizer Retainer Bushing
Assem bly

50
Fig. 2Q ~Transm ission A ssem b ly-E xplod e

1. C lutch Gear Bearing 13. 1st-2nd Speed 26. 2nd Speed Gear 37. Snap Ring 48. Rear Retainer Gasket
Retainer S ynchronizer Hub 27. 3rd Gear Bushing 38. Snap Ring 49. Rear Retainer
2. R etainer Gasket 14. Synchronizer Keys 28. T hrust W asher 39. T h ru st W asher 50. Retainer Bolts
3. Lip Seal 15. Synchronizer Spring 29. 3rd Speed Gear 40. Clutch Countergear 51. Retainer Lip Seal
4. Snap Ring 16. Reverse Driven Gear 30. 3rd Speed B locker 41. Snap Ring 52. Reverse Idler S haft
5. C lutch Gear Bearing 17. 1st Gear Bushing Ring 42. Snap Ring 53. Drain Plug
6. O il S lin g e r 18. 1st Gear 31. Synchronizer Spring 43. 3rd Speed 54. Reverse Idle r Gear
7. C lutch Gear and Pilot 19. T hrust W asher 32. S ynchronizer Keys C ountergear 55. Case
B earings 20. Rear M ain Bearing 33. 3 rd -4 th S ynchronizer 44. C ountergear Shaft 56. Fill Plug
8. P ow er T ake-O ff Cover 21. B earing Snap Ring Hub 45. C ountergear Rear 57. C ountergear Front
G asket 22. S peedom eter Gear 34. S ynchronizer Spring B earing Bearing
9. P ow er T ake-O ff Cover 23. Rear M a in sh a ft Lock 35. 3 rd -4 th Speed 46. Snap Ring 58. Gasket
10. R etaining Screw s Nut B lo cker Ring 47. B earing Outer Snap 59. Front Cover
1 1. 1st-2nd Speed 24. 2nd Speed Bushing 36. 3 rd -4 th Speed Ring 60. Cover Screw s
B lo cke r Ring (On Shaft) Synchronizer Sleeve
12. S ynch ron izer Spring 25. M a in sh a ft
CAUTION: Make sure Tool J-22832 engages full 15. To remove reverse idler gear, drive reverse idler gear
circumference of groove in bearing to prevent tool shaft out of case from front to rear using a drift.
damage. Remove reverse idler gear from case.
10. Remove clutch gear bearing outer race to case retaining

ring. S U B A S S E M B L Y O PERA TIO N S
11. Remove clutch gear and bearing by tapping gently on Transmission Cover
bottom side of clutch gear shaft and prying directly
opposite against the *case and bearing snap ring groove Disassem bly (Fig. 5Q)
at the same time. Rem ove 4th gear synchronizer ring.
1. Using a small punch drive out pins retaining lst-2nd
and 3rd-4th shifter forks to shifter shafts and also drive
out expansion plugs.
CAUTION: Index cut out section of clutch gear in
down position with countergear to obtain clearance
for removing clutch gear. J-8433-1
12. Remove rear m ainshaft bearing retainer ring (snap

ring) and using Tool J-22832 and J-8433-1, remove
bearing from case (fig. 4Q). Slide 1st speed gear thrust
washer off m ainshaft.
13. Raise rear of m ainshaft assembly and push rearw ard in

case bore, then swing front end up and lift from case.
Remove synchronizer cone from shaft.
14. Slide reverse idler gear rearw ard and move countergear
rearw ard until front end is free of case, then lift to
remove from case.
Fig. 4Q--Removing M ainshaft Rear Bearing
REVERSE
3RD/4TH f
1ST/2ND
Fig. 3Q -R em oving Countergear Rear Bearing Fig. 5Q--Cover Assem bly

NOTE: The pin retaining the third and fourth shifter Assem bly (Fig. 6Q)
fork to the shaft must be removed, and the shifter
fork removed from the cover before the reverse 1. In reassembling the transmission cover, care m ust be
shifter head pin can be removed. used in installing the shifter shafts. They should be
installed in the order shown in Fig. 7Q, namely, reverse
2. W ith shifter shafts in neutral position, drive shafts out 3rd-4th, and lst-2nd.
of cover and shifter forks. 2. Place fork detent ball springs and balls in position in
holes in cover.
CAUTION: Exercise care so shaft detent balls, 3. Start shifter shafts into cover; depress yoke detent balls
springs and innerlock pin located in the cover are with small punch and push shafts on over balls. Starting
not lost as the shifter shafts are removed. with reverse shifter shaft, hold fork in position and push
shaft through yoke. Install split pin in fork and shaft,
3. Drive out pin holding reverse shifter head and drive out then position fork in neutral position.
the shaft. 4. Push 3rd and 4th shaft through to the neutral position
and line up retaining hole in the fork with the hole in
the shaft. Install retaining pin.
CAUTION: Exercise extreme care during shaft re
moval since detent balls are under spring tension in NOTE: Detent balls should line up with detents in
the rear rail boss holes. shaft.
Fig. 6Q -C over Assem bly-Explode
1. Transm ission Cover 8. 3rd-4th S hifter Fork 13. Interlock Plunger

2. Interlock Balls 9. "C " Ring Lock Clip Spring
3. 3rd-4th S hifter Shaft 10. Reverse S hifter Fork 14. Reverse Interlock
4. Reverse S hifter Shaft 1 1. S hifter S haft Hole Plunger
5. Fork Retaining Pin Plugs 15. 1st-2nd S hifter Shaft
6. Detent Ball 12. 1st-2nd S hifter Fork 16. Interlo ck Pin
7. Detent Spring 17. Cover Gasket

Clutch Gear and Shaft (Fig. 8Q)

Disassem bly
1. Remove mainshaft pilot bearing rollers (17) from
clutch gear if not already removed, and remove roller
retainer. D o not remove snap ring on inside of clutch
REVERSE
gear.
2. Remove snap ring securing bearing on stem of clutch
3RD/4TH
gear.
3. To remove bearing, position Tool J-22872 to the bear
1 S T /2N D ing (fig. 9Q) and using an arbor press and Tool J-0358
press gear and shaft out of bearing (fig. 10Q).
Inspection
1. W ash all parts in cleaning solvent.
2. Inspect roller bearings for pits or galling.
Fig. 7Q --Shifter S haft Installation 3. Inspect bearing diam eter in shaft recess for galling.
4. Inspect gear teeth for excessive wear.
5. A fter 1st and 2nd fork is installed, place two innerlock 5. Inspect clutch shaft pilot for excessive wear.
balls between the low speed shifter shaft and the high 6. Re-oil bearing, then rotate clutch gear bearing slowly
speed shifter shaft in the crossbore of the front support by hand and check for roughness.
boss. Install the innerlock pin in the high speed (center
position) shifter shaft hole and grease to hold in place.
Continue pushing this shaft through cover bore and Assem bly
fork until retainer hole in fork lines up with hole in 1. Press bearing and new oil slinger onto clutch gear shaft
shaft. Install retainer pin and move to neutral position. using Tool J-22872 (fig. 1 IQ). Slinger should be located
flush with bearing shoulder on clutch gear. See Figure
6. Place two innerlock balls in crossbore in front support
8Q for direction of slinger installation.
boss between reverse, and 3rd and 4th shifter shaft.
Then push rem aining shaft through fork and cover
bore, keeping both balls in position between shafts until CAUTION: Extercise care to prevent distortion of
retaining holes line up in fork and shaft. Install retain the oil slinger.
ing pin.
2. Install snap ring to secure bearing on clutch gear shaft.
7. Install new shifter shaft hole expansion plugs and ex 3. Install bearing retainer ring in groove on O.D. of bear
pand in place. ing.
O IL S L IN G E R
R E T A IN E R R IN G
SNAP R IN G
Fig. 8Q -C lutch Gear Assem bly

Fig. 10Q~Removing Clutch Gear Bearing
3. Install new seal on Tool J-22833 with lip of seal toward

flange of tool.
4. Support front surface of retainer in press, start seal and
tool in retainer bore and drive seal into retainer until
flange of tool bottom s on retainer (fig. 13Q).
5. Install new gasket on retainer and install retainer on
transmission case (when assembling transmission).
M ainshaft Assembly
Disassem bly (Fig. 14Q)
Fig. 9Q ~Positioning Tool J -2 2 8 7 2 to Clutch Gear
CAUTION: The bearing must turn freely, after it is

installed on the shaft.
4. Install snap ring on I.D . of m ainshaft pilot bearing bore

in clutch gear (if previously removed).
5. A pply a small am ount of grease to bearing surface in
shaft recess, install transm ission m ainshaft pilot roller
bearings (17) and install roller bearing retainer (fig.
12Q).
OIL
SLINGER
NOTE: This roller bearing retainer holds bearing in
position and in final transmission assembly is
pushed forward into recess by mainshaft pilot.
Clutch Gear Bearing Retainer Oil Seal
Replacement
1. Remove retainer and oil seal assembly and gasket.
2. Pry oil seal out of retainer. Fig. 1 1Q -R eplacing Clutch Gear Bearing

Fig. 12Q ~Roller Bearing Retainer Fig. 13Q --lnstalling Bearing Retainer Oil Seal
Fig. 14 Q -M a in s h a ft A ssem bly-E xploded V iew
1. 1st Speed Gear 5. 2nd Speed Blocker 10. 3rd Speed Blocker 13. 4th Speed Blocker
2. Reverse Driven Gear Ring Ring Ring
3. 1 st Gear Bushing 6. 2nd Speed Gear 11. 3rd-4th Speed 14. Snap Ring
4. 1st-2nd Gear 7. T hrust W asher Synchronizer Hub 15. M ainshaft
Synchronizer Hub 8. 3rd Speed Bushing Assem bly 16. 2nd Speed Gear
Assem bly 9. 3rd Speed Gear 12. 3rd-4th Speed Bushing
Synchronizer Sleeve

5. Check second speed thrust washer for excessive scoring.

■H
6. Inspect 2nd speed gear for excessive wear at thrust
4* i
m surface. Check synchronizer springs for looseness or
li 7.
breakage.
Inspect second gear synchronizing ring for excessive
3R D & 4T H wear.
S Y N C H R O N IZ E R 8. Inspect bronze synchronizer cone on 2nd speed gear for
excessive wear or damage. Also inspect clutch gear syn
chronizer cone and third speed gear synchronizer cone
for excessive wear or damage.
3R D G EAR NOTE: First and reverse sliding gear must be sliding

fit on synchronizer hub and must not have excessive
radial or circumferential play. If sliding gear is not
free on hub, inspect for burrs which may have rolled
2ND GEAR up on front end of half-tooth internal splines and
remove by honing as necessary.
9. Inspect all gear teeth for excessive wear.
Assem bly
Fig. 1 5Q--Disassembly of M ainshaft
1. Using Tool J-22873 press 2nd speed bushing onto m ain
1. Remove first speed gear. shaft until it bottom s against shoulder (fig. 16Q).
2. Remove snap ring in front of 3rd-4th synchronizer as
sembly. NOTE: Lubricate bushing with E.P. oil before press
3. Remove reverse driven gear. ing.
4. Press behind second speed gear to remove 3rd-4th syn
chronizer assembly, 3rd speed gear and 2nd speed gear
along with 3rd speed gear bushing and thrust washer CAUTION: 1st, 2nd and 3rd speed gear bushings are
(fig. 15 Q). sintered iron, exercise care when installing.
5. Remove 2nd speed synchronizer ring.
6. Remove 2nd speed synchronizer keys. 2. Press 1st and 2nd speed synchronizer hub onto m ain
7. Supporting 2nd speed synchronizer hub at front face, shaft until it bottom s against shoulder with annulus
press m ainshaft through removing 1st speed gear bush tow ard rear of shaft.
ing and 2 nd speed synchronizer hub.
8. Split 2nd speed gear bushing with chisel and remove
bushing from shaft.
CAUTION: Exercise care not to damage mainshaft.
Inspection
1. W ash all parts in cleaning solvent.
2. Inspect m ainshaft for scoring or excessive wear at
th ru st surfaces or splines.
3. Inspect clutch hub and clutch sleeve for excessive wear
and m ake sure sleeve slides freely on clutch hub. Also
check fit of clutch hub on m ainshaft splines.
NOTE: Third and fourth speed clutch sleeve should

slide freely on third and fourth speed clutch hub but
clutch hub should be snug fit on shaft splines.
4. Inspect 3rd speed gear thru st surfaces for excessive

scoring and inspect th ird speed gear m ainshaft bushing
for excessive wear.
NOTE: Third speed gear must be a running fit on

mainshaft bushing and mainshaft bushing should
be press fit on shaft. Fig. 1 6Q ~ lnstalling 2nd Speed Gear Bushing

9. Install reverse driven gear with fork groove toward

rear.
10. Install 1st speed gear onto m ainshaft and against 1st
and 2nd synchronizer hub. Install 1st speed gear thrust
washer.
Countershaft Assembly
NOTE: The 30-60 series trucks with transmission
mounted parking brake incorporate a spacer instead
of the damper plate. The clutch countergear and
spacer are pressed on using the same procedures
utilized for the clutch countergear with the damper
plate.
Disassem bly
1. Remove front countergear retaining ring and thrust
washer. Discard snap ring.
1ST GEAR
BUSHINGl
Fig. 17Q—Installing 3rd Speed Gear Bushing 3RD GEAR

BUSHING
3. Install 1st and 2nd synchronizer keys and springs (if
previously removed).
4. Using Tool J-22873 press 1st speed gear bushing onto
m ainshaft until it bottom s against hub (fig. 17Q).
NOTE: Lubricate all bushing with E.P. oil before in

stallation of gears.
5. Install synchronizer blocker ring and 2nd speed gear

onto m ainshaft and against synchronizer hub. Index
synchronizer key slots with keys in synchronizer hub.
6 . Install 3rd speed gear thrust washer onto mainshaft
with tang on th ru st w asher in slot on shaft and against
2nd speed gear bushing. Then press 3rd speed gear
bushing onto m ainshaft using Tool J-22875 until it bot J-22872
toms against th ru st washer (fig. 18Q).
7. Install 3rd speed gear synchronizer blocker ring and
3rd speed gear onto m ainshaft, against 3rd speed gear
thru st washer.
8 . Index synchronizer ring key slots with synchronizer
assembly keys and drive 3rd and 4th synchronizer as
sembly onto m ainshaft using Tool J-22875 and against
3rd speed gear bushing th ru st face tow ard 3rd speed
gear (fig. 19Q). R etain synchronizer assembly with snap
Fig. 18Q ~ lnstalling 3rd Speed Gear Bushing
ring.

5. Position assembly on an arbor press and press shaft

from 3rd speed countergear.
Assem bly
1. Position 3rd speed countergear and shaft in arbor press
and press the gear onto the shaft.
NOTE: Install gear with marked surface toward

front of shaft.
3RD & 4TH GEAR
2. Install new 3rd speed countergear retaining ring using
SYNCHRONIZER
snap ring pliers.
3. Install new clutch countergear rear retaining ring using
Tool J- 22830, J-22873 and snap ring pliers as follows:
Install Tool J-22830 on end of shaft and position snap
ring on Tool (fig. 21Q). Using Tool J-22873, push down
on snap ring until it engages groove on shaft. Using
snap ring pliers, carefully expand ring until it ju st slides
onto splines, then push ring down shaft until it engages
groove on shaft.
CAUTION: Do not over stress snap ring.

4. Position clutch countergear on shaft and press counter
gear onto shaft against snap ring using Tool J-22873,
(fig. 22Q).
5. Install clutch countergear thrust washer and front re
Fig. 19Q --lnstalling 3rd and 4th Gear Synchronizer
taining ring using Tool J-22830 and J-22873 (fig. 21Q).
2. Install Tool J-22832 on countershaft, open side to CAUTION: Do not over stress snap ring. Ring should
dam per, (fig. 20Q); support assembly in an arbor press be tight in groove without side play.
and press countershaft out of clutch countergear assem
bly. TRA N SM ISSIO N A S S E M B L Y
1. Lower the countergear into the case until it rests on
bottom s of case.
DAMPER
Fig. 2 0 Q -P o sitio n in g Tool J -2 2 8 3 0 On C ountershaft
3. Remove clutch countergear rear retaining ring. Discard

snap ring.
4. Remove 3rd speed countergear retaining ring. Discard
snap ring. Fig. 21 Q—I nsta 11i ng Counter Gear Snap Ring

3. Install m ainshaft assembly into case with rear of shaft

protruding out rear bearing hole in case. Position Tool
J-22874-5 in clutch gear case opening and engaging
front m ainshaft (fig. 23Q). R otate case onto front end.
NOTE: Install 1st speed gear thrust washer on

shaft if not previously installed.
4. Install snap ring on bearing O.D. and position rear
m ainshaft bearing on shaft. Using Tool J-22874-1 drive
bearing onto shaft and into case (fig. 23Q). Align tangs
on snap ring w ith lube slot of case and slot in tool before
driving bearing. R otate case and remove Tool J-22874-
5.
5. Install synchronizer cone on pilot end of m ainshaft and
slide rearw ard to clutch hub.
CAUTION: Make sure three cut out sections of 4th

speed synchronizer cone align with three clutch
keys in clutch assembly.
6. Install snap ring on clutch gear bearing O.D. Index cut

out portion of clutch gear teeth to obtain clearance over
countershaft drive gear teeth, and install clutch gear
assembly onto case. Raise m ainshaft to get clutch gear
Fig. 2 2 Q ~ ln sta llin g Clutch Countergear started and tap bearing outer race with plastic tip ham
mer.
2. Place reverse idler gear in transmission case with gear 7. Install clutch gear bearing retainer using a new gasket.
teeth tow ard the front. Install idler gear shaft from rear Install bolts and tighten to 15-18 ft. lbs.
to front, being careful to have slot in end of shaft in 8 . Install Tool J-22874-2 in countergear front bearing
facing down. Shaft slot face m ust be at least flush with opening in case to support countergear and rotate case
case. onto front end (fig. 24Q).
9. Install snap ring on countergear rear bearing O.D., po
sition bearing on countergear and using Tool J-22874-2,
drive bearing into place (fig. 25Q). R otate case, install
snap ring on countershaft at rear bearing and then
remove Tool J-22874-2.
Fig. 23Q --lnstalling M ainsha ft Rear Bearing Fig. 24Q --C ountergear Front S up po rt Tool

J-23070
Fig. 2 6 Q ~ ln sta llin g M ainsha ft Rear Bearing Lock Nut (4-W heel
Drive Only)
14. Install parking brake drum a n d /o r universal joint

flange.
NOTE: Apply light coat of oil to seal surface.

Fig. 25Q --lnstalling C ountergear Rear Bearing
10. Tap countergear front bearing assembly into case. 15. Lock transm ission in two gears at once. Install univer
11. Install countergear front bearing cap and new gasket. sal joint flange locknut and tighten to 90-120 ft. lbs.
T orque cap screws to 20-30 in. lbs. 16. Move all transm ission gears to neutral except the re
12. Slide speedometer drive gear over m ainshaft to bearing. verse idler gear which should be engaged approximately
13. Install rear bearing retainer with new gasket. Be sure 3/8 of an inch (leading edge of reverse idler gear taper
snap ring ends are in lube slot and cut out in bearing lines up with the front edge of the 1st speed gear).
retainer. Install bolts and tighten to 15-18 ft. lbs. Install Install cover assembly with new gasket to transmission
brake backing plate assembly on models equipped with case. Shifting forks m ust slide into their proper posi
propeller shaft brake. tions on clutch sleeves and reverse idler gear. Forks
m ust be positioned as in removal.
NOTE: On models equipped with 4-wheel drive, in
stall rear lock nut and washer using Tool J-23070 17 Install cover attaching bolts and torque to 20-25 ft. lbs.
(fig. 26Q). Torque lock nut to 120 ft. lbs. and bend 18. Using Tool J-8109, replace gearshift lever and check
washer tangs to fit slots in nut. operation of transmission.
NEW PROCESS 4-SPEED TRANSMISSION (MODEL 4 3 5 )

INDEX
SU BJECT PAGE
Disassembly of T ran sm issio n ........................................ 7-51 C ountershaft Bearing R ep lac em en t.......................... ....... 7-56
Cleaning and In sp ectio n ................................................. 7-52 Reverse Idler G e a r ............................................................... 7-56
Subassembly O p e ra tio n s................................................. 7-52 D isassem bly................................................................... ....... 7-56
Transm ission Cover........................................................ 7-52 A ssem bly............................................................................... 7-56
D isassem bly................................................................... 7-52 Assembly of T ra n sm issio n ............................................ ....... 7-57
A ssem b ly........................................................................ 7-54 Countershaft ................................................................... .......7-57
M ain Drive G ear............................................................ 7-54 Reverse Idler G ear and Shaft..................................... .......7-57
D isassem bly................................................................... 7-54 M ainshaft.................................................................................7-57
A ssem b ly........................................................................ 7-54 M ain Drive G ear............................................................ .......7-57
M ain Drive G ear Bearing Retainer Oil S eal.......... 7-55 R ear Bearing Retaining and Parking Brake .......... .......7-58
M ainshaft.......................................................................... 7-55 Transmission Cover...............................................................7-59
D isassem bly................................................................... 7-55 Rem ote Control A ssem b ly .................................................7-59
A ssem b ly ........................................................................ 7-55 Miscellaneous ........................................................................7-59
M ainshaft R ear Bearing R etainer Oil Seal ............ 7-55

Fig. 1 K~Transmission Cross Section *

1. M ain Drive (Clutch) 13. 3rd Speed 26. O utput Yoke 39. Reverse Idler Gear
Gear Synchronizer Outer 27. M ainshaft Rear Shaft
2. Drive Gear Bearing Stop Ring Bearing Retainer 40. M ainsha ft 3rd Speed
Retainer 14. S hift Rail 28. M ainshaft 1st Speed Gear
3. Snap Ring (Selective) 15. 2nd Speed Gear S liding Gear 41. C ountershaft and
4. Snap Ring 16. 2nd Speed 29. Countershaft Rear Gear Cluster
5. Needle Bearing Synchronizer Spring Bearing Retainer 42. 3rd Speed
Rollers (1 4) 17. 1st and 2nd S hift 30. T hrust Bearing Race S ynchronizer Inner
6. 4th Speed Fork 31. C ountershaft Rear Ring and Pin Assy.
Synchronizer O uter 18. M ainshaft T hrust Bearing 43. 3rd and 4th Speed
Stop Ring 19. M ainshaft Rear 32. C ountershaft Rear Synchronizer Sliding
7. Poppet Ball Spacer Bearing Assy. Clutch
8. Poppet Spring 20. M ainshaft Rear 33. Snap Ring 44. 4th Speed
9. 3rd and 4th Speed Bearing Assy. 34. Lock Plate Retaining S ynchronizer Inner
Synchronizer Clutch 21. Snap Ring Screw Ring and Pin Assy.
Gear 22. Speedom eter Drive 35. Lock Plate 45. Transm ission Case
10. 3rd and 4th Shift Gear 36. Revese Idler Gear 46. C ountershaft Front
Fork 23. M ainshaft Rear Oil Bushing Bearing Assy.
1 1. G earshift Lever Seal 37. Reverse Idler Gear 47. M ain Drive Gear
12. Transm ission Cover 24. W asher 25. Yoke 38. Snap Ring Front Bearing
Retaining Nut 48. Oil S linger
*4.56:1 R atio M odels incorporate an anti-rattle spring

on m ainshaft splines under low gear.
Fig. 2K--Transm ission Exploded V iew

1. Screw and Lock 16. T hrust W asher 31. 4th Speed 41. Snap Ring
W asher Assy. 17. C ountershaft and Synchronizer O uter 42. M ainshaft 2nd Speed
2. Main Drive Gear C luster Gear Stop Ring Gear
Bearing Retainer and 18. T hrust Bearing 32. 4th Speed 43. S ynchronizer Spring
Oil Seal 19. Bearing Race Synchronizer Inner 44. Inner Stop and
3. Gasket 20. Gasket ring and Pin Assy. Clutch Pin Ring Assy.
4. Drive Gear Bearing 21. C ountershaft Rear 33. Synchronizer Sliding 45. M ainshaft
Retainer Snap Ring Bearing Retainer Clutch 46. M ainsha ft 1st Speed
(Selective) 22. Screw and Lock 34. 3rd Speed Reverse S liding Gear
5. Main Drive Gear W asher Assy. Synchronizer Inner 47. M ainshaft Rear
Front Bearing 23. Screw and Lock Ring and Pin Assy. Spacer
6. Drive Gear Bearing W asher Assy. 35. 3rd Speed 48. M ainshaft Rear
Oil S linger 24. Reverse Idler Gear Synchronizer Outer Bearing
7. M ain Drive Gear S haft Lock Plate Stop Ring 49. Speedom eter Drive
8. Retaining W asher 25. Reverse Idler Gear 36. Snap Ring Gear
9. Snap Ring Shaft 37. 3rd and 4th Speed 50. Gasket
10. Drain Plug 26. Snap Ring Synchronizer Clutch 51. M ainshaft Rear
1 1. Filler Plug 27. Reverse Idler Gear Gear Bearing Retainer
12. Screw and Lock 28. Snap Ring 38. A dju stin g Shim 52. Screw and Lock
W asher Assy. 29. C ountershaft Front 39. M ainshaft 3rd Speed W asher Assy.
13. Power and Take-O ff Bearing Gear 53. M ainshaft Nut
Cover 30. Pilot Bearing Rollers 40. M ainsha ft 2nd Speed 54. M ainshaft Rear
14. Gasket (14) Gear S p lit Ring (2 Bearing Oil Seal
15. Transm ission Case Halves)
D ISA SSEM B LY OF TRANSM ISSIO N (Refer to Figures 1K and 2K)

The following procedures cover complete overhaul of the 2. Remove eight screws and washers, and remove cover
transmission. The transm ission should be overhauled in se from transm ission case. Remove cover to case gasket
quence described unless only one unit is to be worked on. and discard.
1. M ount transm ission assembly in holding fixture; then 3. Lock transm ission into two speeds at one time.
if not previously removed, remove drain and filler 4. Remove four screws with lock washers and remove rear
plugs. Shift transm ission into neutral position. bearing retainer and gasket from case. Discard gasket.

5. Remove speedometer drive gear from rear end of m ain NOTE: After cleaning and inspecting bearings as
shaft. directed, lubricate bearings generously with lubri
6. Using a suitable puller over snap ring on bearing cant recommended in LUBRICATION (SEC. 0) of
remove m ainshaft rear bearing. this supplement; then wrap each bearing in clean
7. Remove four self-locking, self-sealing screws and paper until ready to reinstall in transmission.
remove main drive gear retainer and gasket. Discard
gasket. 2. Remove all portions of old gaskets from parts, using a
8. R otate m ain drive gear assembly so part of gear with stiff brush or scraper.
missing clutch teeth is on the bottom . Pull drive gear
assembly straight out o f transmission.
9. Lift 3rd and 4th speed synchronizer parts out of case Inspection
(fig. 11K). 1. Inspect all parts for discoloration or warpage due to
heat.
NOTE: On light duty models remove the roller type 2. Examine all gear teeth and splines for chipped, worn,
thrust bearing on the mainshaft then slide synchro broken, or nicked teeth or splines. Small nicks or burrs
nizer parts from mainshaft. may be removed with a fine abrasive stone.
3. Inspect the breather assembly to see that is open and
10. Lift m ainshaft and gears assembly from transmission
not damaged.
case.
4. Check all threaded parts for damaged, stripped or
11. Remove screw and lock plate retaining reverse idler
crossed threads.
shaft.
5. Replace all gaskets, oil seals, and snap rings.
12. Using a suitable puller, pull reverse idler shaft from
6. Examine housing, retainers, and covers for cracks or
case. Remove idler gear from inside case.
other damage. Since repairs by welding, brazing, etc.,
13. Remove four screws and lock washers, then remove
are not recommended, replace damaged parts.
countershaft rear bearing retainer and gasket. Discard
7. Check keys and keyways for condition and fit.
gasket.
8. Inspect shift forks for wear, distortion, or other dam
14. Remove countershaft rear thrust bearing and race.
age.
15. Lift countershaft gear out of transm ission case.
9. Check detent ball springs for distortion or collapsed
16. If so equipped, remove power take off cover attaching
coils.
screws and lock washers. Remove cover and gasket.
10. Inspect thrust washers, stop rings, and spacers for wear
Discard gasket.
or damage.
11. Check fit of bearing on their respective shafts and in
CLEAN IN G AND IN SPECTIO N their bores. Inspect bearings, shafts, and case for wear.
If installation of a new bearing does not correct condi
(Refer to Figure 2K) tions, install new shafts or replace the case.
12. M ake sure synchronizer sliding clutch slides freely on
Cleaning clutch gear. Check pins on synchronizer outer stop
rings for straightness and tightness.
D uring overhaul procedures all com ponents of the trans
13. Inspect all bearing rollers for pitting or galling.
mission (except bearing assemblies) should be thoroughly
14. Examine detent balls for corrosion or brinneling. If shift
cleaned w ith cleaning solvent and dried with air pressure
lever shaft detents show signs of wear, replace them.
prior to inspection and reassembly of the transmission.
15. Replace all worn or damaged parts. W hen reassembling
1. Clean the bearing assemblies as follows:
the transmission, coat all moving parts with lubricant
a. Careful and proper cleaning of bearings is of utm ost
recommended in L U B R IC A T IO N (SEC.O) of the ap
importance. Bearings should always be cleaned
propriate Chevrolet Service M anual.
separately from other parts.
b. Soak all bearing assemblies in C L E A N cleaning sol S U B A S S E M B L Y O PERA TIO N S
vent. G asoline is not recommended. Bearings
should never be cleaned in hot solution tank. Transmission Cover
c. Slush bearings in solvent until all old lubricant is
loosened. H old bearing races so bearings will not Disassem bly (Fig. 4K)
rotate; then brush bearings with a soft bristled brush 1. Using a No. 2 easy out as shown in Figure 4K, remove
until A L L D IR T has been removed. Remove loose roll pin retaining 3rd and 4th shift fork to 3rd and 4th
particles of dirt by striking bearing flat against a shift rail.
block of wood. 2. Remove 3rd and 4th shift rail and shift fork driving
d. Rinse bearings in clean solvent; then blow bearings shift rail out through welch plug opening in cover forc
dry with air pressure. D O N O T SPIN B E A R IN G S ing out welch plug.
W H IL E D R Y IN G . 3. Remove detent ball and spring.
e. R otate each bearing slowly while examining balls or 4. Using a No. 2 easy out, remove roll pin from 1st and
rollers for roughness, damage, or excessive wear. 2 nd shift lug.
Replace all bearings th at are not in first class condi 5. W ith a No. 2 easy out remove roll pin from 1st and 2nd
tion. shift fork.

Fig. 3K~Transm ission Cover Com ponents
1. Gasket (Not Shown) 11. Retaining Ring 20. Detent Ball

2. T ransm ission Cover 12. Reverse S hift Lug 21. Plunger
(Not Shown) 13. Detent Ball 22. Spring
3. W asher (Not Shown) 14. Spring 23. 3rd and 4th Shift
4. Cap Screw (Not 15. S hift Rail Interlock Fork
Shown) Plunger 24. Lock Pin
5. Lock Pin 16. S hift Rail Interlock 25. Lock Pin
6. 1st and 2nd S hift Pin 26. 1st and 2nd S hift
Fork 17. 3rd and 4th Shift Lug
7. Reverse S hift Fork Rail 27. 1st and 2nd S hift
8. Lock Pin 18. s h ift Rail Interlock Rail
9. Reverse S hift Rail Plunger 28. Detent Ball
10. Lock Pin 19. Spring 29. Spring

5. Position detent spring and ball in bore of cover.

6. Paritally insert reverse shift rail into bore of cover.
Position reverse shift fork and reverse shift lug on rail.
7. Push reverse shift rail the remaining distance (to neu
tral position) into cover and install new lock pins.
NOTE: Tapered end of pins go in first.
8. Install two rail interlock plungers in bores of cover.

9. Position rail interlock pin in 3rd and 4th shift rail.
10. Install detent spring and ball in bore cover.
11. Install detent spring and ball in bore of cover and posi
tion 3rd and 4th shift form on rail.
12. Push 3rd and 4th shift rail the remaining distance into
cover and install new lock pin.
NOTE: Tapered end of pin goes in first.
13. Check intelocks by shifting reverse shift rail in reverse

position. O ther shift rails should not shift when this rail
is shifted.
14. Install three new welch plugs in bores of shift rail holes.
Fig. 4K~Removing S hift Fork Lock (Roll) Pin
Install rail interlock hole plug.
1. Transm ission Cover 8. Reverse S hift Fork

2. No. 2 Easy Out 9. W elch (expansion) Main Drive Gear
3. 3rd and 4th S hift Plugs
Fork 10. Lock Pins Disassem bly (Fig. 5K and 6K)
4. Reverse S hift Lug 11. 1st and 2nd S hift
5. 3rd and 4th S hift Rail Lug 1. Remove m ainshaft pilot bearing snap ring from cavity
6. Reverse S hift Rail 12. 1st and 2nd S hift at rear of main drive gear.
7. 1st and 2nd Shift Rail 2. Remove pilot bearing washer and 14 pilot bearing roll
Fork ers from drive gear.
6. Using ham m er and drift, drive 1st 2nd shift rail out of 3. Using snap ring pliers, remove drive gear bearing re
cover forcing out welch plug. Remove shift rail, 1st and taining selective snap ring.
2 nd shift lug. and 1st and 2 nd shift fork. 4. Using bearing remover plates (J-8176), or other suitable
7. Remove detent ball and spring. tool, press main drive gear gront bearing off drive gear
8. Using No. 2 easy out, rem ove roll pins from reverse shaft.
shift lug assembly and shift fork. 5. Remove drive gear bearing oil slinger from drive gear
9. W ith ham m er and drift, drive reverse shift rail out of shaft.
cover forcing out welch plug. Remove reverse shift lug
assembly, and reverse shift fork. Assem bly
10. Remove detent ball and spring. Remove two shift rail
interlock plungers and interlock pin from cover. 1. Position oil slinger, dished side down, on main driver
11. Using a screw driver, remove retaining ring from re gear; then, using a suitable sleeve, press or drive front
verse shift lug assembly. Remove washer, plunger and bearing on shaft of gear.
spring from reverse shift lug. 2. Using snap ring pliers; install front bearing selective
snap ring in groove of drive gear shaft.
A s s e m b ly (Fig. 3K)
NOTE: Install the thickest snap ring that can be
1. Position detent spring and ball in bore of cover. used. These snap rings come in four different thick
2. Partially insert 1st and 2nd speed shift rail into bore of nesses as shown in table following:
cover. Position 1st and 2nd speed shift fork and 1st and
2 nd speed shift lug on rail. T h i n .................................................... 0.087” - 0.089”
3. Push 1st and 2nd speed shift rail the remaining distance Medium .............................................. 0.090” - 0.092”
(to neutral position) into cover and install new lock Thick .................................................. 0.093” - 0.095”
pins.
Extra Thick .......................................... 0.096” - 0.098”
NOTE: Tapered end of pins go in first. 3. Using light grease to retain bearing rollers, position 14
bearing rollers in cavity of main drive gear.
4. Install reverse shift plunger spring and lug plunger in 4. Position thrust washer over bearing rollers; then using
bore of reverse shift lug. Com press plunger and install a small screw driver, install snap ring in groove of drive
retaining clip. gear.

F R O N T B E A R IN G
B E A R IN G SNAP R IN G
O IL S LIN G E R
DRIVE G E A R SHAFT
S N A P R IN G
M IS S IN G
(SELECTIVE)
C LU TC H TEETH
M A IN DRIVE G E A R
Fig. 5K~M ain Drive Gear Removed
Main Drive Gear Bearing Retainer Oil 2. Place m ainshaft 2nd speed gear over spring and ring.
3. Install retaining snap ring, when tangs of snap ring
Seal pointing out.
4. Position 2nd speed gear and synchronizer assembly on
Replacem ent
mainshaft.
1. Remove bearing retainer oil seal from main drive gear 5. Install m ainshaft 2nd speed gear split ring in groove of
bearing retainer. m ainshaft making sure ends of ring are securely lock
2. Using a suitable sleeve, press or drive new oil seal into together (fig. 8 K).
bore of bearing retainer.
NOTE: Lubricate parts. Parts should turn freely.
NOTE: Lip of oil seal should point toward gasket
surface of retainer. 6. Position m ainshaft 3rd speed gear on mainshaft and
lubricate freely. G ear should turn easily.
M ainshaft 7. Install 3rd and 4th synchronizer sliding clutch gear on
mainshaft.
Disassem bly 8. Using snap ring pliers, install mainshaft clutch gear
snap ring in groove of mainshaft.
1. Remove m ainshaft rear spacer from rear of mainshaft.
NOTE: Install the thickest snap ring possible in
2. Remove m ainshaft 1st speed sliding gear from m ain groove of shaft. Snap rings are available in four dif
shaft. ferent thicknesses as shown in the following table:
3. Remove synchronizer clutch gear snap ring, then
remove synchronizer clutch gear.
4. Remove m ainshaft 3rd speed gear and synchronizer T h in .......................................................... 0.086” - 0.088”
adjusting shims if used. M ed iu m .................................................... 0.089” - 0.091”
5. Remove m ainshaft 2nd speed gear split ring. T h ic k .........................................................0.091” -0 .0 9 4 ”
6. Remove m ainshaft 2nd speed gear and synchronizer Extra T h ic k ............................................ . 0.095” - 0.097”
assembly from m ainshaft. 9. Position m ainshaft 1st speed sliding gear (51) on m ain
7. Remove 2nd speed synchronizer retaining ring from shaft.
synchronizer pins. Remove synchronizer spring assem
bly and synchronizer spring from 2 nd speed gear.
M ainshaft Rear Bearing Retainer Oil
Assem bly Seal
1. Position 2nd speed gear and synchronizer inner stop Replacement (Fig. 2K)
ring and pin assembly on bench. Place synchronizer
spring in stop ring (fig. 7K).
1. Press or drive bearing retainer oil seal out of retainer.

BEARING CONE
OIL SEAL
GASKETS
BEARING RETAINER
M A IN S H A F T
SYNCHRONIZER
CLUTCH GEAR
TORRINGTON BRG.
M O D EL C A -C L U T C H GEAR W ITH TAPERED ROLLER BEARING
OIL MAIN DRIVE ROLLER

SLINGER GEAR ASSEMBLY BEARING WASHER
BEARING \
GASKET
ASSEMBLY \
BEARING
RETAINER
*
RETAINER
BEARING
RING
ROLLERS (14)
SCREW AND SNAP

LOCK WASHER RING
ASSEMBLY
MODEL C L -C L U T C H GEAR W ITH BALL BEARING
Fig. 6 K -M a in Drive Gear Com ponents
2. Prelubricate between lips of seal before installing and Clean and inspect retainer, if not previously accom
using a suitable sleeve, press or drive new oil seal into plished.
bore of retainer. Press oil seal into bore of retainer until
it bottoms. 2. Using a heavy grease to hold rollers in place, position
needle rollers in bore of bearing retainers.
NOTE: Coat outer diameter of oil seal with a light
coat of sealing cement. Wipe off excess cement. Lip Reverse Idler Gear Assembly
of seal goes toward front of retainer.
Two different design reverse idler gears are used in the
4-speed New Process transmission models on Chevrolet
Countershaft Bearings
trucks. All models use a bushing in the gear except for Tilt
Replacement (Front or Rear) Cab models (6.69 ratio) which use a reverse idler gear incor
porating a heavy duty needle roller bearing assembly. Nei
1. If inspection shows countershaft bearing needle rollers ther the bushing or roller bearing is serviced separately and
are worn or damaged, remove rollers from retainer. the gear and bearing must be replaced as an assembly.

SYNCHRONIZER BEARING
SPRING BEARING
2ND SPEED BEARING RACE
RETAINER
GEAR
REAR BEARING
SNAP
RING
INNER STOP
AND CLUTCH PIN
RING ASSEMBLY
Fig. 7K--2nd Speed Gear and Synchronizer Components
Assem bly of Transm ission (Fig. 2K)

Countershaft and Gear Cluster
TRANSMISSION
Installation CASE
Fig. 9K--lnstalling C ountershaft and Cluster Gear Rear Bearing
1. Position transm ission case on work bench with front of
case down.
NOTE: Use sealing cement on the four screw and
2. Coat front thrust washer with grease and position it in lock washer assemblies. Tighten screws securely.
case over countershaft front bearing. Check by feel for some slight end play of the coun
3. Position countershaft and gear cluster in tranm ission tershaft.
case making sure the front thrust washer is not dis
turbed. Reverse Idler Gear and Shaft
4. Install countershaft cluster gear rear thrust bearing and
bearing race on pilot diam eter at rear of countershaft Installation
(fig. 9K).
1. Position reverse idler gear assembly in transmission
5. Using a new gasket, install gasket and countershaft rear case (15) with large gear tow ard rear of case.
bearing and retainer assembly. 2. Insert reverse idler gear shaft, with slot in shaft down,
partially into bore of case and idler gear. Coat outer end
of idler gear shaft with sealing cement.
3. Coat lock screw with sealing cement. Position lock
plate in groove of idler gear shaft. Install lock screw.
Drive idler gear shaft the remaining distance into trans
mission case and gear. Tighten lock screw securely.
M ainshaft
Installation
1. Position the m ainshaft assembly in transmission case,
using a block of wood at front end of mainshaft to help
m aintain its position.
2. Install m ainshaft rear spacer on rear end of m ainshaft.
3. W ith block of wood still positioned in transm ission case
as described in Step 1, use a suitable sleeve and ham m er
and drive m ainshaft rear bearing onto m ainshaft (fig.
10K). Remove block of wood.
4. Install 3rd and 4th speed synchronizer parts on front
end of m ainshaft, (fig. 11K) then move mainshaft as
Fig. 8 K -ln s ta llin g M ainsha ft 2nd Speed Gear Ring sembly forward into position in transmission case.

WOOD BLOCK
MAINSHAFT ASSEMBLY
, SPACER f
REAR BEARING
SLEEVE
WLU\__ .jL - ljd ms___________________

Fig. 10K—Installing M ainshaft Rear Bearing
NOTE: On transmission having a tapered front main 2. Install rear bearing retainer and new gasket. Using seal
bearing, install roller bearing thrust washer. ing cement on the four screw and lock washer assem
blies. Tighten screws firmly.
Rear Bearing Retainer and Parking
Brake
Installation NOTE: When installing output yoke, shift transmis
sion into two speeds at one time. Torque on yoke
1. Position speedometer drive gear on rear end of m ain
attaching nuts is 110 foot-pounds.
shaft.
SYNCHRONIZER
SLIDING CLUTCH
INNER PIN AND

RING ASSEMBLY
OUTER
STOP RING
SYNCHRONIZER
CLUTCH GEAR
OUTER
STOP RING
INNER PIN AND

RING ASSEMBLY
Fig. 1 1K "3rd and 4th Speed Synchronizer Parts

Main Drive Gear

! OUTER MAINSHAFT
STOP RIN 3RD SPEED GEAR
Installation
1. W ith part of clutch gear with missing teeth down to

allow for passage over countershaft gear, guide main
drive gear assembly into transm ission case and over
front end of m ainshaft. Be sure front synchronizer stop
ring engages teeth of drive gear. Push the assembly in
until snap ring on bearing is against transmission case. FEELER FEELER
GAUGE
2. Position main drive gear bearing retainer (without gas

ket), over drive gear shaft and against the transmission
case.
3. W hile holding bearing retainer in place and using a

F ig . 1 3 K - C h e c k i n g 3 r d a n d 4 th S p e e d S y n c h r o n iz e r F lo a t
feeler gauge, check gap between retainer and transm is
sion case. Remove bearing retainer; then reinstall bear
ing retainer, two new gaskets and sufficient shims to CAUTION: Mainshaft must be seated on bearing
obtain a thick ness approxim ately .010-.015" greater and bearing correctly installed in case.
than previously measured.
Transmission Cover
4. Install four self-sealing, self-locking screws attaching
drive gear bearing retainer to transm ission case.
Tighten screws firmly (25-35 lb. ft.). Installation
1. Place all transm ission and cover parts in "N eutral"
5. Using a dial indicator, check end play of the input gear position.
(fig. 12K). If end play is not .007 to .017", remove or 2. Using a new gasket, install transmission cover and gas
add shims as required. ket. Tighten the eight attaching screws firmly.
6. Using feeler gauges, check float in 3rd and 4th speed Remote Control Assembly
synchronizer assembly. Insert feeler gauges between
m ainshaft 3rd speed gear and 3rd and 4th speed syn
Installation
chronizer outer stop ring (fig. 13K). Float should be
0.050"-0.070". If necessary, disassemble the unit and 1. On transm ission having remote controls, position
add or subtract synchronizer adjusting shims as neces remove control assembly and new gasket on transm is
sary to bring float within limits. sion cover.
2. Install four attaching screws and lock washers. Tighten
screws firmly.
3. Secure bell crank to stud in boss of transm ission cover
with retaining clip.
NOTE: On transmissions having a conventional

gearshift lever, install gearshift lever on transmis
sion cover.
M iscellaneous (Fig. 2K)

1. If previously removed, install power take-off cover and
new gasket. Tighten six attaching screws firmly.
2. Install drain plug in transmission case. Tighten plug
firmly.
3. Refill transmission with lubricant as directed in
LUBRICATION (SEC. 0 ) of the appropriate Chevrolet
Fig. 1 2 K -ln p u t S haft Bearing End Play Service Manuel and Install filler plug.

DANA MODEL 2 0 TRANSFER CASE

Index
SUBJECT PA G E
Disassembly o f C a s e ........................................................ 7-60 Assembly of R ear O utput S haft................................... 7-63

Cleaning and In sp ectio n ................................................. 7-60 Assembly of Transfer C ase............................................ 7-65
Disassembly of R ear O utput Shaft ............................ 7-60
Disassembly of Transfer Case Remove front washer, front bearing, gear washer, and
output gear from case as they clear shaft. This proce
1. Remove cover from bottom of transfer case. dure will also remove the rear bearing cup.
2. Remove poppet hole cap screws from the outside of the
front bearing retainer.
3. Remove the interm ediate gear shaft lockplate at the NOTE: Remove front bearing cup as required, using
rear side of the transfer case. a suitable puller or driver.
4. Using dum m y shaft J-23419, drive interm ediate shaft
out of rear of case as shown in Figure 2D. 11. Loosen dog set screw from the front wheel drive shift
5. Remove interm ediate gear and thrust washers from fork. Swing fork and gear tow ard cover opening and lift
case. out gear. R otate shift rail to preload poppet ball and
6 . Remove bolts attaching rear output shaft subassembly pull rail out of the retainer. Remove fork as it clears the
to transfer case and remove complete unit from case as shift rail and remove poppet ball and spring from re
shown in Figure 3D. tainer.
12. Support inner race of rear bearing and press bearing
from shaft as shown in Figure 5D.
NOTE: Disassembly of rear output shaft sub-assem- 13. Remove front output shaft bearing retainer and gasket.
bly is covered later in this section. 14. Remove shift rail lip seals with a suitable puller or pry
tool.
7. Remove locknut and washer from front output shaft 15. Remove the front bearing retainer seal using a suitable
yoke, if not removed during unit removal from vehicle, puller or pry tool.
and slide yoke from output shaft.
8. Loosen dog set screw from rear wheel drive shift fork.
R otate shift rail to preload poppet ball and pull rail out Cleaning and Inspection
of the housing. Remove shift fork and clutch gear from
case. Remove poppet ball and spring from retainer. B earings-Place all bearings and rollers in cleaning solu
9. Remove front output shaft rear cover and shims. Tie tion and allow to remain long enough to loosen all ac
shims together before laying aside. cum ulated lubricant. Bearings should be sloshed up and
10. Tap on front end of front output shaft, removing shaft down and turned slowly below surface of solution to remove
from the rear of the case as shown in Figure 4D. as much lubricant as pollible. Remove bearings and blow out
1. Inp ut Shaft 13. Rear O utput Shaft 24. Interm ediate Shaft 34. Drain Plug
2. Transfer Case Rear Bearing Cup Bearing Spacer 35. Front O utput Shaft
3. Input Gear 14. Rear O utput S haft 25. Interm ediate Shaft Drive Gear
4. Snap Ring Rear Bearing 26. Interm ediate Shaft 36. Spacer
5. S liding Clutch Gear 15. Rear O utput Shaft Needle Bearings 37. Front O utput Shaft
6. Rear Input Shaft Yoke 27. Interm ediate Shaft Front Bearing
Needle Bearing 16. Rear O utpu t Shaft Tanged T hrust 38. Front O utpu t Shaft
7. Rear O utput Shaft Locknut W asher Front Bearing Cup
Front Bearing 17. W asher 28. Interm ediate Gear 39. Spacer
8. Rear O utput Shaft 18. Rear O utput Shaft 29. Front O utput Shaft 40. Front O utput Shaft
Front Bearing Cup 19. Rear O utput Shaft Rear Cover Seal
9. Rear O utput Shaft Seal 30. Front O utput Shaft 41. Front O utput Shaft
Housing Gasket 20. Shims Rear Bearing Bearing
10. Rear O utput Shaft 21. Speedom eter Drive 31. Front O utput Shaft 42. Front O utput Shaft
Housing Breather Gear Rear Cover Shim Yoke
11. Speedom eter Driven 22. Interm ediate Shaft Pack 43. Rubber "O " Ring
Gear Lock Plate Bolt 32. Front O utput Shaft 44. W asher
12. Rear O utput Shaft 23. Interm ediate Shaft Rear Bearing Cup 45. Front O utput Shaft
Housing Lock Plate 33. Front O utput S haft Locknut
S liding Clutch Gear

Fig. 1D--Dana Transfer Case Cross Section

with com pressed air, being careful to direct air across bearing 2. Support yoke assembly in a soft jaw vise and remove
so that bearings do not spin. yoke locknut and washer.
Shafts and G ears-C lean all shafts in cleaning solution to 3. Remove assembly from vise and using a soft hammer,
remove all accum ulations. D ry with compressed air. tap yoke from shaft.
Case, Cover and Bearing C ups-T ransfer case, cover, and
bearing cups m ust be thoroughly cleaned in solution to 4. Support rear face of retainer and press output shaft
remove all accum ulations of lubricant and dirt. Remove all from the retainer.
trace of gaskets from surfaces where used. 5. Pry seal from housing bore.
Inspection-C arefully inspect all bearings and rollers for 6. Remove the tapered bearing and, using a drift, drive the
evidence o f chipping, cracks, or worn spots that would render bearing cup from the housing rear bore.
bearing unfit for further service. Bearings are non-adjustable
and if worn or damaged, m ust be replaced with new parts. 7. Using a brass drift, remove the bearing cup from the
Inspect shaft splines and gears. If any indication of failure, housing front bore.
such as chipped teeth or excessive wear is indicated, those 8. Remove shims and speedometer gear from the shaft.
parts should be replaced with new parts. Tie shims together before laying aside.
Disassembly of Rear Output Shaft 9. Using press plates J-8331, remove front bearing from
Sub-Assembly the shaft as shown in Figure 7D.
1. Remove speedom eter driven gear lockplate and gear 10. Collapse and remove pilot bearing from output shaft
from rear retainer. pilot bore.
Fig. 2D~Removing Interm ediate Gear S haft Fig. 4D--Removing Front O utput Shaft
Fig. 3D -R em oving Rear O utpu t Shaft Sub-Assembly Fig. 5D--Removing Front O utput Shaft Rear Bearing

Fig. 6D~Dana Transfer Case Exploded V iew
1. Cover Bolts (4) 15. Spacer 30. Interm ediate Gears 44. Rear O utput Bearing
2. Front O utput Shaft 16. Front O utput Bearing 31. Tanged T hrust Retainer
Rear Cover Retainer Gasket W asher 45. Rear Retainer Bolts
3. Front O utput Rear 17. Front O utput Bearing 32. Interm ediate Shaft (10)
Cover Shims Retainer 33. Transfer Case 46. Rear O utput Rear
J 4. Front O utput Rear 18. Seal 34. Interm ediate S hift Bearing Cup
Bearing Cup 19. O utput Yoke Lockplate and B olt 47. Rear O utput Rear
5. Front O utput Rear Assem bly 35. Rear W heel Drive Bearing
Bearing 20. ” 0 " Ring S hift Fork 48. Rear O utput Retainer
6. Front O utput S haft 21. W asher 36. Rear W heel S liding Seal
7. Bottom Cover Gasket 22. Locknut Gear 49. Rear O utpu t Yoke
8. Bottom Cover and 23. S hifter Rail Seals 37. Pilot Bearing A ssem bly
Bolts 24. Poppet Ball, Spring 38. Rear O utput Shaft 50. Spacer
9. Front W heel Drive and Cap Screw 39. Rear O utput Front 51. Locknut
S hift Fork 25. Rear W heel Drive Bearing 52. Snap Ring (Input
10. Front O utpu t S liding S hift Rail 40. Rear O utput Front Shaft)
Gear 26. Front W heel Drive Bearing Cup 53. Direct Drive Gear
11. Front O utput Gear S hift Rail 41. Speedom eter Drive 54. Snap Ring (Part of
12. T hrust W asher 27. Tanged Thrust Gear A dapter Assem bly)
13. Front O utput Bearing W asher 42. Rear O utpu t Shaft 55. Bearing (Part of
14. Front O utput Bearing 28. Spacer Shims Adapter Assembly)
Cup 29. Needle Bearings 43. Rear Retainer Gasket 56. Input Shaft
2. Using Tool J-5590, press front bearing on shaft as

Assem bly of Rear Output Shaft shown in Figure 9D.
Sub-Assembly
3. Install the front bearing cup in the front housing bore
using Tool J-23423 as shown in Figure 10D until cup
1. Press new pilot bearing in bore of rear output shaft with seats in housing.
bearing identification facing out using Tool J-23420 as
shown in Figure 8 D.
4. Install the rear bearing and cup in the rear housing bore
using Tool J-23423 as shown in Figure 11D until cup
seats in housing.
CAUTION: Bearing identification must face out. Op
posite end of bearing is soft and must not be used to 5. Install the seal in the housing rear bore using Tool
install bearing in bore or damage to the bearing may J-22833 as shown in Figure 12D until seal bottom s in
result. housing.

J-23422
BEARING CUP
J -2 3 4 2 3
Fig. 8D --lnstalling Rear O utput Shaft Pilot Bearing Fig. 1 1 D— Installing Rear O utput Shaft Rear Bearing Cup
J-5590
Fig. 9 D--Installing Rear O utpu t S haft Front Bearing Fig. 12 D--I nsta 11i n g Rear O utput S haft Rear Seal

6. Insert output shaft into front bore of housing and posi

tion yoke on rear of shaft. Support front of shaft and
press assembly together seating the front bearing on the
shaft.
7. Support yoke assembly in soft jaw vise and install
w asher and locknut.
CAUTION: Locknut must be torqued to 200-250 ft.

lbs. before installing prop shaft during unit installa
tion in vehicle.
8. Install speedometer driven gear and lockplate in hous

ing.
Assem bly of Transfer Case

1. Position front wheel drive shift fork in case and push
shift rail through case front. Align set screw hole in fork
with shaft hole and install set screw. Torque set screw F ig . 1 4 D ~ l n s t a lli n g F r o n t O u t p u t S h a f t F r o n t B e a r in g
to 15 ft. lbs.
7. Slide spacer onto shaft. Position front bearing cup and
NOTE: Shift fork set screw boss should face front tap into bore until flush with inner face.
of case. 8. Install shim pack and rear cover. Torque bolts to 30 ft.
lbs.
2. Position rear wheel drive clutch gear and shift fork in 9. Position retainer gasket to case and start rails into front
the case. Push shift rail through case front into fork and bearing retainer.
case rear. Install set screw and torque to 15 ft. lbs.
NOTE: If shift rail seals were removed, position new
NOTE: Gear shift collar should face to case rear. seals in retainer rail bores and press seals into place
using a block of wood or other suitable tool.
3. Place front wheel drive clutch in shift fork with collar
tow ard case rear.
4. Support front output shaft and press rear bearing onto 10. Install the poppet ball springs in the housing access
shaft using Tool J-6219 as shown in Figure 13D. holes.
5. Install front output shaft through rear of case into
clutch gear, drive gear and spacer. Position rear bearing CAUTION: The longer spring (yellow) must be used
cup to case and tap to within 1 /8 inch of seat. on the rear wheel drive rail and the shorter (red) on
6. Position front bearing on shaft. Supporting rear of the front wheel shift rail.
shaft, press bearing into position using Tool J-6219 as
shown in Figure 14D. Tap front of shaft rearw ard to
repostion rear bearing cup. 11. Depress the poppet ball on the poppet spring for the
rear wheel drive and tap housing until end of rail passes
over the ball. Repeat with other rail.
12. Lubricate rail seals and carefully slide shift rails
through seals , then tap housing against case.
CAUTION: Seals may be damaged unless rails are

free of burrs or rough edges.
13. Install front output shaft retainer bolts. Torque to 30 ft

lbs.
14. Install front output shaft retainer seal using Tool J-
22833 as shown in Figure 15D.
15. If shift rail cups are damaged or have been removed,
position new cup in case bore and install by tapping on
end of cup.
CAUTION: Distorted cups may permit leakage and

interfere with shift rail operation.
Fig. 1 3 D—Installing Front O utput S haft Rear Bearing 16. Install front output shaft yoke, washer and locknut.

A L IN E S H A F T S L O T
W IT H B O LT H O LE
Fig. 1 5D --lnstalling Front O utput S haft Seal Fig. 16D --lnstalling Interm ediate Shaft
CAUTION: Locknut must be torqued to 250 ft. lbs. CAUTION: Rear yoke locknut must be torqued to
before installing prop shaft during unit installation. 200-250 ft. lbs. before checking end play and before
installing the rear prop shaft.
17. Using dum m y shaft J-23419, install needle bearings and

21. Shift transfer gears. Check gear engagement and shift
spacers in interm ediate gear. Position thrust washers in
rail movement. The four-wheel drive rail will have the
case with tang in groove on case and supporting inter
greater poppet ball spring tension.
mediate gear in case, installing interm ediate shaft
through rear of case as shown in Figure 16D. 22. Position bottom cover and gasket to case. Install cover
bolts and torque to 15 ft. lbs.
CAUTION: Intermediate shaft is a press fit into the 23. A fter the complete rebuild of the parts, and bearing
case front bore. Align lock plate slot in shaft with retainer caps into unit, check the rear and front output
bolt hole before installing shaft in front bore. Use shafts end play for .001 to .005 inch. A dd or remove
care not to damage shaft" 0 'ering. shims at the proper location on rear output bearing cap
taper bearing, and the front output rear bearing cover.
18. Install interm ediate shaft lock plate and bolt. Torque To obtain proper specified end play, checking of the end
bolt to 15 ft. lbs. play of shafts is im portant. It controls the seating of all
19. Install rear output shaft bearing assembly. Torque re the taper bearings in the transfer case during the operat
taining bolts to 30 ft. lbs. ion in the vehicle. Im proper end play can shorten the
life of the taper bearings in the unit.
CAUTION: Use care to prevent damage to pilot bear
ings when engaging input shaft pilot. NOTE: When installing transfer case in vehicle,
yoke locknuts may be torqued after placing trans
20. Install rear output shaft yoke, washer and locknut if not mission in 1st gear and transfer case in front-wheel
previously done under reassembly of the sub-assembly. drive.
NEW PROCESS MODEL 2 0 5 TRANSFER CASE

Index
SUBJECT PA G E
Disassembly of Transfer Case .......................................... 7-68 Assembly of Transfer C ase............................................ ... 7-70
Rear O utput Shaft A sse m b ly ................................... 7-68 Idler G ear .................................................................... 7-70
F ro n t O utput Shaft Assembly ............................ .... 7-68 Shift Rail and Fork A ssem blies.......................... ... 7-70
Shift Rail and Fork A ssem blies.......................... .... 7-69 F ront O utput Shaft Assembly ................................ 7-70
Idler G ear ................................................................. .... 7-69 R ear O utput Shaft A ssem b ly .................................. 7-72
Cleaning and Insp ectio n ................................................. .... 7-69 M iscellaneous............................................................ ... 7-73

Fig. 1C— New Process Transfer Case Cross Section (See Legend on Page 7-68)

1. Input S haft 18. Rear Bearing 32. IdlerG ear S haft Bearing 43. S liding Clutch
2. " 0 " Ring Retainer Cup 44. Front W heel Hi-Gear
3. Snap Ring 19. Rear Yoke Assem bly 33. Idler S haft Bearing 45. Spacer
4. Bearing 20. Locknut Cone 46. Bearing
5. Snap Ring 21. W asher 34. Idler S haft Cover 47. Snap Ring
6. Input S haft Gear 22. Rear O utput Shaft Bolts and 48. Seal
7. S liding Clutch 23. Bearing Retainer Lockwasher 49. Front O utpu t Shaft
8. Tanged Bronze T hrust Seal 35. Idler S haft Gear 50. W asher
W asher 24. Snap Ring Cover and Gasket 51. Locknut
9. Roller Bearings 25. Bearing 36. T hrust W asher 52. O utput Yoke
10. Spacer 26. Speedom eter Gear 37. Snap Ring 53. Bearing Retainer
11. T hrust W asher 27. Pilot Bearings 38. T hrust W asher Pin 54. Idler Gear
12. T hrust W asher Pin 28. Rear O utput Shaft 39. Rear Bearing 55. Idler Gear Spacer
13. Snap Ring Front Bearing Retainer and O utput 56. Idler S haft
14. B olt and Lockwasher 29. W asher Shaft Cover 57. Locknut
15. Needle Bearings 30. Bearing Retainer 40. Front W heel Drive 58. W asher
16. Spacer 31. Rear W heel Drive Low Gear 59. Bearing Cone
17. Rear O utput S haft Low Gear 41. Roller Bearings 60. Bearing Cup
Housing 42. Spacer
Disassembly of Transfer Case (Fig. 1C) Front Output Shaft Assembly (fig. 3C)
Rear Output Shaft and Yoke Assembly 1. Remove lock nut, washer and yoke.
2. Remove front bearing retainer attaching bolts and re
(Fig. 2C) tainer.
3. Remove front output shaft rear bearing retainer attach
1. Loosen rear output shaft yoke nut.
ing bolts.
2. Remove rear output shaft housing bolts and remove
4. Tap on output shaft with a soft ham m er (Fig. 4C) and
housing and retainer assembly from case.
remove shaft, gear assembly, and rear bearing retainer
3. Remove retaining n ut and yoke from shaft, then remove from case.
shaft assembly from housing.
4. Remove snap ring using Tool J-23432 and discard. NOTE: Remove the sliding clutch from output high
5. Remove thrust washer and washer pin. gear, washer, and bearing which will have remained
in the case.
6. Remove tanged bronze washer. Remove gear needle
bearings (32 per row), spacer and second row of needle 5. Using large snap ring picks, such as J-23432-1, remove
bearings. the gear retaining ring from the shaft (Fig. 5C) and
7. Remove tanged bronze thru st washer from shaft. discard.
8. Remove pilot rollers (15), retainer ring and washer. 6. Remove thrust washer and pin from shaft.
9. Remove oil seal retainer, ball bearing, speedometer gear 7. Remove gear, needle bearings (32 per row) and spacer.
and spacer. D iscard all gaskets. Press out bearing as 8. If necessary to replace front output shaft rear bearing,
required. replace bearing and retainer assembly. Do not attem pt
10. Remove oil seal from the retainer. to press new bearings into old retainer.
POPPET NUTS
SHIFT RAIL
LINK
REAR OUTPUT
ASSEMBLY
IDLER SHAFT COVER

FRONT OUTPUT FRONT INPUT
FRONT OUTPUT SHAFT SHAFT ASSEMBLY SHAFT ASSEMBLY
REAR BEARING RETAINER
Fig. 2C -R ear V iew of Transfer Case Fig. 3C~Front V iew of Transfer Case

“ T” HANDLE W / # 2 EASY
OUT WELDED O N END
FRONT—
OUTPUT SHAFT
REAR BEARING
RETAINER
Fig. 4C -R em oving Front O utpu t Shaft Rear Bearing Retainer
Shift Rail and Fork Assemblies Fig. 6C--Removing S hift Fork Pins
1. Remove the two poppet nuts on top of case, two poppet 9. Tip case on P.T.O. and remove two interlock pins from
springs, and using a m agnet, remove the poppet balls. inside of case.
2. Remove cup plugs on top of case using a 1/4 inch Idler Gear
punch.
3. Position both shift rails in neutral and remove shift fork 1. Remove idler gear shaft nut.
pins (Fig. 6 C) using a long handle screw extractor. 2. Remove idler shaft rear cover.
4. Remove clevis pins and shift rail link. 3. Remove idler gear shaft using a soft ham m er and tool
5. Remove shift rails (Fig. 7C), upper (range) rail first, J-23429 (Fig. 8C).
then lower (4-wheel) rail. 4. Roll idler gear to front output shaft hole and remove
6. Remove shift forks and sliding clutch from case. from case.
7. Remove the front output high gear, washer, and bear 5. Remove bearing cups (2) as required from idler gear.
ing from the case. Remove the shift rail cup plugs from
the case. Cleaning and Inspection
Input Shaft Assembly Bearings-Place all bearings and rollers in cleaning solu
tion and allow to remain long enough to loosen all ac-
8. Remove snap ring in front of bearing. Using a soft
ham m er, tap shaft out rear of case. Tap bearing out
front of case.
SNAP RING
Fig. 5C~Removing Gear Retaining Ring Fig. 7 C—S hift Rail Removal

CLUTCHES AND TRANSMP SIONS 7-70
5. Install washer and new locknut. Check for end play and
free rotation. Torque nut to 150 ft. lbs.
6. Install idler shaft cover and gasket. Torque bolts to 20

ft. lbs.
NOTE: Flat on cover must be located adjacent to

front output shaft rear cover (Fig. 14C).
Shift Rail and Fork Assemblies
1. Press the two rail seals into the case. Seals should be
TOOL J-23429
installed with metal lip outward.
2. Install interlock pins through large bore or P.T.O.

opening.
3. Start front output drive shift rail into case from back,
Fig. 8C~Removing Idler Gear Shaft slotted end first, with poppet notches up.
cum ulated lubricant. Bearings should be sloshed up and
4. Install shift fork (long end inward) into rail, push rail
down and turned slowly below surface of solution to remove through to neutral position.
as m uch lubricant as possible. Remove bearings and blow out
with com pressed air, being careful to direct air across bearing 5. Install input shaft bearing and shaft into case.
so that bearings do not spin.
6. Start range rail into case from front, poppet notches up.
Shafts and G ears-C lean all shafts in cleaning solution to
remove all accum ulations. D ry with compressed air. 7. Install sliding clutch onto fork, place over input shaft
in case. Position to receive range rail and push rail
Case, Cover and Bearing C ups-T ransfer case, cover, and through to neutral position.
bearing cups m ust be thoroughly cleaned in solution to
remove all accum ulation of lubricant and dirt. Remove all 8. Install new lock pins through holes at top of case and
trace of gaskets from surfaces where used. drive them into the forks (Fig. 15C).
Inspection-C arefully inspect all bearings and rollers for
evidence o f chipping, cracks, or worn spots that would render NOTE: Tip case on P.T.O. opening when installing
bearing unfit for further service. Bearings are non-adjustable range rail lock pin.
and if w orn or damaged, m ust be replaced with new parts.
Front Output Shaft and Gear Assembly
Inspect shaft splines and gears. If any indication of failure,
such as chipped teeth or excessive wear, is indicated, those
parts should be replaced w ith new parts. 1. Install two rows of needle bearings (32 each) separated
by a spacer in the front low output gear and retain with
a sufficient am ount of grease.
Assembly of Transfer Case (Fig. 9C)
2. Place front output shaft in soft jaw ed vise, spline end
down. Install front low gear over shaft with clutch gear
Idler Gear facing down and install thrust washer pin, thrust
washer and new snap ring using Tool J-23432.
1. Press the two bearing cups in the idler gear (if previ
ously removed) using Tool J-9276-2 and H andle J-8092
NOTE: Position the snap ring so that the opening is
(Fig. 10C).
opposite the pin.
2. Assemble the two bearing cones, spacer, shims and idler
gear on dum m y shaft J-23429 with bore up. Check end 3. Position front wheel hi-gear and washer in case. Install
play (Fig. 11C). Lim its are .000 to .002 inch. sliding clutch in the shift fork, then put fork and rail in
the front wheel drive (4-Hi) position with the clutch
3. Install idler gear assembly with dumm y shaft into case teeth in mesh with the teeth of the front wheel hi-gear.
through front output bore, large end first (Fig. 12C).
4. Line up washer, high gear, and sliding clutch with bear
Install idler shaft from large bore side and drive through ing bore. Insert front output shaft and low gear assem
using a soft ham m er (Fig. 13C). bly through the high gear assembly.

Fig. 9C~New Process Transfer Case Exploded V iew

1. Rear O utput S haft Locknut 26. S liding Clutch 49. Cover Gasket
2. W asher 27. Input S haft 50. Rear Cover
3. Yoke 28. T ransfer Case 51. Front O utput Shaft Locknut
4. Bearing Retainer and Seal 29. Poppet Plug, Spring and Ball 52. W asher
Assem bly 30. P.T.O. Gasket and Cover 53. Yoke
5. Snap Ring 31. Inp ut S haft Bearing and Snap 54. Bearing Retainer and Seat
6. Bearing Ring 55. Gasket
7. Speedom eter Gear 32. Snap Ring and Rubber " 0 ” 56. Snap Ring
8. Spacer Ring 57. Front Bearing
9. Gasket 33. S h ift Link Clevis Pin 58. T hrust W asher
10. Housing 34. Range S h ift Rail 59. Front W heel High Gear
11. Gasket 35. S hift Rail C onnector Link 60. Front O utput Shaft
12. Bearing 36. Front W heel Drive S hift Rail 61. Needle Bearings
13. Snap Ring 37. Interlo ck Pins 62. Spacer
14. T hrust W asher 38. Rear Idler Lock Nut 63. Needle Bearing
15. Thrust W asher Lock Pin 39. W asher 64. S liding Clutch Gear
16. Thrust W asher (Tanged) 40. S hift Rail Seals 65. S hift Fork
17. Low Speed Gear 41. Idler S haft Bearing 66. Roll Pin
18. Needle Bearings 42. Bearing Cup 67. Front O utput Low Gear
19. Spacer 43. Shims 68. Thrust W asher Lock Pin
20. Needle Bearings 44. Idler Gear 69. Thrust W asher
21. Tanged W asher 45. Bearing Cup 70. Snap Ring
22. Rear O utput Shaft 46. Spacer 71. Rear Cover Gasket
23. Needle Bearings 47. Idler S haft Bearing 72. Rear Cover and Bearing
24. W asher and Retainer 48. Idler Shaft
25. S hift Fork

FRONT OUTPUT
BORE
J-8092
J-9276-2
IDLER GEAR ASSEMBLY
Fig. 10C--I nsta 11i ng New Bearing Cups Fig. 1 2C --lnstalling Idler Gear
5. Install new seal in bearing retainer using Tool J-22836 2 Install thrust washer onto rear output shaft, tang down
(Fig. 16C) and install the front output bearing and in clutch gear groove. Install output low gear onto shaft
retainer in the case. with clutch teeth facing down.
6. Clean and grease rollers in front output rear bearing
retainer. Install onto case using one gasket. Dip bolts 3 Install thrust washer over gear with tab pointing up and
into sealant. Install bolts and torque to 30 ft. lbs. away from gear. Install washer pin and also large thrust
7. Install front output yoke, washer and lock nut. Torque washer over shaft and pin. R otate washer until tab fits
nut to 150 ft. lbs. into slot approximately 90 degrees away from pin. Fi
Rear Output Shaft Assembly nally, install snap ring using Tool J- 23423 and J-23423-
1 and check end play which should be withing .002 -
1. Install two rows of needle bearings (32 each) separated
.027 inch.
by a spacer into the output low gear.
NOTE: Use sufficient grease to retain needles. 4 Grease pilot bore or rear output shaft and install needle
bearings (15). Install thrust washer and new snap ring
in bore.
Fig. 1 1C--Checking Idler Gear End Play Fig. 13C --lnstalling Idler Shaft

Fig. 1 4 C - l n s t a l l i n g Idler S h a ft Rear Co ve r
5. Clean, grease, and install new bearing in retainer hous

ing using Tool J-23431 (Fig. 17C).
6. Install housing onto output shaft assembly, install

spacer and speedom eter gear, then install bearing (Fig.
Fig. 16 C--I nsta 11i ng Front O utput Bearing Retainer Seal
18C.)
7. Install rear bearing retainer seal using Tool J-2 1359 or

J- 22834-2 (Fig. 19c). Miscellaneous
1. Install P.T.O. cover and gasket. Torque bolts to 15 ft.
8. Install bearing retainer assembly onto housing with one lbs.
or two gaskets, depending on clearance. Torque bolts to
30 ft. lbs. 2. Install and seal cup plugs at rail pin holes, if not previ
ously done.
9. Install yoke, washer, and lock nut output shaft.
10. Position range rail in ’high’ and install output shaft and
retainer assembly on transfer case. Torque housing
bolts to 30 ft. lbs.
J-23431
BEARING
Fig. 1 5 C--I nsta 11i ng S h ift Rail Lock Pins Fig. 1 7 C--I nsta 11ing Rear O utput S haft Housing Bearing

SPEEDO M ETER
-G E A R
S P A C ER
J-21359
O UTPUT
LO W G E A R
C LU T C H G E A R
SEAL
Fig. 1 8C—Installing Rear O utput S haft Spacer and
Speedom eter Gear
3. Install drain and filler plugs and torque to 30 ft. lbs.
4. Install shift rail cross link, clevis pins and lock pins. Fig. 19C—Installing Rear Bearing Retainer Seal
ADAPTER ASSEMBLIES
INDEX
SUBJECT PAGE
M anual Transm issions ................................................... 7-75 Blazer M o d e ls.......................................................... 7-75

All Except Blazer M odels...................................... 7-75 A utom atic T ransm issions............................................... 7-76
Fig. 1H--Manual Transm ission A da pter Assem blies except Blazer

1. Spline Sleeve 2. Snap Ring 3. Seal 4. Snap Ring

3-SPEED TRANSMISSION 4-SPEED TRANSMISSION

Fig. 2H--M anual Transm ission A da pter A ssem blies-B lazer M odels
1. Seal 3. Polyurethane Seal 5. Snap Ring

2. Spline Sleeve 4. Bearing 6. Inp ut Shaft
M ANUAL TR A N SM ISSIO N S 3. Using a suitable tool or piece of pipe with a diam eter
Except Blazer Models comparable to splined sleeve, tap sleeve from adapter.
D isassem bly of Adapter (Figs. 1H and 2H)
4. Using a brass drift, punch out the oil seals from the
1. Using a brass drift or other suitable tool, tap sleeve from
adapter bore.
adapter.
2. Using a brass drift, punch out oil seal from adapter
bore. 5. If required, support bearing and press input shaft from
bearing.
Inspection
Inspect the sleeve for any indication of failure. If the sleeve
has chipped teeth or excessive wear, it should be replaced.
Check internal snap ring in sleeve. Replace if bent or broken.
A ssem bly of Adapter

1. Position sleeve to adapter bore and tap into place using
a suitable piece of pipe.
NOTE: Assemble drive sleeve with oil groove facing

transmission side. Lubricate sleeve spline with J-8092
transmission oil before assembly.
J-7137
2. Coat O.D. o f seal with sealing com pound and install
seal using Tool J-23504 and H andle J-8092 in a similar
m anner as shown in Fig. 3H.
Blazer Models
D isassem bly of Adapter (Fig. 2H)
1. Remove snap ring retainer drive gear to input shaft and
slide gear from shaft.
2. Remove snap ring retaining bearing in adapter bore.

Pull input shaft and bearing from adapter. Fig. 3H ~lnstalling A da pter Seal

Assem bly of Adapter 1. Remove small snap ring on sleeve retaining bearing to
sleeve.
i
1. If removed during disassem bly, press new bearing onto
2. Remove snap ring retaining bearing to adapter.
input shaft.
2. Using Tool J-7137 and H andle J-8092, install new seals
in the adapter bore as shown in Figure 3H. 3. Using a soft ham m er, tap sleeve and bearing through
3. Insert splined sleeve through seals into adapter bore. seals and out of adapter.
4. Insert input shaft and bearing into adapter and install
bearing retaining ring.
4. Using a suitable punch or drift, drive seals from
5. Slide drive gear onto input shaft and install retaining
adapter.
ring.
5. Support inner race of bearing and press sleeve from

NOTE: Assemble drive sleeve with oil groove to bearing.
tansmission side. Lubricate sleeve spline and O.D.
with transmission oil before assembly.
Assem bly of Adapter
Automatic Transm issions
All Models 1. Support sleeve and press bearing onto sleeve using Tool
J- 22875 as shown in Figure 5H.
Disassem bly of Adapter (Fig. 4H)
2. Install new seals in adapter using Tool J-7137 and J-
1 2 3 4 8092 as shown in Figure 3H.
3. Insert sleeve and bearing through seals into adapter

bore and tap into place.
4. Install small snap ring (new) on sleeve, retaining bear

ing to sleeve.
5. Install large snap ring retaining bearing in adapter bore.
Fig. 4H ~Autom atie Transm ission A da pter Cross Section
1. Snap Ring 5. Seal

2. Bearing 6. Sleeve
3. Seal 7. Snap Ring
4. A da pter Fig. 5 H -ln s ta llin g A da pter Bearing

POW ERGUDE AND TORQUE DRIVE

INDEX
SU BJECT PA G E
Disassembly of T ran sm issio n ........................................ 7-77 Valve Body ...................................................................... 7-91

Extension, G overnor and G overnor Support.......... 7-77 R em oval.......................................................................... 7-91
Internal Com ponents ................................................... 7-80 D isassem bly................................................................... 7-92
Oil Pan and Valve B ody............................................... 7-81 Inspection ..................................................................... 7-93
Overhauling U nit A ssem blies........................................ 7-82 A ssem bly........................................................................ 7-93
Convertor and Stator ................................................... 7-82 Installation...................................................................... 7-93
Oil P u m p .......................................................................... 7-82 Vacuum M o dulator........................................................ 7-93
Seal Replacem ent ........................................................ 7-82 R em oval.......................................................................... 7-93
D isassem bly................................................................... 7-82 Inspection and R e p a irs............................................... 7-93
Inspection ...................................................................... 7-82 Installation...................................................................... 7-93
A ssem bly........................................................................ 7-86 Transmission Case.......................................................... 7-93
G overnor Support Bushing Replacement ............... 7-87 Inspection ...................................................................... 7-93
Clutch D ru m ................................................................... 7-87 R epairs............................................................................ 7-93
D isassem bly................................................................... 7-87 R ear Bushing Replacem ent...................................... 7-93
Inspection ...................................................................... 7-87 Transmission Extension ............................................... 7-93
Bushing R ep lacem en t................................................. 7-88 Inspection ...................................................................... 7-93
A ssem bly ........................................................................ 7-88 R epairs............................................................................ 7-95
Low B a n d ........................................................................ 7-88 R ear Bushing Replacm ent ...................................... 7-95
Planet Assembly and Input Shaft ............................. 7-88 Assembly of T ran sm issio n ............................................ 7-95
Inspection ...................................................................... 7-88 Internal Com ponents ................................................... 7-95
R epairs............................................................................ 7-89 Extension, G overnor and G overnor Support.......... 7-97
Planet C arrier A ssem bly-0verhaul........................ 7-89 Oil Pan and Valve B ody............................................... 7-97
G o v e rn o r.......................................................................... 7-91 Low Band A d ju stm e n t................................................... 7-98
D isassem bly................................................................... 7-91 Throttle Valve A djustm ent............................................ 7-98
Inspection ...................................................................... 7-91
A ssem b ly ........................................................................ 7-91
D IS A S S E M B LY OF TRA N SM ISSIO N NOTE: When the overhaul is due to tranmission

clutch failure it is mandatory that the converter be
NOTE: The following overhaul procedures will also replaced.
apply to the Torque Drive transmission as well as to
the powerglide except where noted. Extension, Governor and Governor
1. Place transmission in Holding Fixture J-3289-01 and Support (Powerglide)
A dapters J-9506 (fig. 2PG).
NOTE: Cleanliness is an important factor in the 3. If replacement is necessary, remove speedometer driven
overhaul of the transmission. Before attempting any gear. Loosen capscrew and retainer clip holding speed
disassembly operation, the exterior of the case ometer driven gear in extension and remove gear.
should be thoroughly cleaned to prevent the possi
bility of dirt entering the transmission internal
4. Remove transmission extension by removing five bolts
mechanism. During disassembly, all parts should be
retaining extension to case. Note seal ring on governor
thoroughly cleaned in cleaning fluid and then air
support. (Pilot on Torque Drive.).
dried. Wiping cloths or rags should not be used to
dry parts as lint may be deposited on the parts
which may cause later trouble. 5. Remove the speedometer drive gear from output shaft
as shown on Figure 3PG.
CAUTION: Do not use solvents which could damage

rubber seals or clutch plate facings. 6. Remove the "C" clip from the governor shaft on the
weight side of the governor, then remove the shaft and
2. Remove converter holding tool previously installed and governor valve from the opposite side of the governor
remove converter assembly. assembly (fig. 4PG ) and the urethane washer.


Fig. 1 PG~Aluminum P o w e rg lid e -T yp ica l Sectioned V iew
1. Transm ission Case 38. Extension Rear Bushing

2. W elded Converter 39. O utput S haft
3. Oil Pump Seal Assem bly 40. Speedom eter Drive and Driven Gear
4. Oil Pump Body 40A. Speedom eter Driven Gear Retaining Clip
5. Oil Pump Body Square Ring Seal 41. G overnor S haft Urethane W asher
7. Oil Pump Cover 42. G overnor S haft
8. Clutch Relief Valve Ball 43. G overnor Valve
9. Clutch Piston Inner and O uter Seal 44. G overnor Valve Retaining Clip
10. Clutch Piston 45. Governor Hub Seal Rings
1 1. Clutch Drum 47. Governor Support Bushing
12. Clutch Hub 51. Reverse Piston Return Springs, Retainer and
13. Clutch Hub T hrust W asher Retainer Ring
14. Clutch Flange Retainer Ring 52. T ransm ission Rear Case Bushing
15. Low Sun Gear and Clutch Flange Assem bly 53. O utput S haft T hrust Bearing
16. Planet Short Pinion 54. Reverse Clutch Pack
17. Planet Input Sun Gear 54A. Reverse Clutch Cushion Spring (Waved)
18. Planet C arrier 55. Pinion T hrust W asher
19. Planet Input Sun Gear T hrust W asher 56. Planet Long Pinion
20. Ring Gear 57. Low Sun Gear Needle T hrust Bearing
21. Reverse Piston 58. Low Sun Gear Bushing (Splined)
22. Reverse Piston O uter Seal 59. Pinion T hrust W asher
23. Reverse Piston Inner Seal 60. Parking Lock Gear
24. G overnor S up po rt Gasket 61. Transm ission Oil Pan
25. Extension Seal Ring 62. Valve Body
26. G overnor S upport 63. High Clutch Pack
27. Extension 64. Clutch Piston Return S pring, Retainer and
28. G overnor Hub Retainer Ring
29. G overnor Hub Drive Screw 65. Clutch Drum Bushing
30. G overnor Body 66. Low Brake Band
31. G overnor S haft Retainer Clip 67. High Clutch Seal Rings
32. G overnor O uter W e ig h t Retainer Ring 68. Clutch Drum T hrust W asher (Selective)
33. G overnor Inner W e ig h t Retainer Ring 69. T urbine S haft Seal Rings
34. G overnor O uter W e ig h t 70. Oil Pump Driven Gear
35. G overnor Spring 71. Oil Pump Drive Gear
36. G overnor Inner W e ig h t 72. S tator Shaft
37. Extension Rear Oil Seal 73. Inp ut Shaft
Fig. 2P G -Tranm ission M ounted in Fixture Fig. 3PG -Rem oving Speedom eter Drive Gear

Fig. 4PG--Removing G overnor Valve and S h a ft-P o w e rg lid e
7. Loosen the governor drive screw and remove the gover

nor assembly over the end of the output shaft (fig.
5PG).
8. Remove the four bolts retaining the governor support
to the transm ission case and remove the support body,
gasket and extension seal ring.
Transm ission Internal Components

9. R otate the holding fixture until the front of the trans
mission is pointing up and remove the seven oil pump
bolts. The bolt holes are offset to facilitate proper loca Fig. 5PG~Removing Governor A ssem b ly-P ow erg lide
tion upon installation.
10. Remove the oil pum p and stator shaft assembly and the 13. Remove the planet carrier and the output shaft thrust
selective fit thru st w asher using J-9539 (or two 3/8"-16 caged bearing from the front of the transmission.
x 10" stove bolts) and the slide weights from Tool J- 14. Remove the reverse ring gear if it did not come out with
6585 (fig. 6 PG ). N ote the two threaded holes to m ount the planet carrier.
the pullers. Remove the ring seal and gasket. 15. Using a large screw driver remove the reverse clutch
pack retainer ring and then lift out the reverse clutch
NOTE: The pump bolts have special sealing washers plates and the (waved) cushion spring.
which must be in place upon installation.
11. Release the tension on the low band adjustm ent, then, NOTE: If difficulty is experienced in getting the
with transm ission horizontal, grasp the transm ission snap ring past the shoulder on the reverse pack pres
input shaft and carefully w ork it and the clutch assem sure plate, a feeler gauge may be used as a guide.
bly out of the case (fig. 7PG). Use care so as not to lose
the low sun gear (splined) bushing from the input shaft.
The low sun gear th ru st w asher will probably rem ain in 16. Install Tool J-9542 through the rear bore of the case
the planet carrier. w ith the flat plate on the rear face of the case and turn
down the wing nut to compress the rear piston spring
retainer and springs, then remove the snap ring (fig.
CAUTION: Use care so as not to damage the ma 8PG). Tool J-8039 may be used to remove the snap ring
chined face on the front of the clutch drum. if desired.
17. Remove Tool J-9542, the reverse piston spring retainer
12. The low brake band and struts may now be removed. and the 17 piston return springs.

Fig. 6PG~Removing Oil Pump Fig. 8PG--Removing Rear Piston Spring Retainer Snap Ring
18. Remove the rear piston by applying air to the reverse 21. Remove the vacuum m odulator and gasket, and the
port in the rear of the transm ission case as shown in vacuum m odulator plunger, dampening spring (except
Figure 9PG. Remove the inner and outer seals. L-4 model) and valve (fig. 10PG).
19. Remove the three servo cover bolts, servo cover, piston 22. Remove the two bolts attaching the detent guide plate
and spring. to the valve body and the transmission case. Remove
the guide plate and the range selector detent roller
Oil Pan and Valve Body spring.
NOTE: The oil pan and valve body may be serviced 23. Remove the rem aining valve body-to-transmission case
without the necessity of removing the extension attaching bolts (indicated by arrows in Figure 11PG)
and internal components covered in the preceding and carefully lift out the valve body and gasket, disen-
steps.
20. R otate the holding fixture until the transm ission is up
side down and the oil pan is at the top. Remove the oil
pan attaching bolts, oil pan and gasket. Remove screen:
replace at assembly using new transm ission case screen.
Fig. 7PG~Removing Clutch Drum and Inp ut Shaft Fig. 9 P G -A p plyin g A ir to Remove Rear Piston

SPRING
L-153)
MODULATOR
PLUNGER M A N U A L VALVE LEVER PARKING
GASKET PAWL
BRACKET
TV LEVER
PARKING
PAWL
Fig. 10PG~Vacuum M od ula tor, Dam pening S pring, Plunger ACTUATOR
and V alve -P o w e rg lid e
gaging the servo apply tube from the transm ission case
as the valve body is removed. PARKING
PAWL
24. If necessary, the TV, shift and parking actuator assem
bly levers, and the parking pawl and bracket (fig. 12PG)
m ay be removed. Fig. 12P G -lnner C ontrol Levers, Parking Pawl and Bracket
This completes the entire transm ission disassembly proce
dure. Com ponent parts disassembly and repair procedures Oil Pump
will be found in succeeding pages of this manual.
Seal Replacem ent
O VERH AULIN G UNIT A S S E M B L IE S If the pum p seal requires replacement, remove the pump
from the transmission, pry out and replace the seal. (Drive
Convertor and Stator new seal into place, fully seated in counterbore using J-6839).
The converter is a welded assembly and no internal re Then, if no further work is required on the pump, reinstall
pairs are possible. Check the seams for stress or breaks and it in the case.
replace converter if necessary.
NOTE: Outer diameter of the seal should be coated
with non-hardening sealer prior to installation.
Disassem bly
1. Remove bolts attaching pum p cover to body and
remove the cover.
2. Remove pum p gears from body.
CAUTION: Do not drop or nick gears. These gears

are not heat treated.
3. Remove the rubber seal ring from the pum p body.
NOTE: See Figure 14PG for a layout of pump parts.
SPRING
UPPER TO LOWER VALVE Inspection

BODY ATTACHING BOLTS
1. W ash all parts in cleaning solvent and blow out all oil
ARE 1%" IN LENGTH
passages. DO N O T USE RA G S TO D R Y PARTS.
CAUTION: Some solvents may be harmful to rubber

Fig. 11PG--Valve Body Removal seals.

43 4 2 41 39 38 37
Fig. 13P G -Tranm ission Case-Exploded V ie w (Typical)
1. Reverse Ring Gear 13. Transm ission Case 31. G overnor Support
2. Reverse Clutch Pack 13A. Transm ission Case 32. G overnor Support to
Snap Ring Screen Case A ttaching Bolts
3. Reverse Clutch 14. Servo Piston Return 33. G overnor Assem bly
Pressure Plate Spring 34. Speedom eter Drive
4. Reverse Clutch 15. Servo Piston Rod Gear and Clip
Reaction Plates 16. Servo Piston A pply 35. Seal
5. Reverse Clutch Drive S pring Seat 36. Speedom eter Shaft
Plates 17. Servo Piston A pply F itting
6. Reverse Clutch Spring 37. Speedom eter Shaft
Cushion Spring 18. Servo Piston Seal F ittin g Oil Seal
7. Reverse Clutch Piston Ring 38. Lock Plate A ttaching
Return Spring 19. Servo Piston Screw
Retainer Snap Ring 20. Servo Piston Rod 39. Lock Plate
8. Reverse Clutch Piston Spring Retainer 40. Speedom eter Driven
Return Spring 21. Servo Cover Seal Gear
Retainer 22. Servo Cover Gasket 41. Transm ission
9. Reverse Clutch Piston 23. Servo Cover Extension
Return Springs 24. Servo Cover Plug 42. Extension Bushing
10. Reverse Clutch Piston 25. Servo Cover Bolts 43. Extension Oil Seal
Inner Seal 26. Transm ission Case 44. Extension to Case
11. Reverse Clutch Piston Bushing A tta chin g Screws
12. Reverse Clutch Piston 27. Gasket
O uter Seal 30. G overnor Support
Bushing

49
/ 47
Fig. 14PG~lnternal M echanism -Exploded V ie w (Typical)
1. Converter Assem bly 13. Oil Pump Cover and 27. Band A pp ly Strut 40. Clutch Hub
2. Input S haft C onverter S tator 28. Band A nchor Strut 41. Clutch Driven Plates
3. Inp ut Shaft Oil Seals S haft 29. Band A nchor (Flat)
4. Oil Pump to Case 14. Oil Pump Gasket A d ju stin g Screw 42. Clutch Cushion
A tta chin g Bolts and 15. Clutch Drum T hrust 30. Band A nchor Spring (Waved)
Sealing W ashers W asher (Selective Fit) A d ju stin g Screw Nut 43. Clutch Drive Plates
5. Low Sun Gear 16. High Clutch Seal 31. Low Brake Band (Waved)
Bushing Rings 32. Clutch Drum 44. Clutch Hub Drive
6. Pump Oil Seal 17. Pump Prim ing Valve 33. Clutch Drum Bushing T hrust W asher
7. Oil Pump Body 18. Pump Prim ing Valve 34. Clutch Piston Outer 45. Low Sun Gear and
8. Pump to Case Oil Spring and Inner Seals Clutch Flange
Seal 20. Pump Prim ing Valve 35. Clutch Piston Assem bly
9. Oil Pump Drive Gear Spring Retaining Pin 36. Clutch Return 46. Clutch Flange
10. Oil Pump Driven Gear 21. Oil Cooler By-Pass Springs Retainer Ring
11. D o w nsh ift T im ing Valve Spring(1) 37. Clutch Spring 47. Planet Carrier and
Valve 22. Oil Cooler By-Pass Retainer O utput S haft
12. Oil Pump Cover to Valve(1) 38. Clutch Spring Assem bly
Pump Body A tta chin g 23. Oil Cooler By-Pass Retainer Snap Ring 49. O utput S haft T hrust
Screws Valve Seat(1) 39. Clutch Hub Front Bearing
T hrust W asher
(l)E xcept air cooled and 11" converter models.

Fig. 15PG--Manual Levers-Typical Exploded V iew
1. Park Lock and Range 7. Park Lock and Range 13. Park Lock Pawl Shaft
Selector O uter Lever Selector Inner Lever 14. Park Lock Pawl
and Shaft 8. Park Lock and Range 15. Park Lock Pawl Shaft
2. T h ro ttle Valve Control Selector Inner Lever Retaining Ring
S haft Oil Seal A tta chin g Screw and 16. Park Lock Pawl
3. T h ro ttle Valve Control Nut Reaction Bracket
S haft W asher 9. Park Lock Pawl 17. Park Lock Pawl
4. T h ro ttle Valve Control D isengaging Spring Reaction Bracket
Lever and Shaft 10. Range Selector A tta chin g Bolts
5. T h ro ttle Valve Control Detent Roller Spring 18. Park Lock A ctuator
Inner Lever to Control 1 1. Park Lock A ctua to r to Park Lock and
Shaft A tta chin g A ssem bly Range Selector Inner
Screw and Nut 12. Range Selector Lever Retaining Clip
6. T h ro ttle Valve Control Detent Roller Spring
Inner Lever Retainer

2. Inspect pum p gears for nicks or damage.

3. Inspect body and cover faces for nicks or scoring. In
spect cover hub O.D. for nicks or burrs which might
dam age clutch drum bushing journal.
4. Check for free operation of the prim ing valve and re
place if necessary.
5. Inspect body bushing for galling or scoring. Check
clearance between body bushing and converter pump
hub (fig. 16PG). M axim um clearance is .005". If the
bushing is damaged, the oil pum p body should be re
placed.
6. Inspect converter housing hub O.D. for nicks or burrs
which m ight dam age pum p seal or bushing. R epair or
replace as necessary.
7. If oil seal is dam aged o r is leaking (and the pum p body
is otherwise suitable for reuse), pry out and install a new
seal, fully seated in counterbore, using Seal D river J-
6839.
NOTE: Outer diameter of seal should be coated with

a non-hardening sealer prior to installation.
8. On w ater cooled models so equipped, check condition

of oil cooler by-pass valve and replace if valve leaks Fig. 1 7PG -C hecking Driven Gear to Pump Body Clearance
excessively. F o r removal, an "Easy O ut" or its equiva c. G ear end clearance (fig. 19PG) should be .0005"-
lent may be used. .0015".
F or installation tap seat in place with soft ham m er or
Assem bly
brass drift so it is flush to .0 1 0 " below the surface.
9. W ith parts clean and dry, install pum p gears and check: W ith the transmission facing up, proceed as follows:
1.Remove the input shaft, clutch drum , low band and
a. Clearance between O.D. of driven gear and body struts as outlined uner "Transm ission Disassembly."
should be .0035 "-.0065" (fig. 17PG). 2. Install the downshift timing valve, conical end out, into
b. Clearance between I.D . of driven gear and crescent place in the pum p cover to a height of 17/32" measured
should be .003 "-.009" (fig. 18PG). from the shoulder of the valve assembly to face of pump
cover.
Fig. 16PG~Checking Pump Body Bushing to Converter Pump

Hub Clearance Fig. 18PG--Driven Gear to Crescent Clearance

Fig. 19PG~Checking Gear End Clearance
3. Oil drive and driven gears generously and install in the

pum p body.
CAUTION: Assemble drive gear with recessed side

of the drive lugs downward-facing the converter.
Fig. 20PG--Removing Clutch Spring Retainer Snap Ring
4. Carefully set the pum p cover in place over the body and
loosely install 2 attaching bolts. face must be protected whenever it must be brought
5. Place the pum p assembly, less the rubber seal ring, to bear on a press or tool of any sort.
upside down into the pum p bore of the case (use guide
pins if desired). Install remaining attaching bolts and 1. Remove retainer ring and low sun gear and clutch
torque to specification. flange assembly from the clutch drum.
6. Remove pum p assembly from case bore. Replace the 2. Remove the hub rear thrust washer.
clutch drum and input shaft, low band and struts as 3. Lift out the clutch hub, then remove the clutch pack
outlined under "Transm ission Assembly." and the hub front washer.
4. Remove the spring retainer using J-9542 as shown in
NOTE: If necessary, remove two bolts and use J- Figure 20PG, or if using an arbor press, use J-5133 and
6585 pullers and J 6585-3 adapters to remove pump J-7782 adapter ring. Compress the springs far enough
assembly. Replace and retorque bolts. to allow removal of the retainer snap ring; then, releas
ing pressure on the springs, remove the retainer and the
7. Replace rubber seal ring in its groove in the pum p body springs.
and install the pum p assembly properly in place in the
case bore, using a new gasket, being sure that the selec NOTE: When using J-9542, place a piece of cloth or
tive fit thrust washer is in place. cardboard between the tool and the front side of the
8. Install the attaching bolts, using new bolt sealing wash clutch drum as protection for the machined face.
ers if necessary.
5. Lift up on the piston with a twisting m otion to remove
Governor Support Bushing Replacement from the drum , then remove the inner and outer seals.
If the governor support bushing m ust be replaced, it may

be removed using Tool J-9557 (and H andle J-7079) and rein Inspection
stalled using Tool J-6582, pressing or driving the bushing in
1. W ash all parts in cleaning solvent (air dry).
from the front of the support.
CAUTION: Do not use rags to dry parts.
CLU TCH DRUM
2. Check drum bushing for scoring or excessive wear.
Disassem bly
3. Check the steel ball in the clutch drum that acts as a
CAUTION: When working with the clutch drum, relief valve. Be sure that it is free to move in the hole
use extreme care that the machined face on the and that the orifice leading to the front of the drum is
front of the drum (fig. 20PG) not be scratched, open. If the clutch relief valve check ball in the clutch
scored, nicked or otherwise damaged during any of drum is loose enough to come out or not loose enough
the following service operations. This machined to rattle, replace the clutch drum as an assembly. R e

placem ent or restaking of the ball should not be at measure this stack height. Now refer to chart and
tempted. select the proper selective driven plate and install it
4. Check fit of clutch flange in drum slots. There should into clutch drum on top of the cushion spring.
be no appreciable radial play between these two parts.
Also check low sun gear for nicks or burrs and bushing 7. Install the steel reaction plates and faced drive plates
for wear. alternately, beginning with a steel reaction plate (fig.
5. Check clutch plates for burning and wear. 22PG). See clutch chart.
8. Install the rear hub thrust washer w ith its flange toward
B u s h in g R e p la c e m e n t (Fig. 2 1 PG) the low sun gear, then install the low sun gear and
flange assembly and secure with retainer ring. When
1. Remove the old bushing w ith Tool J-9546 using care installed, the openings in the retainer ring should be
not to damage the bushing bore or the m achined face adjacent to one of the lands of the clutch drum .
on the front of the clutch drum . 9. Check the assembly by turning the clutch hub to be sure
2. Use the same tool to install the new bushing. Press (do it is free to rotate.
not ham m er) the bushing into the clutch drum from the
m achined face side of clutch drum . Press only far
LOW BAND
enough so th at the tool meets the clutch drum . D o not The brake band used in the alum inum Powerglide trans
force the tool against the clutch drum m achined face. mission has bonded linings which, due to the transmission
characteristics and band usage, should require very little a t
A s s e m b ly tention. However, whenever a transm ission is disassembled
the band should be cleaned of metal particles and inspected.
1. Install new piston inner seal in hub of clutch drum with
1. Check lining for evidence of scoring or burning.
seal lip dow nw ard (tow ard front of transmission).
2. Check band and lining for cracks.
2. Install a new piston seal in clutch piston. Seal lips must
3. Check all band linkage for excessive wear.
be pointed tow ard the clutch drum (front of transm is
sion). Lubricate seals generously and install piston in
clutch drum with a twisting motion. PLA N ET A S S E M B L Y AND INPUT
3. Place the springs in position on the piston, then place
the retainer in place on the springs. SH A FT
4. Using Tools J-5133 and J-7782 and a press, or J-9542
as a hand operation, depress the retainer plate and In s p e c tio n
springs far enough to allow installation of the spring
1. W ash planet carrier and input shaft in cleaning solvent,
retainer snap ring in its groove on the clutch drum hub.
blow out all oil passages and air dry.
5. Install the hub front w asher with its lip tow ard the the
clutch drum , then install the clutch hub.
6. Install (wave) cushion spring wherever used, see chart. CAUTION: Do not use rags to dry parts.
NOTE: On 350 V-8 models only, the first driven plate

to the rear of the cushion spring is a selective fit.
Before installing plates to clutch drum, stack the (5)
drive and (5) driven (exc. selective fit) plates and
REACTION PLATES
DRIVE PLATES
(W A V E ) SPRING
/HEREVER USED; SEE CHART)
C A U T IO N — USE RAG C A U T IO N -D O NOT

TO PROTECT PRESS TOOL HARD
MACHINED FACE AG AIN ST MACHINED FACE
Fig. 21 PG-Rem oving and Installing Clutch Drum Bushing Fig. 22P G ~lnstalling Clutch Drum Plates (typical)

CLUTCH A S S E M B LIE S -P O W E R G LID E
307 V-8;
250 L-6 Taxi
230 L-6 T ru ck;
L-4 & & Hvy. Duty
250 L-6
230 L-6 Chassis; 350 V-8
Exc. Taxi & Hvy.
Pass. Cars 350 V-8
Duty Chassis
Truck
292 L-6 T ruck
Drive Plate 3 4 5 5
Driven Plate 4 5 6 6
Cushion Spring 1 1 None 1
TORQUE DR IVE
L-4, L-6
Drive Plate 5
Driven Plate 6
Fig. 23P G -C hecking Planet Gear End Clearance
Cushion Spring 1
350 V-8 S E LE C T IV E D R IV E N PLATE CHART

Small Planet Carrier Assemb/y-Overhaul
Plate Stack Height Plate Part Color Plate
(Less Selective plate) Number Code Thickness
If during inspection, the planet pinions, pinion needle
.9 0 3 .8 7 2 3833903 Orange .060 .0025 bearing, pinion thrust washers, input sun gear, a n d /o r input
,872-.798 3883904 Blue .090 .0025 sun gear thrust washer should show evidenece of excessive
wear or damage, they should be replaced by using the follow
ing procedure:
Refer to Figure 24PG.
2. Inspect planet pinions for nicks or other tooth damage. 1. Place the planet carrier assembly in a fixture or vise so
that the front (parking lock gear, end) of the assembly
faces up.
3. Check end clearance o f planet gears. This clearance
should be .006" - .030" (fig. 23PG)
2. Using prick punches or other similar means, m ark each
pinion shaft and also the planet carrier assembly (fig.
4. Check input sun gear for tooth damage, also check
25PG), so th at reassembling, each pinion shaft will be
input sun gear rear th ru st washer for damage.
reinstalled in the same location from which it was
removed.
5. Inspect output shaft bearing surface for nicks or scoring
and inspect input pilot bushing.
NOTE: The pinion shafts are not selectively fit but
it is good practice to reinstall them in their original
6. Inspect input shaft splines for nicks or damage and locations.
check fit in clutch hub and input sun gear. Also check
fit o f splines in turbine hub.
3. Remove the pinion shaft lock plate screws and rotate

7. Check oil seal rings for damage; rings m ust be free in
the lock plate counter-clockwise sufficiently to remove
input shaft ring grooves. Remove rings and insert in
stator support bore and check to see th at hooked ring it.
ends have clearance. Replace rings on shaft.
4. Starting with a short planet pinion, and using a soft
steel drift drive on the lower end of the pinion shaft
Repairs until the pinion shaft is raised above the press fit area
of the output shaft flange. Feed J-4599 into the short
NOTE: The large planet carrier assembly now has planet pinion from the lower end, pushing the planet
the pinion shafts flared at each end for retention pinion shaft ahead of it until the tool is centered in the
into the carrier. No overhaul of the large planet car pinion and the pinion shaft is removed from the assem
rier assembly should be attempted. bly.

1. Pinion S haft Lock 5. Short: Planet Pinion 9. Input Sun Gear

Plate Gear 10. Inp ut Sun Gear
2. Pinion T hrust W asher 6. Needle Bearings T hrust W asher
3. Pinion S haft 7. Long Planet Pinion 1 1. C arrier and O utput
4. Needle Bearing Gear Shaft
W asher 8. Low Sun Gear Thrust
Bearing
NOTE: Planet pinion remover and replacer Tool J- 5. Remove the short planet pinion from the assembly.
4599, comes in two pieces, both alike. Only one is
used when removing the planet pinion; two, how 6. Remove J-4599, needle bearings and needle bearing
ever, must be used when reassembling. spacers (3) from short planet pinion.
CAUTION: Use care so as not to lose any of the

planet pinion needle bearings. Twently needle bear
ings are used in each end and are separated by a
bearing spacer in the center.
7. By following the procedure as outlined in Steps 4, 5 and

6 , remove the adjacent long planet pinion that was
paired by thrust washers to the short planet pinion now
removed.
NOTE: Twenty needle bearings are used in each end

of the long pinion separated by a bearing spacer in
the center.
8. Remove the upper and lower thrust washer.
9. Remove and disassemble the rem aining planet pinions,

in pairs, by first removing a short planet pinion and
then the adjacent long planet pinion.
10. Remove low sun gear needle th rust bearing, input sun
Fig. 25PG~Suggested Pinion S haft M arkings gear and input sun gear thrust washer.

11. W ash all parts in cleaning solvent and air dry. 24. Check end clearance of planet gears. This clearance
12. Recheck the planet pinion gears and input sun gear for should be .005" - .030" (fig. 23PG).
nicks or other tooth damage; also check the planet pin 25. Place the pinion shaft lock plate in position, then with
ion thru st washer and input sun gear thrust washer. the extended portions of the lock plate aligned with
Check low sun gear needle th ru st bearing for spalled slots in the planet pinion shafts, rotate the lock plate
needles. Replace w orn or dam aged parts. clockwise until the three attaching screw holes are ac
13. Inspect the planet pinion needle bearings closely and if cessible.
there is indication of excessive wear, all the needle bear 26. Install the pinion shaft lock plate attaching screws and
ings m ust be replaced. Also inspect pinion shafts closely tighten to specification.
and, if worn, replace the worn shafts.
14. Inspect the input shaft bushing installed in the base of GOVERN OR--POW ERGLIDE
the output shaft. If damaged, it m ay be removed by
threading Tool J 9534 into the bushing and pulling the The governor assembly is a factory balanced unit. If body
bushing out using Slide H am m er J-6585. New bearing replacem ent is necessary, the two sections m ust be replaced
can be installed by pressing in flush or below thrust as a unit. Remove the governor as outlined under "Transm is
surface with the pilot end of input shaft as press tool. sion- Disassembly".
15. Using J-4599, assemble needle bearing spacer and nee
dle bearings (20 in each path) in one of the long planet Disassem bly
pinions (fig. 24PG). Use petroleum jelly to aid in assem
bling and holding the needle bearings in position. NOTE: The governor valve and shaft were already
16. Position the long planet pinion with J-4599, centered in disassembled from the assembly during the removal
the pinion assembly and with thru st washers at each procedures.
end, in the planet carrier. Oil grooves on thrust washers
m ust be tow ard gears. 1. Remove the outer weight assembly by sliding tow ard
center of body.
NOTE: The long planet pinions are located opposite 2. Remove the sm aller inner weight retaining snap ring
and remove the inner weight and spring.
the ciosed portions of the carrier, while the short
planet pinions are located in the openings. 3. If it is considered necessary, remove the four body as
sembly bolts and separate the body, hub and gasket.
Remove the two seal rings.
17. Feed the second J-4599 in from the top picking up the
upper th ru st w asher and the planet pinion and pushing Inspection
the already installed Tool J-4599 out the lower end. As
the first tool is pushed down, check th at it picks up the Clean all parts thoroughly in a solvent and air dry. Check
lower th ru st washer. condition of all com ponent parts of the assembly. Replace
18. Select the proper pinion shaft, as m arked in Step 2, any bent, dam aged or scored parts. Body and hub m ust be
lubricate the shaft and install it from the top, pushing replaced as a unit.
the assembling tools ahead of it.
Assem bly
19. T urn the pinion shaft so th at the slot or groove at the
upper end faces the center of the assembly. 1. Reassemble governor weights and reinstall in body
20. W ith a brass or soft steel drift, drive the pinion shaft in bore. Replace seal rings on hub.
until the lower end is flush w ith the lower face of the 2. Slide hub into place on output shaft and lock into place
planet carrier. with the drive screw. Install gasket and governor body
21. Following the same general procedure as outlined in over output shaft, install governor shaft, line up prop
Steps 15 through 20, assemble and install a short planet erly with output shaft and install body attaching bolts.
pinion in the planet carrier adjacent to the long planet Torque to specification.
pinion now installed.
NOTE: Place transmission selector lever in PARK to
keep shaft from turning while tightening these
NOTE: The thrust washers already installed with
the long planet pinion also suffice for this short pla bolts.
net pinion as the two pinions are paired together on 3. Check the governor weight for free fit in body after the
one set of thrust washers. four attaching bolts are torqued. If the weight sticks or
binds, loosen the bolts and retorque.
22. Install the input sun gear th ru st washer, the input sun
gear and low sun gear needle thrust bearing. V A LV E BODY
23. Assemble and install the rem aining planet pinions, in Removal
pairs, by first installing the long planet pinion and then Remove valve body as described under "Transmission-
the adjacent short planet pinion. -Disassembly." If perform ing the operation on the vehicle,

Fig. 26PG--Governor--Exploded V ie w -P o w e rg lid e
1. Valve to Shaft Inner W e ig h t 11 . Body to Hub Screws

Retaining Snap Ring Inner W e ig h t to Outer and Lock W ashers
2. Valve W e ig h t Retaining 12. Gasket
3. S haft Snap Ring 13. Hub Drive Screw
4. U rethane W asher 10 . Outer W e ig h t to 14. Hub
5. Body Body Retaining Snap 15. Hub Oil Seal Rings
6. O uter W e ig h t Ring 16. Inner W e ig h t to Shaft
7. Spring Retaining Snap Ring
the vacuum m odulator and valve, oil pan and gasket, guide the valve body, then remove the detent valve assem
detent plate and range selector detent roller spring m ust be bly and throttle valve spring. Tilt the valve body to
removed in order to remove the valve body from the trans allow the throttle valve to fall out. If necessary,
mission. remove the "C" clip and disassemble the detent
valve assembly.
Disassem bly
CAUTION: Do not disturb the setting of the adjust
1. Remove the m anual valve, suction screen and gasket. ment hex nut on the detent valve assembly. This is
2. Remove valve body bolts and carefully remove lower a factory adjustment and should not normally be
valve body and transfer plate from upper valve body. changed. However, some adjustment is possible if
D iscard gaskets. desired. See” Throttle Valve Adjustment."
3. F rom the upper valve body, remove TV and detent
valves and the downshift tim ing valve as follows: b. Downshift Timing V alve-D rive out the roll pin,
a. TV and D etent V alve-R em ove the retaining pin by remove the valve spring and the downshift timing
wedging a thin screw driver between its head and valve.

4. From the lower valve body, remove the low drive shift and continually low transm ission oil. No vacuum m odulator
valve and the pressure regulator valve as follows: repairs are possible; replace as an assembly.
a. Low-Drive Shift V alve-R em ove the snap ring and
tilt the valve body to remove the low-drive regulator
Installation
valve sleeve and valve assembly, valve springs and
the shifter valve-Pow erglide and Torque Drive. 1. Install vacuum m odulator valve, dam pening spring (ex
b. Pressure R egulator V alve-R em ove the snap ring, cept L- 4 model) and plunger in bore of transmission.
then tilt valve body to remove the hydraulic
m odulator valve sleeve and valve, pressure regulator 2. Place a new gasket on vacuum m odulator. The gasket
valve spring retainer, spring and pressure regulator has centering tabs to hold it centered during installa
valve assembly. tion.
3. Install vacuum m odulator, tighten firmly, and install
Inspection vacuum line as follows (fig. 10PG): R ubber tubing "A"
Since most valve failures are caused initially by dirt or should bottom against m odulator can. Pipe assembly
other foreign m aterial preventing a valve from functioning "B" should bottom against the m odulator extension.
properly, a thorough cleaning of all parts in clean solvent is
m andatory. Check all valves and their bores for burrs or TRA N SM ISSIO N C A S E
other deformities which could result in valve hang-up.
Inspection
Assem bly
1. W ash case thoroughly with cleaning solvent, air dry
1. Replace valve com ponents in the proper bores, revers and blow out all oil passages.
ing the disassembly procedures given above and check
ing Figure 27PG, if necessary. CAUTION: Do not use rags to dry parts.
2. Inspect case for cracks which may contribute to leak

NOTE: Upper and lower valve body gaskets are the age.
same. 3. Inspect case rear bushing for damage or excessive wear.
2. Carefully install the lower valve body and gasket and NOTE: This is a precision bushing and if damaged or
install 15 1-3/8" attaching bolts. Torque to specifica worn excessively must be replaced.
tion.
4. Check shifter shaft seal. If it shows signs of damage or
leaking, pry it out and install a new seal. The new seal
Installation
m ust be firmly seated in case counterbore.
Install the valve body onto the transm ission as outlined
under T ransm ission-A ssem bly. Repairs
VA CU U M M ODULATOR--POW ERGLIDE Rear Bushing-Replacement

Transm ission case rear bushing is a precision bushing
The vacuum m odulator is m ounted on the left rear of the which requires no ream ing or finishing after assembly.
transm ission and can be serviced from beneath the vehicle. 1. Remove bushing by driving or pressing from within
case using J-9557 and H andle J-7079.
2. To install new bushing, drive or press bushing into
Removal
place from rear of case using Tool J-9557 and H andle
1. Remove the vacuum line at the vacuum m odulator. J-7079 (fig. 28PG).
2. Unscrew the vacuum m odulator from the transmission
using J-9543, if available, or any thin 1" tappet type CAUTION: Install bushing only until shoulder of J-
wrench. 9557 contacts the rear face of the case. Excessive
3. Rem ove the vacuum m odulator plunger, dampening force, either hammering or pressing may crack or
spring (except L- 4 model) and valve (fig. 10PG) from otherwise damage the aluminum case.
the transmission case.
Inspection and Repairs TRA N SM ISSIO N EXTENSIO N
Check the vacuum m odulator plunger and valve for nicks Inspection
and burrs. If such cannot be repaired with a slip stone, re
place the part. 1. W ash extension thoroughly with cleaning solvent and
The vacuum m odulator can be checked with a vacuum air dry.
source for leakage. However, leakage norm ally results in
transm ission oil pull-over and results in oil smoky exhaust CAUTION: Do not use rags to dry parts.

Fig. 27P G -V alve B ody-E xploded V ie w -P o w e rg lid e
1. Snap Ring 11. Low and Drive Valve 22. High Speed Down 32. Detent Valve
2. H ydraulic M o d u la to r Inner Spring S hift T im ing Valve 33. T h ro ttle Valve Spring
Valve Sleeve 12. Low and Drive Valve Spring R egulator
3. H ydraulic M o d u la to r O uter Spring 23. High Speed Down 34. T h ro ttle Valve Spring
Valve 13. Low and Drive S hift T im ing Valve R egulator Nut
4. Pressure R egulator Regulator Valve 24. U pper Valve Body 35. U pper Valve Body
S pring Retainer 14. Low and Drive 25. M anual Control Valve Plate Gasket
5. Pressure R egulator Regulator Valve 26. Vacuum M od ula tor 36. U pper Valve Body
Spring Sleeve and Cap Valve, Plunger and Plate
6. Pressure R egulator 15. Snap Ring S pring (exc. L-4) 37. Detent Valve and
S pring Seat 16. Transfer Plate to 27. T h rottle Valve Spring Retaining
7. Pressure R egulator Low er Valve Body 28. T h ro ttle Valve Spring Stud
Valve Gasket 29. T h ro ttle Valve Spring 38. Range Selector
8. Lower Valve Body 17. T ransfer Plate Seat Detent Lever
9. Suction Screen, 18. T ransfer Plate to 30. T h ro ttle Valve Spring 39. Snap Ring
G asket and A tta chin g Upper Valve Body R egulator Guide 40. U pper Valve Body
Screws Gasket W asher Plate to U pper Valve
10. Low and Drive Valve 21. High Speed Down 31. Detent Valve Spring Body A tta chin g Bolts
S hift T im ing Valve and W ashers
Stop Pin

4. Fit the actuator assembly between the parking lock

pawl and the bracket.
5. Insert the outer shift lever into the case, being careful
of the shaft seal, and pick up the inner shift lever and
parking lock assembly and tighten alien head screw.
Lubricate the shaft and seal with oil.
6. Insert outer TV lever and shaft, special washer and "O"
ring into case and pick up inner TV lever. Tighten alien
head nut.
NOTE: To prevent possible binding between throttle

and range selector controls; .010 to .020"clearance
must exist between inner TV lever and inner shift
lever after assembly.
7. Thread the low band adjusting screw into case.
NOTE: The above internal components are shown in

their proper relationship in Figure 15PG.
Transmission Internal Components

8. Install the inner and outer seals on the reverse piston
and, lubricating the piston and case with transmission
Fig. 28P G ~lnstalling Case Rear Bushing
oil, install the piston into the case (fig. 29PG). If neces
2. Inspect extension for cracks th at may contribute to sary, carefully slide a feeler gauge around the outer
leakage. diam eter of the piston to start the seal ring into the bore.
3. Inspect extension rear bushing for dam age or excessive 9. W ith the support fixture turned so that the transm is
wear. sion case is facing up, install the 17 reverse piston return
4. Inspect rear oil seal and replace if damaged or worn. springs and their retainer ring.
10. Carefully install Tool J-9542 over the retainer ring and
Repairs through the rear bore of the case. W ith the flat plate on
the rear face of the case, turn down on the wing nut to
Rear Bushing-Rep/acemen t compress the return springs and allow the retaining ring
F o r service, the transm ission extension rear bushing is of snap ring to be installed. Remove Tool J-9542.
a precision type which requires no reaming or finishing after
installation.
1. Place transm ission extension in air arbor press rear end
up.
2. Using J-5778, press old bushing from extension.
3. Place new bushing on pilot end of J-5778 and press it
into place.
4. Replace extension rear oil seal, using Seal Installer J-
5154. Prelubricate between lips of seal with cup grease.
T R A N S M IS S IO N -A S S E M B LY
NOTE: Use only transmission oil or petroleum jelly
as lubricants to retain bearings or races during as
sembly. Lubricate all bearings, seal rings and clutch
plates prior to assembly.
If removed, assemble m anual linkage to case as described

in Step 1-7.
1. Install the parking lock pawl and shaft and insert a new
"E" ring retainer.
2. Install the parking lock pawl pull-back spring over its
boss to the rear of the pawl. The short leg of the spring
should locate in the hole in the parking pawl.
3. Install the parking lock pawl reaction bracket with its
Fig. 29PG— Installing Reverse Piston
two bolts.

CAUTION: Use care when performing this operat

ion that the spring retainer is correctly guided over
the case internal hub and is not damaged by catch
ing on the edge of the hub or in the snap ring groove.
OUTPUT SHAFT
11. Install the large (waved) cushion spring. THRUST BEARING
12. Lubricate and install the reverse clutch pack (fig.
30PG) beginning with a reaction (spacer) plate and
alternating with the drive plates (faced) until all reac
tion plates and all drive plates are in place. The nutched
lug on each reaction plate is installed in the groove at
the 7 o’clock position in the case. Then install the thick
pressure plate which has a "dimple" in one lug to align
with the same slot in the case as the notched lugs on the
other reaction plates.
All models have 4 reaction and 4 drive plates except truck
models with V 8 engines which have 5 reaction and 5 drive
plates.
13. Install the clutch plate retaining ring.
14. W ith the rear of the transm ission case downward, align
the internal lands and grooves of the reverse clutch
pack faced plates, then engage the reverse ring gear with
these plates. This engagem ent m ust be m ade by "feel"
while jiggling and turning the ring gear. Fig. 3 1 P G -lnstalling Gearset
15. Place the output shaft th ru st bearing over the output
shaft and install the planetary carrier and output shaft 19. To check for correct thickness of the selective fit thrust
into the transm ission case (fig. 3 IPG ). washer, move transmission so th at ouput shaft points
16. Move the transm ission into a horizontal position. The down and proceed as follows:
two input shaft seal rings should be in place on the a. M ount a dial indicator so that plunger of indicator
shaft. Install the clutch drum (machined face first) onto is resting on end of the input shaft. J-5492 may be
the input shaft and install the low sun gear bushing used to support the dial indicator as shown in Fig
(splined) against shoulder on shaft. ure 32PG. Zero the indicator.
17. Install clutch drum and input shaft assembly into case, b. Push up on the transmission output shaft and ob
aligning thrust needle bearing on input shaft and index serve the total indicator movement.
ing low sun gear with the short pinions on the planet c. The indicator should read .028" to .059". If the
carrier. reading is within limits, the proper selective fit
18. Remove the rubber seal ring from the oil pum p body washer is being used. If the reading is not within
and, using guide studs from J-3387 set, install clutch limits, it will be necessary to remove the front pump,
drum selective thrust washer, oil pum p gasket and oil change to a thicker or thinner selective fit thrust
pum p to case. Install two pum p-to- case bolts.
Fig. 32PG--Checking End Play fo r Proper T hrust W asher

Fig. 3 0 P G -ln s ta llin g Clutch Plates (Typical) Selection

washer, as required to obtain the specified clear

ance, and repeat the above checking procedure.
NOTE: Clutch drum selective thrust washers are

available in thicknesses of .061", .078" .092'and .106'.'
20. Install the servo piston, piston ring, and spring into the
servo bore. Then, using a new gasket and "O" ring,
install the servo cover. See th at gasket is properly SERVO
aligned with the three bolt holes and the drain back APPLY
passage in the case.
21. Remove the oil pum p and the selective fit washer from
the case, and install the low brake band, anchor and
apply struts into the case. Tighten the low band adjust
ing screw enough to prevent struts from falling out of
case.
22. Place the seal ring in the groove around the oil pump
Fig. 33PG ~lnstalling Valve Body
body and the two seal rings on the pum p cover exten
sion. Install clutch drum selective th ru st washer, oil
pum p gasket and oil pum p to case. Remove guide pins servo apply line into its boss in the case as the valve
and install all pum p bolts, replacing any damaged bolt body is set into place (fig. 33PG). Install six m ounting
sealing washers necessary and torque bolts to specifica bolts and range selector detent roller spring shown in
tion. Figure 1 IPG .
NOTE: Position the manual valve actuating lever

Extension, Governor and Governor fully forward when installing valve body to more
Support easily pick up the manual valve.
23. T urn transm ission so th at shaft points upward. 30. Install new suction screen and gasket.
24. Install governor support and gasket, drain back baffle,

and support to case attaching bolts. Bolt holes are posi 31. Install the guide plate (fig. 34PG) m aking sure that the
tioned so th at the support may be assembled only in the inner lever properly picks up the manual valve. Install
proper position. attaching bolts.
25. Install governor over output shaft (See "Governor- 32. Install the vacuum m odulator valve and the vacuum
-Assembly" for body to hub installation.) Install gover m odulator and gasket.
nor shaft and valve, urethane washer, and retaining "C"
clips. Center shaft in output shaft bore and tighten
governor hub drive screw.
26. Using Tool J-5 8 14, install speedom eter gear into output
shaft.
27. Place extension seal ring over governor support and

install transm ission extension and five retaining bolts.
28. If removed, replace speedom eter driven gear.
Oil Pan and Valve Body
29 W ith transm ission upside down, and m anual linkage

installed as previously described, and the selector lever
detent roller installed, install the valve body (servo ap
ply tube installed) and a new gasket. Carefully guide the Fig. 3 4 P G -ln s ta llin g Detent Guide Plate

33. Install the oil pan, using a new gasket, and the oil pan TH RO TTLE V A LV E A D JU STM EN T
attaching bolts.
34. Install converter and Safety Holding Strap J- 9 549 or a Powerglide

suitable substitute.
No provision is made for checking TV pressures. How

ever, if operation of the transm ission is such that some adjust
ment of the TV is indicated, pressures may be raised or
lowered by adjusting the position of the jam nut on the
throttle valve assembly (fig. 36PG). To raise TV pressure 3
LOW BAND A D JU S TM EN T
psi, backoff the jam nut one (1) full turn. This increases the
dimension from the jam nut to the throttle valve assembly
Tighten the low servo adjusting screw to 70 inch lbs. using stop. Conversely, tightening the jam nut one (1) full turn
torque wrench, J-5853 and a 7/32" hex head driver (fig. lowers TV pressure 3 psi. A difference of 3 psi on TV pressure
35PG) or J- 21848. The input and output shaft m ust be will cause a change of approxim ately 2 to 3 M PH in the wide
rotated sim ultaneously to properly center the low band on open throttle upshift point. Smaller pressure adjustm ents can
the clutch drum . Then back off four (4) complete turns for be made by partial turns of the jam nut. The end of TV,
a band which has been in use for 6,000 miles or more, or 3 adjusting screw has an alien head so the screw may be held
turns for one in use less than 6,000 miles. Tighten the locknut stationary while the jam nut is moved.
to specified torque.
CAUTION: The amount of back-off is not an approxi- NOTE: Use care when making this adjustment since
mate figure, it must be exact. no pressure tap is provided to check TV pressure.
TV ADJUSTMENT ALLEN WRENCH

NUT
Fig. 35PG -Low Band Adjustment F ig .3 6 P G -T V Adjustment N u t Powerglide

TURBO HYDRA-MATIC 3 5 0 TRANSMISSION
INDEX
SU BJECT PA G E
Transm ission Disassembly and Reassembly ............... 7-101 Extension Housing B u sh in g ..................................... ...7-130
D isassem bly........................................................................ 7-101 R em oval........................................................................... 7-130
Removal of Extension, Speedometer Installation................................................................... ... 7-130
D riven G ear,O il Pan and S train er........................ ..7-101 O utput Shaft B ushing.................................................... 7-130
Removal of Valve Body and Linkage ................... .. 7-104 R em oval........................................................................... 7-130
Removal o f Oil Pum p and Internal Installation................................................................... ...7-130
Case Com ponents ........................................................7-108 Case B ushing....................................................................7-130
Valve Body ................................................................... .. 7-114 R em oval...........................................................................7-130
D isassem bly................................................................. ..7-115 Installation................................................................... ...7-131
Inspection........................................................................7-115 Stator Shaft B ushing................................................... ...7-131
Reassembly ................................................................. ..7-115 Removal ( F r o n t) ...........................................................7-131
Oil Pum p Installation................................................................... ...7-131
D isassem bly................................................................. ..7-116 Removal (R e a r).............................................................7-131
Inspection........................................................................7-118 Installation................................................................... ...7-131
Reassembly ................................................................. ..7-119 Input Ring G ear Support B ushing.......................... ...7-131
D irect C lutch R em oval...........................................................................7-131
D isassem bly................................................................. .. 7-120 Installation................................................................... ...7-132
Inspection........................................................................7-122 Sun G ear B ushing...........................................................7-132
Reassembly ................................................................. ..7-122 R em oval...........................................................................7-132
F orw ard C lu tch ............................................................ .. 7-123 Installation................................................................... ...7-132
D isassem bly................................................................. ..7-123 Reaction C arrier B ushing.......................................... ...7-132
Inspection........................................................................7-124 R em oval...........................................................................7-132
Reassembly ................................................................. ..7-125 Installation................................................................... ...7-132
Sun G ear and Sun G ear D rive S h e ll........................7-126 D irect Clutch Bushing ..................................................7-132
D isassem bly................................................................. ..7-126 R em oval...........................................................................7-132
Inspection........................................................................7-126 Installation................................................................... ...7-133
Reassembly ................................................................. 7-126 Reassembly ..................................................................... ...7-133
Low and Reverse Clutch .......................................... ..7-127 Transmission Internal C om p o n en ts........................ ...7-133
D isassem bly................................................................. 7-127 Pum p to D irect C lutch Thrust
Inspection..................................................................... ..7-127 W asher Selection P ro ce d u re ................................... ...7-134
Reassembly ...................................................................7-129 Speedometer Drive G ear and E x te n sio n ..................7-135
G overnor Assembly........................................................7-129 M anual Linkage .............................................................7-135
D isassem bly................................................................. ...7-129 Interm ediate Servo Piston,
Inspection..................................................................... .. 7-129 Valve Body, Oil Pan and G a sk e t.......................... ...7-136
G overnor G ear R e p la c e m e n t................................. .. 7-129 G overnor and Vacuum M odulator.......................... ...7-136
Reassembly ................................................................. .. 7-130 Intermediate Clutch A ccum ulator.............................. ..7-136
Bushing R ep lacem en t................................................... .. 7-130

Sectioned V iew
350
Hydra-Matic
Fig. 1M~Turbo

TRANSMISSION DISASSEMBLY AND REASSEMBLY

D IS A S S E M B L Y NOTE: Cleanliness is an important factor in the
overhaul of the transmission. Before attempting any
1. Install Holding Fixture J-8763-01 (M odified as shown disassembly operation, the exterior of the case
on fig. 2M) on transm ission and place into Holding should be thoroughly cleaned to prevent the possi
Tool base J-3289-14 with converter facing up (fig. 3M). bility of dirt entering the transmission internal
mechanism. During disassembly, all parts should be
thoroughly cleaned in cleaning fluid and then air
GRIND OFF MATERIAL dried. Wiping cloths or rags should not be used to
IN THIS AREA TO dry parts.
CLEAR 1-2 ACCUMULATOR
HO U SING
CAUTION: Do not use solvents which could damage

rubber seals or clutch facings.
2. W ith transm ission in holding fixture remove torque

converter assembly.
3. Remove vacuum m odulator assembly attaching bolt

and retainer.
j-8763-01
4. Remove vacuum m odulator assembly, "O" ring seal,
and m odulator valve from case (fig. 4M). D iscard "O"
ring.
Fig. 2 M ~ M od ifying J-87 63 -01 Holding Fixture Removal of Extension, Speedometer

Driven Gear, Governor, Oil Pan and
Strainer
1. Remove four housing to case attaching bolts.
VACUUM MODULATOR
O-RING-SEAL
Fig. 3M --Transm ission in H olding Fixture Fig. 4M -R em oving Vacuum M od ula tor Assem bly

E XT ENSI ON H O U S I N G
LIP SEAL
Y OK E SEAL
J-23103
Fig. 5M ~Removing Extension Housing Seal Fig. 7M ~Rem oving O utput S haft Yoke Seal
2. Remove extension housing from case and remove Remove extension housing bushing using screwdriver
square cut "O" ring seal from extension housing. to collapse bushing (fig. 6 M) if necessary to replace.
3. Remove extension housing lip seal using screw driver 5. Remove speedometer drive gear and retaining clip from
(fig. 5M). output shaft.
6. Remove governor cover retainer wire with a screw

driver.
EXTENSI ON H O U S I N G Using a screwdriver and hammer, gently tap along gov

BUSHI NG ernor cover lip (fig. 8M), remove governor cover and
"O" ring seal (fig. 9M). Discard seal.
Fig. 6M ~Rem oving Extension Housing Bushing Fig. 8M -R em oving G overnor Cover

GOVERNOR COVER
TO C A S E " O ” RING
SEAL
Fi g. 9 M —G o v e r n o r C o v e r a n d “ O ” R in g Seal Fig. 1 1M~Removing Transm ission Oil Pan
CAUTION: Do not attempt to pry the screwdriver NOTE: Check governor bore and governor sleeve for
between the case and governor cover as this could scoring.
cause damage to the case.
9. Remove oil pan attaching screws (fig. 11M), oil pan, and
gasket. D iscard gasket.
10. Remove oil pum p suction screen (strainer) to valve
8. W ithdraw governor assembly from case (fig. 10M). body attaching screws (fig. 12M).
Fig. 10M ~Removing G overnor from Case Fig. 12M ~Removing Oil Pump Strainer from Valve Body

V ALVE B O D Y
A SSEM B LY
VALVE BODY
SPACER PLATE
DETENT S P R I N G A N D Q
R OLLER A SSE M B LY
VALVE BODY T O ^ ^ f c *
SPACER PLATE GASKET
Fig. 13M ~D etent Spring and Roller Assem bly

Fig. 15M--Removing Valve Body to T ransfer Plate Gasket
11. Remove oil pum p screen (strainer) and gasket from

valve body.
2. Remove m anual control valve link from range selector

Removal of Valve Body and Linkage inner lever. Remove detent control valve link from de
tent actuating lever (fig. 14M). Refer to page 7-115
1. Remove detent roller and spring assembly from valve for valve body disassembly.
body. Remove valve body to case attaching bolts (fig.
13M).
3. Remove valve body to transfer plate gasket (fig. 15M).
VALVE BODY ASSEMBLY 4. Remove transfer support plate bolts. Remove transfer
support plate (fig. 16M).
TORQUE
WRENCH
RANGE SELECTOR INNER LEVER
mm |DETENT®
I f v jih
^ i
.Jig > j S S l i c O N TR O L l f
m M wA aN ^ .UaA. L^S^ V A L V E WIRE
CONTROL®
VALVE LINK SPACER SUPPORT PLATE
Fig. 14M ~Rem oving M anual C ontroi Valve Link, Valve Body Fig. 1 6M--Removing Transfer (Spacer) S up po rt Plate
and Detent A ctua tin g Lever

VALVE
V A L V E B O D Y SP A CER PLATE
TO C A S E G A S K E T
Fig. 17 M -R em oving T ransfer (Spacer) Plate and Gasket Fig. 19M--Removing Oil Pump Pressure Screen
5. Remove valve body transfer plate and valve body trans- 7. Remove oil pum p pressure screen from oil pum p pres
fer plate to case gasket (fig. 17M). sure hole in case (fig. 19M).
6. Remove four (4) check balls from correct passages in 8. Remove governor feed screen from governor feed hole
case face (fig. 18M). (drive oil) in case (fig. 20M).
CHECK BALLS
** B1MI
GOVERNOR
SCREEN
GOVERNOR
FEED HOLE
Fig. 18M ~Check Ball (4) Locations Fig. 20 M -R em o ving G overnor Feed Screen

RANGE SELECTOR
INNER LEVER
MANUAL SHAFT TO
CASE RETAINER
SCREWDRIVER
MANUAL SHAFT
PARKING PAWL
ACTUATING ROD
Fig. 23M ~R em oving M anual S haft and Inner Lever and

Parking Pawl A ctua to r Rod from Case
Fig. 21 M--Removing M anual Shaft to Case Retainer
9. Remove m anual shaft to case retainer with screwdriver 11. Remove range selector inner lever from m anual shaft.
(fig. 21M). Remove m anual shaft from case. Remove inner lever
and parking pawl actuator rod from case. Disassemble
10. Loosen n ut holding range selector inner lever to m anual
inner lever from parking pawl actuator rod (fig. 23M).
shaft (fig. 22M).
12. Remove m anual shaft to case lip seal (fig. 24M).
SCREW DRIVER
RANGE SELECTOR INNER M AN U AL SHAFT TO

C A S E LIP SEAL
LEVER TO MANUAL SHAFT
NUT. TORQUE TO 30 LB.FT.
Fig. 2 2 M -L o o se n in g Nut H olding Range Selector Inner Lever

to M anual Shaft Fig. 24M--Rem oving M anual S haft to Case Lip Seal

PARK PAWL
A C T U A T IN G ROD SHAFT
PARKING PAWL SHAFT

RETAINING PLUG
PARK L O C K L O C K B R A C K E T 1
Fig. 25M ~R em oving Park Lock, Lock Bracket Fig. 27M --Parking Pawl S haft and Retaining Plug
13. Remove parking lock bracket (fig. 25M). (Special NOTE: The parking pawl shafts retaining plug may
Bolts). be removed by using a bolt extractor.
14. Rem ove parking pawl disengaging spring (fig. 26M). 16. Remove interm ediate servo piston and seal ring.
Remove washer, spring seat and apply pin (fig. 28M).
15. Remove parking pawl shaft retaining plug, parking
pawl shaft, and parking pawl (fig. 27M) if necessary.
PARKING PAWL
PARKING PAWL
D ISEN G A G IN G SPRING
Fig. 2 6 M -R em o ving Parking Pawl Disengaging Spring Fig. 2 8 M ~ lnterm ed iate Servo Piston and Related Parts

PUMP A S S E M B L Y INTERMEDIATE CLUTCH

TO C A S E A T T A C H I N G ™ CU SH IO N S P R I N G — f t
B O LTS (8)
Fig. 29M --Rem oving Pump A tta chin g Bolts Fig. 31 M--Removing Interm ediate Clutch Cushion Spring
SLIDE INTERMEDIATE CLUTCH

HAMMERS
FACED PLATES
TIGHTEN JAM NUTS STEEL PLATES til
Fig. 30M ~R em oving Pump from Case Fig. 32M ~R em oving Interm ediate Clutch Plates
Removal of oil pump and internal case pum p assembly from case (fig. 30M). Discard pum p
components gasket.
Refer to pages 7 -1 1 6 and 7-1 1 9 for disassembly and
1. Remove eight ( 8) pum p attaching bolts w ith washer of the oil pump.
type seals (fig. 29M). 3 Remove interm ediate clutch cushion spring (fig. 31M).
4. Remove interm ediate clutch faced plates and steel reac
2. Install two (2) threaded slide ham m ers J-9539 (weights tion plates (fig. 32M).
J-6585) into threaded holes in pum p body and remove 5 Remove interm ediate clutch pressure plate (fig. 33M).

INTERMEDIATE CLUTCH FORWARD A ND DIRECT

PRESSURE PLATE H CLUTCH ASSEMBLIES
Fig. 33M ~R em oving Interm ediate Clutch Pressure Plate Fig. 35 M -R em o ving D irect and Forward Clutch Assemblies
INPUT RING GEAR
INTERMEDIATE O V E R R U N S FRONT INPUT RING

BRAKE BAND GEAR THRUST WASHER
Fig. 3 4 M -R em o ving Interm ediate Overrun Band Fig. 36M ~R em oving Inp ut Ring Gear Front T hrust W asher
6. Remove interm ediate overrun brake band (fig. 34M).
Refer to pages 7-1 2 0 th ru 7-125 for disassembly and

7. Remove direct and forw ard clutch assemblies from case reassembly of the direct and forward clutches.
(fig. 35M). 8 . Remove input ring gear front thrust washer (fig. 36M).

INPUT RING GEAR
OUTPUT SHAFT
SNAP RING
Fig. 37M --Rem oving O utpu t C arrier to O utput S haft Snap Ring Fig. 3 9 M -R em o ving Input Ring Gear Rear T hrust W asher
NOTE: Washer has 3 tangs. 10. Remove input ring gear (fig. 38M).
9. Remove output carrier to output shaft snap ring (fig. 11. Remove input ring gear rear (output carrier) thrust
37M). washer (fig. 39M).
NOTE: Use new snap ring at assembly. 12. Remove output carrier assembly (fig. 40M).
------- 1 ^ —’ 'V
OUTPUT CARRIER ASSEMBLY
INPUT R IN G G E A R
Fig. 38 M -R em o ving Inp ut Ring Gear Fig. 4 0 M -R em o ving O utput C arrier Assem bly

— - — - — —
WKKmmtm m 1 - ! >Wm ■
S U N G E A R DRIVE
SHELL ASSEMBLY
LO W A N D REVERSE
CLUTCH PACK
Fig. 4 1 M -R em o ving Sun Gear Drive Shell Fig. 43 M -R em o ving Low and Reverse Clutch Pack
13. Remove sun gear drive shell assembly (fig. 41M). 16. Remove low and reverse clutch faced plates and steel
reaction plates (fig. 43M).
14. Remove low and reverse roller clutch support to case
retaining ring (fig. 42M).
17. Remove reaction carrier assembly from output ring
15. Remove low and reverse clutch support and race assem gear and shaft assembly (fig. 44M).
bly and anti-clunk spring.
OUTPUT RING GEAR

AND SHAFT ASSEMBLY
REACTION CARRIER
ASSEMBLY
Fig. 42 M -R em o ving Low and Reverse Clutch Support

Retaining Ring Fig. 44M--Rem oving Reaction Carrier Assem bly

18. Remove output ring gear and shaft assembly from case 20. Remove output ring gear to case needle bearing assem
(fig. 45M). bly (fig. 47M).
21. Compress low and reverse clutch piston spring retainer
19. Remove reaction carrier to output ring gear tanged using tool J-23327 and remove piston retaining ring and
(front) thru st washer (fig. 46M). spring retainer (fig. 48M).
OUTPUT
RING
GEAR
OUTPUT RING
GEAR TO CASE
OUTPUT RING GEAR ^ NEEDLE B E A R IN G
AND OUTPUT S H A F Tt !e* i
ASSEMBLY
Fig. 4 5 M -R em o ving O utpu t Ring Gear and S haft Assem bly Fig- 4 7 M “ Rem oving O utput Ring Gear to Case Needle Bearing
Assem bly
OUTPUT RING GEAR
TANGED THRUST WASHER
Fig. 4 6 M -R em o ving O utput Ring Gear T hrust W asher Fig. 48M --Com pressing Low and Reverse Clutch Springs
Retainer

LOW AND REVERSE CLUTCH

PISTON RETURN SPRINGS (1
OUTER
SEAL
REVERSE
LUTCH
PISTON
f
LOW AND REVERSE
CLUTCH PISTON
Fig. 49M --Low and Reverse Clutch Springs and Piston Fig. 5 1 M--Removing Low and Reverse Clutch Piston Oil Seals
22. Remove seventeen (17) piston springs from piston (fig. 24. Remove low and reverse clutch piston outer seal (fig.
49M). 51M).
23. Remove low and reverse clutch piston assembly by ap 25. Remove low and reverse clutch piston center and inner
plying compressed air in passage shown on Figure 50M. seal (fig. 52M).
APPLY AIR PRESSURE

V N HERE TO REMOVE LOW & i.
‘ ^ R E V E R S E CLUTCH PISTON |
; : I
W
WW"”*
Fig. 52M--Rem oving Low and Reverse Clutch Piston Center

Fig. 50M ~Rem oving Low and Reverse Clutch Piston , . 0 .
and Inner Seal

CLUTCHES A N D TR A N SM ISSIO N S 7-114
J-23069
Fig. 53M --Rem oving 1-2 A ccum u lato r Piston Cover Fig. 54 M ~lnterm ed iate Clutch A ccum u lato r Components
26. Install tool J-23069 to compress interm ediate clutch Remove interm ediate clutch accum ulator piston assem
accum ulator piston cover and remove retaining ring bly. See Figure 54M.
(fig. 53M).
27. Remove interm ediate clutch accum ulator piston cover. Also, remove inner and outer hook type oil seal rings if
Remove "O" ring seal from case. required.
28. Remove interm ediate clutch accum ulator piston

spring.
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J-1 M A N U A L VALVE 1-2 SHIFT V A L V E 27 DETENT V A L V E

'2 PRESSURE REGU LATOR V A L V E 1-2 SHIFT C O N T R O L VA L V E 28 WASHER
3 PRESSURE RE G U L AT O R VA L V E SPRING 1-2 SHIFT C O N T R O L V A L V E SPRING 29 DETENT V A L V E I NNE R SPR ING
4 REVERSE A N D M O D U L A T O R B O O S T V A L V E 1-2 SHIFT C O N T R O L V A L V E SLEEVE 30 DETENT V A L V E OUTER SPR ING
5 IN TE RM E DI A TE B O O S T VA LV E R E T A IN IN G PIN 31 DE TE NT V A L V E OUTER SPRING SEAT
6 B O O S T V A L V E SLEEVE M A N U A L LOW CONTROL VALVE 32 DE TE NT V A L V E SPRING RETAINER
. 7 R E T A I N I N G PIN 20 M A N U A L L O W C O N T R O L V A L V E SPR IN G 33 DETENT V A L V E STOP
'8 2- 3 SHIFT V A L V E 21 PLUG 3 4 DETENT V A L V E A C T U A T I N G LEVER BRACKET
9 3 SHIFT V A L V E SPRING 22 R E T A IN IN G PIN 35 DE TE NT V A L V E A C T U A T I N G LEVER
10 3 SHIFT C O N T R O L V A L V E 23 DETENT R E G U L A T O R VAL VE 36 R E T A I N I N G BOLT
11 3 SHIFT C O N T R O L V A L V E SPR ING 24 DETENT R E G U L AT O R V A L V E SPRIN G SEAT . 3 7 R E T A IN IN G PIN
12 3 SHIFT C O N T R O L V A L V E SLEEVE 25 DETENT R E G UL AT O R V A L V E SPRING 38 DIRECT CLUTCH A C C U M U L A T O R SPRING
U 3 R E T A IN IN G PIN 26 R E T A IN IN G PIN 39 OIL SEAL RI N G
40 DIRECT CL UTC H A C C U M U L A T O R PISTON
41 R E TA IN ER RI NG
Fig. 55M --Valve Body-E xploded V iew

Valve Body Disassembly, Inspection, and 9. Remove direct clutch accum ulator piston, and metal oil
Reassembly (fig. 55M) seal ring, and spring.
10. From the next bore down from the direct clutch ac
Disassembly cum ulator, remove the detent actuating lever bracket
bolt, bracket, actuating lever and retaining pin, stop,
spring retainer, seat, outer spring, inner spring, washer
1. Position valve body assembly with cored face up and
and detent valve.
direct clutch accum ulator piston pocket positioned as
shown in Figure 55M.
Inspection
2. Remove m anual valve from lower left hand bore.
1. Inspect all valves for scoring, cracks and free movement

3. From lower right hand bore remove the pressure
in their respective bores.
regulator valve train retaining pin, boost valve sleeve,
interm ediate boost valve, reverse and m odulator boost 2. Inspect valve body for cracks, scored bores, intercon
valve, pressure regulator valve spring, and the pressure nected oil passages and flatness of m ounting face.
regulator valve.
3. Check all springs for distortion or collapsed coils.
4. From the next bore, remove the 2-3 shift valve train
retaining pin, sleeve, control valve spring, 2-3 shift con
trol valve, shift valve spring, and the 2-3 shift valve.
Reassembly
1. Install direct clutch accum ulator piston spring and pis

5. From the next bore, remove the 1-2 shift valve train
ton into valve body.
retaining pin, sleeve, shift control valve spring, 1-2 shift
control valve, and the 1-2 shift valve. 2. Install special tool J-2 1885, and compress spring and
piston and secure with retaining ring.
6. From the next bore, remove retaining pin, plug, manual
low control valve spring, and the m anual low control
valve. NOTE: Align piston and oil seal ring when entering
bore.
7. From the next bore, remove the retaining pin, spring,

3. Install the detent valve, washer, outer spring, inner
seat, and the detent regulator valve. spring, spring seat, and spring retainer. Install detent
valve stop and detent valve actuating bracket. Torque
8. Install Tool J-2 1885, on direct clutch accum ulator piston bolt to 52 in. lbs. Assemble detent actuating lever with
and remove retaining "E" ring (fig. 56M). retaining pin.
4. Install the pressure regulator valve, spring, reverse and

m odulator boost valve, interm ediate boost valve, boost
valve sleeve and retaining pin.
J-21885
5. In the next bore up, install 2-3 shift control valve, shift
control valve spring, 2-3 shift control valve, shift con
trol valve spring, shift control valve sleeve and retaining
pin.
6. In the next bore up, install the 1-2 shift valve, 1-2 shift
control valve, control valve spring, control valve sleeve
and retaining pin.
7. In the next bore up, install the manual low control

valve, spring, plug and retaining pin.
8. In the top right hand bore, install the detent regulator

valve, spring seat, spring and retaining pin.
Fig. 56M--Removing D irect Clutch A ccum u lato r Piston

Oil Pump Disassembly, Inspection and

Reassembly (Fig. 57M)
.PUMP TO CONVERTER INTERMEDIATE CLUTCH

RING SEAL
HUB LIP SEAL PISTON ASSEMBLY
PRIMING VALVE FORWARD CLUTCH
TO PUMP HUB HOOK
SPRING
TYPE RINGS (2) SPRING
RETAINER
DIRECTCLUTCH TO PUMP
-DRIVE GEAR HUB HOOK TYPE OIL
SEAL RINGS (3)
PUMP BODY ASSEMBLY
INTERMEDIATE CLUTCH
PUMP COVER AND STATOR
RETURN SPRINGS (30)
SHAFT ASSEMBLY
PUMP COVER TO PUMP BODY
ATTACHING BOLTS (5)
Fig. 57M ~Pum p A ssem bly-E xploded V iew
Disassembly
1. Place pum p cover and stator shaft assembly through 3. Remove interm ediate clutch spring seat retainer, thirty
hole in bench. (30) interm ediate clutch return springs and the inter
2. Remove pum p cover to body attaching bolts 5/16 x m ediate clutch piston assembly (fig. 59M).
18-1 1/2 (fig. 58M).
IN T E R M E D I A T E RETURN
CLUTCH S P R I N G S P RIN G S (30)
SEAT R E T A I N E R
IN T E R M E D IA T E
CLUTCH P IS T O N
SPRING
PU M P B O D Y BOLTS (5) RETAINER
Fig. 58M --Removing Interm ediate Clutch Spring Seat Retainer Fig. 5 9 M -ln te rm e d ia te Clutch Spring and Retainer

PUMP C O V E R A N D
S TA TO R S H A F T
ASSEMBLY
PUMP B O D Y
Fig. 6 0 M -R em o ving Interm ediate Clutch Piston Inner and

Fig. 62M --Separating Pump Cover from Pump Body
O uter Seal
4. Remove interm ediate clutch piston inner seal and outer 7. Remove pum p cover and stator shaft assembly from
seal (fig. 60M). pum p body (fig. 62M).
5. Remove forw ard clutch to pum p hub hook type oil seal 8. Remove pum p drive gear and driven gear.
rings (2) and (3) direct clutch to pum p hub hook type
oil rings (fig. 61M). 9. Remove pum p outside diam eter to case (square cut)
6. Remove pum p cover to direct clutch drum housing "O" ring seal. D iscard seal.
selective thrust washer. 10. Remove pum p to converter hub lip seal (fig. 63M).
FORWARD PUMP TO CONVERTER

CLUTCH HUB LIP SEAL
OIL SEAL
RINGS
PUMP BODY
DIRECT
CLUTCH
OIL SEAL
RINGS
SCREWDRIVER
PUMP COVER TO DIRECT CLUTCH
SELECTIVE THRUST WASHER
WOOD BLOCKS
Fig. 61 M -P um p Hub Oil Seal Rings Fig. 63M -R em o ving Pump to Converter Hub Seal

COOLER
BY-PASS
BOLT EXTRACTOR VALVE SEAT
Fig. 66M --Checking Pump Body to Gear Face Clearance
CAUTION: Some solvents may be harmful to rubber

seals.
Fig. 64M -R em o ving Cooler By-Pass Valve 2. Inspect pum p gears for nicks or damage.
NOTE: Place pump on wood blocks so surface finish 3. Inspect body and cover faces for nicks or scoring. In
is not damaged. spect cover hub O.D. for nicks or burrs which might
11. Remove oil pum p prim ing valve and spring. damage clutch drum bushing journal.
12. Remove cooler by-pass valve seat, check ball, and 4. Check for free operation of the priming valve and re
spring (fig. 64M). place if necessary.
Inspection 5. Inspect body bushing for galling or scoring. Check

1. W ash all parts in cleaning solvent and blow out all oil clearance between body bushing and converter pump
passages. DO N O T USE RA G S TO D R Y PARTS. hub. M aximum clearance is .005". If the bushing is
damaged, the oil pump body should be replaced.
6. Inspect converter housing hub O.D. for nicks or burrs

which might damage pum p seal or bushing. Repair or
replace as necessary.
7. If oil seal is damaged or is leaking (and the pum p body

is otherwise suitable for reuse), pry out and install a new
seal, fully seated in counterbore, using Seal Driver J-
J-2 135 9 21359 (fig. 65M).
PUMP TO NOTE: Outer diameter of seal should be coated with

CONVERTER a non-hardening sealer prior to installation.
HUB LIP SEAL
8. Check condition of oil cooler by-pass valve and replace
if valve leaks excessively. For removal, an "Easy Out"
or its equivalent may be used.
F or installation tap seat in place with soft ham m er or

brass drift so it is flush to .0 1 0 " below the surface.
PUMP BODY
W OOD BLO CKS 9. W ith parts clean and dry, install pum p gears and check:
Place pum p gears in pum p body and check pum p body
face to gear face clearance, should be .0005"-.0015" (fig.
Fig. 65 M --lnstalling Hub Lip Seal 66 M).

PRIM ING V A LV E LO C A T IO N
EXH A U ST
E X H A U ST
PUMP
INTERM EDIATE
PRESSURE
CLU TCH
R EV E R SE CO O LER
B Y -P A S S
V A LV E
C O O L E R OUT
( FROM R A D IA T O R
C O O L E R IN
R EV E R SE ( TO R A D IA T O R |
D IR E C T C LU T C H
O UTER)
E X H A U ST
C O N V E R T E R FEED
PUMP LIP S E A L D RA IN
F O R W A R D C LU T C ..
D IR E C T C LU T C H EXHAU ST
PUMP B O D Y
Fig. 6 7 M ~ ln sta llin g Pump Drive and Driven Oil Pump Gears Fig. 68M ~Pum p Body Oil Passages
Reassembly
1. Install pum p drive gear and driven gear (fig. 67M).
EXH A U ST INTERM EDIA TE CLUTCH
2. Install direct clutch drum housing to pump cover selec
D IRECT C L U T ^
tive thrust washer over pum p cover delivery sleeve. FO RW A RD CLUTCH C O O L E R IN
( TO R A D IA TO R |
3. Install three (3) direct clutch to pum p hub hook type C O N V E R T E R FEED
oil seal rings. Install two (2) forw ard clutch to pump
hub hook type oil seal rings. SU C TIO N
C O O L E R OUT
FROM R A D IA T O R )
PUMP
PRESSU RE
CAUTION: Check three (3) pump cover hub lube REVERSE

( D IRECT CLUTI
holes to make sure they are not restricted. O UTER!
INTERM EDIATE
CLU TCH
EXHAUST
4. Install oil pum p prim ing valve spring and priming
valve.
PRIM ING V A LV E
5. Install cooler by-pass valve spring, check ball and seat.

PUMP C O V E R A N D STATOR SH AF T A S S E M B LY
6. Install interm ediate clutch piston inner seal and outer
seal on piston.
7. Install interm ediate clutch piston assembly into pump

cover being careful not to dam age seals. Fig. 69M --Pum p Cover Oil Passages
8. Install thirty (30) clutch return springs.
9. Install spring retainer and install five (5) attaching

bolts. 11. Install pum p outside diam eter to case (square cut) "O"
ring seal.
10. Align pum p body to cover and start bolts.
12. Install pump to converter hub lip seal using seal in
staller J- 21359 (fig. 65M).
NOTE: To facilitate assembly locate pump priming
valve in pump body to priming valve cavity in pump
cover (figs. 68M and 69M). 13. Tighten attaching bolts. Torque to 18 ft. lb.

Fig. 70M --lnterm ediate Overrun Clutch Assem bly-E xploded V iew
Direct Clutch Disassembly, Inspection,

and Overhaul (Fig. 70M)
Disassembly 2. Remove interm ediate clutch overrun outer race.
3. Remove interm ediate overrun roller clutch assembly
1. Remove interm ediate overrun clutch drum front retain
(fig. 72M).
ing ring and retainer (fig. 71M).
INTERMEDIATE OVERRUN
R CLUTCH ASSEMBLY
OVERRUN
RETAINING RIN
DIRECT
CLUTCH
DRUM
DIRECT CLUTCH ASSEMBLY
__ __ ^ , Fig. 72 M -R em o ving Interm ediate Overrun Roller Clutch

Fig. 7 1 M -Rem oving Overrun Clutch Retaining Ring and
Retainer

STEEL
PLATES
- D IR E C T C L U T C H DRUM
STEEL SEPARATO R
F A C E D PLA TE -
D IR E C T C L U T C H P R E S S U R E P L A T E '
R E T A IN IN G R IN G '
LINED PLATES
Fig. 73M ~ D irect Clutch Assem bly-E xploded V iew Fig. 7 5 M -R em o ving Direct Clutch, Clutch Pack
5. Remove direct clutch pressure plate to clutch drum

retaining ring and pressure plate (fig. 74M).
6. Remove face plates, steel reaction plates (fig. 75M).
7. Using compressing tool J-23327-1, remove direct clutch

piston return spring seat retaining ring, spring seat and
4. Remove direct clutch drum to forw ard clutch housing
seventeen (17) clutch return coil springs (fig. 76M).
special thrust washer (fig. 73M).
R E T A IN IN G RING
PRESSURE PLATE
IRECT CL UTCH D R U M
Fig. 7 4 M -R em o ving D irect Clutch Pressure Plate Fig. 76 M -C om p ressin g D irect Clutch Spring Retaining Seat

OUTER SEAL
.020" PIANO WIRE CRIMPED
INTO COPPER TUBING
DIRECT CLUTCH
'PISTON
PISTON
INNER SEAL
DIRECT CLUTCH HOUSING
Fig. 77M --Removing D irect Clutch O uter and Inner Seal Fig. 79 M --lnstalling Direct Clutch Piston
8. Remove direct clutch piston assembly.

2. Inspect seventeen (17) springs for collapsed coils or
9. Remove direct clutch piston outer seal and inner seal signs of distortion.
(fig. 77M). 3. Inspect piston for cracks.
10. Remove direct clutch piston center seal on drum (fig. 4. Inspect clutch housing for wear, scoring, open oil pas
78M). sages and free operation of ball check.
5. Inspect roller clutch inner and outer race for scratches
Inspection or indentations.
1. Inspect drive and driven clutch plates for signs of burn 6. Inspect roller cage for wear and roller springs for dis
ing, scoring or wear. tortion.
Reassembly
1. Install the direct clutch piston outer seal and inner seal.
2. Install direct clutch piston center seal on drum with lip
facing upward.
3. Install the direct clutch piston (fig. 79M).
NOTE: Install direct clutch piston into housing with

aid of a piece of .020' piano wire crimped into copper
D IR ECT tubing.
C LU TCH
4. Install seventeen (17) clutch return coil springs.
DRUM 5. Install spring retainer. Compress spring retainer with
tool J- 23327-1 and install retaining ring (fig. 80M).
6. Lubricate with transmission fluid and install face plates
and steel reaction plates, alternating steel and faced
plates.
7. Install direct clutch pressure plate and retaining ring.
C L U T C H P IS T O N 8. Install interm ediate overrun clutch assembly.
CENTER SEAL 9. Install interm ediate clutch overrun outer race.
NOTE: When outer race is installed, it should free

Fig. 78M ~R em oving Direct Clutch Piston Seal on Drum wheel in counterclockwise direction Only.

CLUTCH ASSEMBLIES
DRIVE D RIV EN C U S H IO N
C LU TC H PLATE PLATES S P R IN G
FORWARD
L-6, 307 V-8 4 4 1
350 V-8, 400 2-bbl. 5 5 1
TAXI AND TRUCK
INTERMEDIATE
L-6, 307 V-8 2 2 1
350 V-8, 400 2-bbl. 3 3 1
TAXI AND TRUCK
DIRECT
L-6, 307 V-8 3 3 NONE
350 V-8, 400 2-bbl. 4 4 NONE
TAXI AND TRUCK
REVERSE
L-6, 307 V-8 4 4 NONE
350 V-8, 400 2-bbl. 5 5 NONE
TAXI AND TRUCK
Disassembly
1. Using tool J-23327-1, compress retainer and remove

forw ard clutch drum to pressure plate retaining ring
Fig. 80M ~A ssem bly Direct Clutch Springs, Retainer and (fig. 82M).
Retaining Ring
10. Install interm ediate overrun clutch retainer and re 2. Remove forward clutch pressure plate (fig. 83M).
tainer ring as shown on Figure 76M.
3. Remove face plates, steel reaction plates and cushion
Forward Clutch Disassembly, Inspection,
spring (fig. 84M).
and Overhaul (Fig. 8 1 M)
F O R W A R D CLUTCH PISTON ASSEMBLY

RETAIN ING
STEEL S E P E R A T O R PL A TE S RING
FO RW ARD CLUTCH DRUM
C U S H I O N SPRIN G"
- iinr u i o n Ar i
P IS TO N RETURN S EA T '
F A C E D PLATES
R E TA IN IN G RING
F O R W A R D C L U T C H PRESSURE P LA T E '
Fig. 8 1 M -F o rw a rd Clutch A ssem bly-E xploded V iew

Fig. 82M ~C om pressing Forward Clutch Spring Retaining Seat Fig. 84M ~R em oving Forward Clutch, Clutch Pack
-m | . ^
RETAINING FORWARD CLUTCH OUTER SEAL
m
RING ASSEM BLY
FORWARD
CLUTCH
PISTON
IN N E R SEAL
FORWARD CLUTCH
PRESSURE PLATE
Fig. 8 3 M -R em o ving Forward Clutch Retaining Ring and Fig. 8 5 M -R em o ving Forward Clutch Piston Inner and Outer
Pressure Plate Seals
4. Remove forward clutch piston return spring seat retain 7. If required, remove input shaft from forward clutch
ing ring and spring seat and twenty-one ( 21 ) clutch housing with ram press or arbor press.
return coil springs. Inspection
5. Remove forw ard clutch piston assembly.
6. Remove the forw ard clutch inner and outer piston seals 1. Inspect drive and driven clutch plates for signs of burn
(fig. 85M). ing, scoring or wear.

FORWARD CLUTCH .020" PIANO WIRE CRIMPED

BALL CHECK INTO COPPER TUBING
EXHAUST PISTON
FORWARD CLUTCH DRUM

FORWARD CLUTCH HOUSING
Fig. 8 6 M -F o rw a rd Clutch Ball Check Exhaust Fig. 8 7 M ~ ln sta llin g Forward Clutch Piston
2. Inspect twenty one (21) springs for collapsed coils or

signs of distortion. 7. Install forward clutch pressure plate (selective fit) and
3. Inspect piston for cracks. retaining ring.
4. Inspect clutch housing for wear, scoring, open oil pas
sages and free operation of ball check (fig. 86 M). The forward clutch pressure plate is a selective fit.
5. Inspect input shaft. See Figure 88 M for determ ining dimension to select proper
a. Inspect for open lubrication passages at each end. pressure plate size for correct clutch pack running clearance.
b. Inspect splines for damage. See chart below.
c. Inspect ground bushing journals for damage.
d. Inspect shaft for cracks or distortion.
WHEN DIM. C IS
NOTE: Input shaft and clutch housing are serviced
separately. .0160— .0520 6261072
.0520— .0830 6261349
.0830— .1218 6261350
Reassembly
1. If input shaft was removed, install using ram press or
arbor press.
2. Install the forward clutch inner piston seal and outer
piston seal.
3. Install the forw ard clutch piston assembly (fig. 87M).
NOTE: Install forward clutch piston with the aid of

a piece of .020" piano wire crimped into copper tub
ing.
4. Install twenty-one (21) clutch return coil springs.

5. Install spring retainer. Com press spring retainer and
install retaining ring using tool J-23327-1 as shown on
Figure 82M.
6. Lubricate with transm ission fluid and install cushion
spring face plates and steel reaction plates, starting with Fig. 88M --D eterm ining Selective Fit Forward Clutch Pressure
the cushion spring and alternating steel and faced. Plate

Fig. 89M ~P lanetary Gear T rain -E xplo de d V iew
Sun Gear and Sun Gear Drive Shell Disassembly

Disassembly, Inspection, and 1. Remove sun gear to sun gear drive shell rear retaining
ring (fig. 90 M).
2. Remove sun gear to drive shell flat rear steel thrust
washer (fig. 91M).
3. Remove sun gear assembly from drive shell.
4. Remove sun gear to drive shell front retaining ring (fig.

SUBTRACT D IM .B FROM A TO OBTAIN D IM .C 92M). D iscard retaining ring.
When D im Use P late Part
C is: Number:
Inspection
.0 1 6 -0 5 2 0 6261072
1. Check gear and sun gear shell for damage or wear.
.0 5 2 -0 8 3 0 6261349
.083—.1218 6261350 Reassembly

1. Install new sun gear to drive shell front retaining ring.

SUN G EA R
RETA IN IN G
RING
SUN G EAR DRIVE SHELL

Fig. 90M --Rem oving Sun Gear Drive Shell Rear Retaining Ring Fig. 92 M -R em o ving Sun Gear to Drive Shell Front Steel T hrust
W asher
NOTE: Do not stress front and rear retaining rings

at installation.
S U N G E A R D R I V E SHELL
mamsm
Low and Reverse Clutch Support
SUN GEAR
Disassembly, Inspection, and
Disassembly
1. Remove low and reverse clutch to sun gear shell thrust

washer. *
2. Remove low and reverse overrun clutch inner race from

support (fig. 94M).
3. Remove low and reverse clutch roller clutch retaining

FLA T T H R U S T W A S H E R ring (fig. 95M).
Fig. 91 M~Removing Sun Gear to Drive Shell Rear Steel T hrust 4. Remove low and reverse roller clutch assembly (fig.
W asher 96M).
2. Install sun gear assembly into drive shell. Inspection

3. Install sun gear to drive shell flat steel thrust washer. 1. Inspect roller clutch inner and outer race for scratches
and indentations.
4. Install new sun gear to sun gear drive shell retaining
ring. 2. Inspect rollers for wear and roller springs for distortion.

L O W A N D REVERSE
CLUTCH SUPPORT
RO LLERCLUTCH
ASSEM BLY
SNAP RING
IN N E R RACE
THRUST W A S H E R
C A G E M U ST H A V E (4) EQ U A LLY SPACED
.091 LUBE H O LE S O N THIS SIDE IF ROLLER FALLS O U T , IN S T A L L ROLLER
FROM "O U T S ID E I N ” AS S H O W N TO
A V O ID B E N D IN G SPRINGS
Fig. 93M ~Low and Reverse Clutch A ssem bly-E xploded V iew
L O W & REVERSE ROLLER

CLUTC H R E T A I N I N G R I N G
LOW AND REVERSE

OVERRUN CLUTCH RACE
Fig. 94M ~R em oving Overrun Clutch Inner Race Fig. 9 5 M -R em o ving Overrun Roller Clutch Retaining Ring

LO W & R EV ER SE RO LLER
CLUTCH A S S E M B LY
~ -l — —— ..." W ’’”
Fig. 9 6 M -R em o ving Overrun Roller Clutch Assem bly Fig. 9 7 M -G o ve rn o r Assem bly-E xploded V iew T ypical
Reassembly 3. Perform following inspections and replace governor

driven gear, if necessary.
1. Install low and reverse roller clutch assembly to inner
race.
Inspection
NOTE: Roller clutch is assembled with oil holes to
1. W ash all parts in cleaning solvent, air dry and blow out
rear of transmission.
all passages.
2 . Inspect governor sleeve for nicks, burrs, scoring or gall
2. Install low and reverse overrun clutch outer race.
ing.
3. Install low and reverse clutch to cam retaining ring.
3. Check governor sleeve for free operation in bore of
transmission case.
NOTE: Low and reverse overrun clutch inner race
4. Inspect governor valve for nicks, burrs, scoring or gall
should free wheel in the clockwise direction only.
ing.
5. Check governor valve for free operation in bore of gov
ernor sleeve.
Governor Assembly 6 . Inspect governor driven gear for nicks, burrs, or dam
age.
All com ponents of governor assembly, with exception of
7. Check governor driven gear for looseness on governor
driven gear, are a select fit and each assembly is calibrated.
sleeve.
The governor, including the driven gear, is serviced as a
8 . Inspect governor weight springs for distortion or dam
complete assembly. However, the driven gear can also be
age.
9. Check governor weights for free operation in their re
It is necessary to disassemble governor assembly in order
tainers.
to replace driven gear. Disassembly may also be necessary
10. Check valve opening at entry and exhaust (.020 inch
due to foreign m aterial causing im proper operation. In such
minimum).
cases, proceed as follows:
Disassembly Governor Driven Gear Replacement

1. C ut off one end of each governor weight pin and remove To facilitate governor repair in the field, a governor
pins, governor thrust cap, governor weights, and driven gear and replacement pins are available for service
springs. G overnor weights are interchangeable from use. The service package contains a nylon driven gear, two
side to side and need not be identified (fig. 97M). governor weight retaining pins and one governor gear re
2. Remove governor valve from governor sleeve. Be care tainer split pin. Replacement of gear m ust be performed with
ful not to damage valve. care in the following manner:

1. Drive out governor gear retaining split pin using small

punch.
2. Support governor on 3/16 inch plates installed in ex
haust slots of governor sleeve, place in arbor press, and J-8092
with a long punch, press gear out of sleeve.
3. Carefully clean governor sleeve of chips that remain
from original gear installation.
4. Support governor on 3/16 inch plates installed in ex
haust slots of sleeve, position new gear in sleeve and, J-21424-9
with a suitable socket, press gear into sleeve until nearly
seated. Carefully remove any chips that may have
shaved off gear hub and press gear in until it bottoms EXTENSION
on shoulder. HOUSING
5. A new pin hole m ust be drilled through sleeve and gear.
Locate hole position 90 degrees from existing hole, cen
ter punch and then, while supporting governer in press,
drill new hole through sleeve and gear using a standard
( 1 /8 inch) drill.
6 . Install split retaining pin.
7. W ash governor assembly thoroughly to remove any
chips th at may have collected.
Reassembly
Fig. 9 8 M ~ ln s ta llin g Extension Housing Bushing
1. Install governor valve in bore of sleeve, large land end
first.
2. Install governor weights and springs, and thrust cap on
Installation
governor sleeve. 1. Using tool J-2 1424-7 and Drive handle J-8092 install
3. Align pin holes in th ru st cap, governor weight assem output shaft bushing.
blies and governor sleeve, and install new pins. Crimp
both ends of pins to prevent them from falling out.
4. Check governor weight assemblies for free operation on
pins.
Case Bushing
5. Check governor valve for free movement in governor
sleeve.
Removal
1. W ith case properly supported, remove case bushing.
Turbo Hydra-matic 350
Bushing Replacement
Extension Housing Bushing

Removal O U TPU T RING GEAR
1. Remove bushing with screwdriver as shown in Figure
6 M. OUTPUT SHAFT
J-9534
Installation
Using tool J-2 1424-9 and driver handle J-8092 install
extension housing bushing flush to .010 below seal counter
bore surface (fig. 98M). J-2619-4
ADAPTER
Output Shaft Bushing S LIDE H A M M E R
Removal 75-257
1. W ith output shaft properly supported, remove bushing

using J-9534-01 extractor and slide ham m er J-9539,
J-6585 (fig. 99M). Fig. 9 9 M--Removing O utput Shaft Bushing

Installation
1. Using tool J-23062-1 and drive handle J-8092 with ex
tension J-21465-13, install case bushing from interior of
case to 3/16" from front surface. Split in the bushing
should be located at governor pilot upper bore wall
J-8092
area. DRIVE
HANDLE
Stator Shaft Bushing J-21424-7
PUMP C O V E R
Removal (Front) PUMP
A N D STATOR DY
1. W ith stator shaft properly supported, remove front SHAFT ASSEMBLY
bushing using tool J-2 1465-15 with slide ham m er J-
2619 and adapter J-2619- 4 (fig. 100M).
Installation
1. Using tool J - 2 1424-7 and drive handle J-8092 install
front stator shaft bushing (fig. 101M) to .250" from
front face.
Removal (Rear)
1. W ith stator shaft properly supported, remove front Fig. 101 M -ln s ta llin g Front Stator Shaft Bushing
bushing as previously described. Place tool J-2 1424-7
extension J-21465-13 and drive handle J-8092, through
front of the stator shaft and drive out rear ( 2) bushings. Input Ring Gear Support Bushing
Removal
Installation 1. W ith input ring gear support properly supported,
1. Using tool J-23062-2 and extension J-21465-13, install remove bushing.
center bushing to approxim ately 1 5/32" below front
face and rear bushing 3/32" below front face (fig.
102M).
J - 21465-15
J - 2619-4
ADAPTER
J-23062-2
s 'BODY PUMP
PUMP COVER
AND STATOR
SHAFT ASSEMBLY
Fig. 10O M -R em oving S tator S haft Front Bushing Fig. 10 2 M --ln sta llin g Rear and Center S tator Shaft Bushings

Sun Gear Bushing
Removal
J-8092 1. W ith sun gear properly supported, remove sun gear
bushings (fig. 104M).
Installation
1. Using tool J-23062-3 and drive handle J-8092 install
sun gear bushings to .0 1 0 " below surface at either end
J-23062-5 (fig. 105M).
INPUT Reaction Carrier Bushing

RING GEAR
Removal
1. W ith reaction carrier properly supported, remove bush
ing.
Installation
Fig. 10 3 M -ln s ta llin g Inp ut Ring Gear S upport Bushing J Using tool J .23062-3 and drive handle J-8092 install
reaction carrier bushing to flush or .0 1 0 " below inside
face.
Direct Clutch Bushing
Removal
1. W ith direct clutch drum properly supported, remove
PLASTIC bushing (fig. 106M).
MALLET
CAPE CHISEL
S UN G E A R
SUN
BUSHING GEAR
DRIVE J-8092
SUN GEAR SHELL
DRIVE SHELL
75-190
J-23062-3
Fig. 10 4 M -R e m o vin g Sun Gear Bushings
Installation S U N GEAR
ASSEM BLY
1. Using tool J-23062-5 and drive handle J-8092 install

input ring gear bushing to approximately 1/16" below
rear face inside gear end (fig. 103M). Fig. 1 0 5 M -ln s ta llin g Sun Gear Bushings

sembly. Lubricate all bearings, seal rings and clutch

plates prior to assembly.
CAPE CHISEL
Transmission Internal Components
BUSHING
1. Install low and reverse clutch piston assembly.
NOTE: Notch in piston should be installed adjacent

to parking pawl.
2. Install seventeen (17) piston return (coil) springs.

3. Install spring retainer and retaining ring. Using tool
J-23327, compress return seat so spring retainer retain
ing ring may be installed. Install output ring gear rear
thrust bearing in case.
4. Install output ring gear on output shaft.
5. Install reaction carrier to output ring gear front thrust
washer (3 tangs) into output ring gear support.
DIRECT CLUTCH DRUM 75-182
6. Install output shaft assembly into case.
7. Install reaction carrier assembly into output ring gear
and shaft assembly.
8. Oil and install low reverse clutch steel reaction plates
and face plates, starting with a steel plate and alternat
ing with face plates. Install anti-clunk spring.
Fig. 106M --Rem oving D irect Clutch Drum Bushing
NOTE: Notch in steel separator plates should be

placed toward bottom of case.
9. Install low and reverse clutch support assembly with

position of notch with low and reverse clutch support
retainer (anti-clunk) spring as shown on Figure 108M.
IMPORTANT: Make certain the splines on inner

race of the roller clutch align with splines on reac
tion carrier.
L O W A N D REVERSE
CLUTCH SUPPORT
Fig. 107 M --lnstalling D irect Clutch Drum Bushing
Installation L O W A N D REVERSE
CLUTCH SUPPORT
1. Using tool J-23329 and drive handle J-8092, install di
rect clutch bushing (fig. 107M). RETAINER SPRING
TRA N SM ISSIO N R E A S S E M B LY
NOTE: Use only transmission oil or petroleum jelly

as lubricants to retain bearings or races during as- Fig. 108M --lnstalling Low and Reverse Clutch Support Assem bly

10. Install low and reverse roller clutch inner race to sun
gear shell thrust washer.
11. Install low and reverse clutch support to case snap ring
with anti-clunk spring between gap.
12. Install rear th ru st w asher and sun gear drive shell as
sembly.
13. Install output carrier assembly.
14. Install input ring gear rear thru st washer.
15. Install input ring gear.
16. Install input ring gear to output shaft snap ring.
CAUTION: Do not over stress snap ring.
17. Install input gear front th ru st washer.

18. Install direct clutch assembly, and special th ru st washer
to forw ard clutch assembly.
NOTE: 1st design uses thrust washer between for

ward and direct clutches. 2nd design uses Torington
Needle bearing. When replacing 1st design Forward
or Direct clutch housing, use 2nd design parts (Di
rect clutch, forward clutch housings and thrust
PUMP COVER TO DIRECT CLU
bearing). [SELECTIVE THRUST WASHER
19. Install clutch assemblies into case. Fig. 109M ~Pum p Cover to Direct Clutch Selective T hrust
W asher
CAUTION: Make certain forward clutch face plates
washer is being used. If the reading is not within
are positioned over input ring gear and the tangs on
limits, it will be necessary to remove the pum p and
direct clutch housing are installed into slots on the
change to a thicker or thinner selective fit thrust
sun gear drive shell.
washer, as required to obtain the specified clear
ance. Repeat the above checking procedure.
20. Install interm ediate clutch overrun brake band.
21. Install interm ediate clutch pressure plate.
NOTE: Selective fit thrust washers are available in
22. Oil and install face and steel interm ediate clutch plates,
thicknesses of .066", .083" and .100"
starting with a face plate and alternating steel and face.
NOTE: Notch in steel reaction plates is installed

toward selector lever inner bracket.
23. Install interm ediate clutch cushion spring.
Pump to Direct Clutch Thrust W asher

J-5294
Selection Procedure
To check for proper thickness of selective fit thrust
washer between the oil pum p cover and direct clutch assem
bly, proceed as follows:
a. Install selective fit thru st washer, (fig. 109) oil pump
gasket and using guide studs from J-3387 set install
oil pump. Install two pum p to case bolts.
b. Move transm ission so that output shaft points
down. M ount a dial indicator so th at plunger of
indicator is resting on end of the input shaft. J-5492
may be used to support the dial indicator as shown
in Figure 110M. Zero the indicator.
c. Push up on the transm ission output shaft and ob
serve the total indicator movement.
d. The indicator should read .032" to .064". If the Fig. 1 10M --C hecking End Play fo r Proper T hrust W asher
reading is within limits, the proper selective fit Selection

24. Install new pum p assembly in case gasket.

25. Install new pum p assembly to case square cut oil seal
ring.
26. Install guide pins into case.
27. Install pum p assembly into case. Install attaching bolts
with new washer type seals.
IMPORTANT: If the input shaft can not be rotated

as the pump is being pulled into place, the direct and
forward clutch housings have not been properly in
stalled to index the faced plates with their respec
tive parts. This condition must be corrected before
the pump is pulled into place.
Speedometer Drive Gear and Extension

1. Place speedom eter drive gear retaining clip into hole in
output shaft.
2. Align slot in speedom eter drive gear with retaining clip
and install. Install output shaft yoke sleeve assembly
and "O" ring in sleeve (fig. 111M).
3. Install extension housing to case square cut "O" ring
seal.
4. A ttach extension housing to case using attaching bolts. Fig. 1 12 M —Installing Extension Housing Seal
Torque to 25 ft. lb.
5. If necessary, install a new extension housing seal, using 5. Install parking pawl disengaging spring, square end
seal installer J-5154 (fig. 112M). hooked on pawl.
6. Install park lock bracket torque bolts to 29 ft. lb. see
Manual Linkage Figure 113M.
1. If necessary, install a new m anual shaft to case lip seal CAUTION: 290 M Bolts - 6 marks on head.
using 3/4" dia. rod, seat seal in case.
2. Install parking pawl, tooth tow ard the inside of case, 7. Install range selector inner lever to parking pawl actua
into case. tor rod.
3. Install parking pawl shaft into case and through park 8. Install actuating rod under the park lock bracket and
ing pawl. parking pawl.
4. Install parking pawl shaft retainer plug. Drive into case
using a 3/8" dia. rod, until retainer plug is .130"--. 170
below face of case, then stake in three places.
Fig. 1 1 1M --Installing O utput Shaft Yoke Seal Fig. 1 13M~Park Lock Bracket Special Bolt Ide ntification

9. Install m anual shaft through case and range selector 9. Connect detent control valve wire to detent valve ac
inner lever. tuating lever, then attach lever to valve body.
10. Install retaining nut on m anual shaft. Torque to 25 ft.

lbs. 10. Install detent roller and spring assembly to valve body.
11. Install strainer assembly gasket and strainer.

Intermediate Servo Piston, Valve Body,
Oil Pan and G asket
NOTE: Be sure lube holes in strainer match up with
those in valve body.
1. Install interm ediate servo piston, apply pin, spring and
spring seat. Check for proper apply pin selection using
tool J-23071 as shown on Figure 114M. Use long pin if
gauge is flush or below steel rule or short pin if gauge
is above steel rule. 12. Install oil pan using a new gasket. Tighten bolts to 130
. inch pounds in succession until bolts m aintain torque
specification.
2. Install interm ediate servo piston and m etal oil seal ring.
3. Install four (4) check balls into transm ission case pock
ets (fig. 18M).
Governor and Vacuum Modulator
4. Install oil pum p pressure screen and governor feed

screen. 1. Install governor assembly, cover and seal and retainer
wire.
5. Install valve body transfer plate and gasket assembly.
2. Install vacuum m odulator valve.
6. Install valve body to transfer plate gasket.
3. Install vacuum m odulator and retainer clip. Torque
7. Install valve body. Connect m anual control valve link bolt to 130 inch pounds.
to range selector inner lever. Torque bolts in random
sequence to 130 inch pounds.
NOTE: Position retainer with tangs pointing toward
8. Install spacer support plate, torque bolts to 130 inch modulator.
pounds.
Intermediate Clutch Accumulator

STEEL RULE
Refer to Figures 53M and 54M
1. Install interm ediate clutch accum ulator piston assem

bly.
2. Install interm ediate clutch accum ulator spring.
3. Install interm ediate clutch accum ulator cover and "O"

J-23071 ring seal using tool J-23069.
NOTE: Using a new' O" ring seal install seal in groove

Fig. 1 14M ~G auging fo r Proper A pp ly Pin Selection in case before installing cover.

TURBO HYDRA-MATIC 400 TRANSMISSION

INDEX
Transm ission Disassembly and Reassembly ............ 7-137 Sun G ear Shaft B ushing-Front.................................... 7-174
Disassembly of M ajor U n its........................................ 7-137 Sun G ear Shaft Bushing-Rear .................................... 7-174
G overnor, Speedometer Driven Gear, Pan, Filter M ain Shaft Inspection................................................... ... 7-174
and Intake Pipe ...................................................... 7-137 F ront and R ear Bands In sp e c tio n ............................ ... 7-174
Control Valve Assembly, Solenoid Connector, Case Extension .............................................................. ... 7-174
G overnor Pipes and D etent S p rin g................... 7-139 M odulator V alv e ............................................................ ... 7-175
R ear Servo, Valve Body Spacer, Gasket and M anual and Parking Linkage Inspection................. ... 7-175
F ront Servo............................................................... 7-141 Case Assembly Inspection .......................................... ...7-176
Band Apply Pin Selection........................................ 7-142 Case Assembly Bushing ............................................ ... 7-176
R ear Oil Seal and Extension H o u sin g ................... 7-143 Converter Inspection..................................................... ... 7-176
F ront U nit End Play Checking Procedure ........ 7-143 Converter End Clearance C h e c k ............................ ... 7-176
Oil Pum p and Internal Case C om ponents............ 7-144 Assembly of R ear U n it....................................................7-177
Rear End Play Checking Procedure ...................... 7-147 Case M odification-Corvette ...........................................7-181
G ear U nit A ssem bly................................................... 7-148 Assembly of U nits to Transmission Case ............... ...7-181
Speedometer Drive G ear............................................ 7-150 Install M anual Linkage............................................ ...7-184
G overnor Assembly ...................................................... 7-152 Rear Extension A ssem bly.............................................7-186
D isassem b ly I n s p e c tio n ......................................... 7-152 Check Balls, F ront Servo, Spacer and
Driven G ear Replacem ent ...................................... 7-152 S olenoid...........................................................................7-186
F ront Servo Parts In sp e c tio n ................................... 7-153 R ear Servo A ssem b ly ....................................................7-187
R ear Servo Parts Service .......................................... 7-154 Control Valve Assembly and G overnor Pipes.........7-188
Control Valve Service................................................... 7-155 Filter and Intake Pipe....................................................7-190
Oil Pum p Service .......................................................... 7-158 M odulator Valve and Valve and Vacuum
Forw ard Clutch S erv ice............................................... 7-162 M o d u la to r......................................................................7-190
Direct Clutch and Interm ediate Spag Service........ 7-165 G o v e rn o r...........................................................................7-190
Center Support S ervice................................................. 7-170 Speedometer Driven G ear.............................................7-191
Reaction Carrier, Low Roller and O utput Converter Assembly-Installation ............................ ...7-191
C arrier Assembly.......................................................... 7-172
Pinion Replacem ent ................................................... 7-173
O utput Shaft, Rear Internal Gear, Sun G ear
and S h a ft........................................................................ 7-174
D IS A S S E M B L Y OF M A JO R UNITS 4. Remove m odulator assembly attaching screw and re

tainer (fig. 3T).
1. W ith transm ission in cradle on portable jack, remove 5. Remove m odulator assembly and "O" ring seal from
converter assembly by pulling straight out. case (fig. 4T). Discard "O" ring.
NOTE: Converter contains a large amount of oil. 6. Remove m odulator valve from transmission case.
2. Install holding Fixture J-8763-01 on transmission so Removal of Governor, Speedometer

th at m odulator assembly will be located on side of hold
ing fixture nearest bench. Driven Gear, Pan, Filter and Intake Pipe
NOTE: Do not over-torque holding screw. This will 1. Remove attaching screws, governor cover and gasket
bind center support. (fig. 5T). Discard gasket.
2. W ithdraw governor assembly from case.
3. Install fixture and transm ission into holding Tool Base 3. Remove speedometer driven gear attaching screw and
J- 3289-14 with bottom pan facing up (fig. 2T). retainer (fig. 6 T).

Cross S e c tio n -T y p ic a l
Fig. 1T-Side

MODULATOR VALVE
Fig. 2T -T ransm ission in Holding Fixture VACUUM MODULATOR
Fig. 4T~Removing Vacuum M odulator and Valve
RETAINER
Fig. 5T--Removing Governor Cover A ttaching Screws
Fig. 3T~Removing M od ula tor Retainer 8. Remove intake pipe to case "O" ring seal from intake
pipe or case and discard.
4. W ithdraw speedom eter driven gear assembly from case.
Removal of Pressure Sw itch Assembly,
5. Remove bottom pan attaching screws, bottom pan and Control Valve Assembly, Solenoid
bottom pan gasket. D iscard gasket.
Connector, Governor Pipes, Governor
Screen Assembly, and Detent Spring
6. Remove the filter retainer bolt (fig. 7T).
Assembly
7. Remove filter and intake pipe assembly from case (fig. NOTE: CM Model transmission does not have Pres
8T) and discard filter. sure Switch (TCS).

F ig . 8 T — R e m o v in g F ilt e r A s s e m b ly a n d “ O ” R in g
Fig. 6T~Removing Speedom eter Driven Gear Retainer
ELECTRIC WIRE)
CLIP_______ I
PRESSURE SWITCH
ASM. ____ _
Fig. 7T~Removing F ilter Retainer Bolt

Fig. 8T-A--Disconnecting Pressure S w itch Lead W ire Assembly
1. Disconnect the lead wire assembly from the pressure

switch assembly (fig. 8T-A).
2. If necessary, remove the pressure switch assembly (fig. CAUTION: If transmission is in the vehicle, the front
8T- B). servo parts may drop out as the control valve assem
bly is removed.
3. Remove control valve body attaching screws and detent
roller and spring assembly (fig. 9T). 4. Remove control valve body assembly and governor
pipes (fig. 10T).
NOTE: Do not remove solenoid attaching screws. CAUTION: Do not drop manual valve.

GOVERNOR CONTROL VALVE

PIPES ASSY.
(PRESSURE SWITCH
ASM.______________
Fig. 10T--Removing C ontrol Valve Assembly and Governor

Pipes from Case
Fig. 8T-B~Removing Pressure Sw itch
GOVERNOR SCREEN
ASSY.
GOVERNOR FEED
PIPE HOLE
Fig. 10T-A -R em oving G overnor Screen Assem bly
Removal of Rear Servo, Valve Body

Fig. 9T--Removing Detent Roller and Spring Assem bly Spacer, Gasket and Front Servo
5. Remove governor screen assembly from governor feed 1. Remove rear servo cover attaching screws, servo cover
pipe hole in the case or from end of governor feed pipe and gasket. Discard gasket (fig. 1IT).
(fig. 10T-A). Clean governor screen in clean solvent and
air dry.
2. Remove rear servo assembly from case (fig. 12T).
6. Remove governor pipes from control valve assembly.

3. Remove rear servo accum ulator spring.
7. Disconnect solenoid lead from connector term inal (fig. 4. M ake band apply pin selection check to determine poss
10-A). ible cause of m alfunction (fig. 13T).

REAR SERVO
ASSEMBLY
Fig. 1 2T--Removing Rear Servo Assem bly
Fig. 10T-B--Disconnecting Lead W ires from Term inal

TORQUE
WRENCH
370-6
o,
Fig. 13T--Checking Rear Band Pin
b. Apply 25 ft. lb. torque and select proper pin to be

used during assembly of transmission.
Selecting proper length pin is equivalent to adjusting
band. The band lug end of each selective apply pin bears
Fig. 1 1T-Rem oving Rear Servo Cover A tta chin g Bolts indentification in the form of one, two or three rings.
c. If both steps of J-2 1370-5 are below the gauge sur
Rear Band Apply Pin Selection face, the long pin, identified by 3 rings, should be
used.
d. If the gauge surface is between the steps, the
a. A ttach band apply pin selection Gauge J-2 1370-5 medium pin, identified by 2 rings, should be used.
and J-2 1370- 6 to transm ission case with attaching
screws checking to m ake certain the gauge pin does e. If both steps are above the gauge surface, the short
not bind in servo pin hole (fig. 13T). pin, identified by 1 ring, should be used.

SERVO PISTON
RETAINER RING
GASKET
SERVO PIN
SERVO SPRING SERVO PISTON
RETAINER SPRING___ S
Fig. 14T-R em oving Detent Solenoid and Gasket Fig. 16T~Removing Front Servo Piston, Retainer Ring, and Pin
Removal of Rear Oil Seal and Extension

Housing
ELECTRICAL CONNECTOR 1. If necessary to replace, pry rear oil seal from extension
housing @ 1-2
2. Remove extension housing to case attaching bolts.
3. Remove extension housing and extension housing to

case gasket (fig. 18T).
4. M ake front unit end play check as follows: (fig. 19T).
Front Unit End Play Checking Procedure
a. Remove one front pum p attaching bolt, and bolt

Fig. 1 5T--Removing Case Electrical C onnector Sleeve and seal. (See Figure 19T for location).
"0''R ing
b. Install a 3/8"-16 threaded slide ham m er bolt or

NOTE: If the transmission is in the vehicle, be care J-9539, into bolt hole.
ful when the detent solenoid is removed as it pre
vents the spacer plate and gasket and check balls
from dropping down.
5. Remove solenoid attaching screws, solenoid assembly

and gasket (fig. 14T).
6. W ithdraw electrical connector and "O" ring seal (fig.

15T).
7. Remove control valve assembly spacer plate and gasket.
8. Remove six ( 6) check balls from cored passages in

transm ission case.
9. Remove front servo piston, retainer ring, washer, pin,

spring retainer and spring from transmission case (fig.
16T). Fig. 1 7T--Removing Rear Oil Seal from Case Extension

Thickness Color
.060 - .064 Yellow
.071 - .075 Blue
.082 - .086 Red
.093 - .097 Brown
.104 - .108 Green
.115 - .119 Black
.126 - .130 Purple
NOTE: An oil soaked washer may tend to discolor,

so it will be necessary to measure washer for its
actual thickness.
Removal of Oil Pump and Internal Case

Components
1. If necessary to replace, pry front seal from pum p (fig.
20T).
2. Remove pum p attaching bolts.

Fig. 18T~Case Extension and Gasket
3. Install two 3/8"-16 threaded slide ham m er bolts, J-
9539 with weights J-6585-01, into bolt holes in pump
body and remove pum p assembly from case (fig. 2 IT).
(See illustration for location of threaded holes.)
4. Remove and discard pum p to case seal ring and gasket.
5. Remove forw ard clutch assembly and turbine shaft

from transm ission (fig. 2 2 T ).
6. Remove forward clutch hub to direct clutch housing

thrust washer, if it did not come out with forward
clutch housing assembly.
Fig. 19T~Checking Front U nit End Play
c. M ount a dial indicator on rod and index indicator

to register with end of turbine shaft.
d. Push on turbine shaft rearward.
e. Push output shaft forward.
f. Set dial indicator to Zero.
g. Pull turbine shaft forward.
R ead resulting travel or end play. Should be .003"-.024".

Selective washer controlling this end play is the washer
located between pum p cover and forw ard clutch housing. If
more or less washer thickness is required to bring end play
with specifications, select proper washer from the following
chart: Fig. 20T~Rem oving Front Seal

Fig. 23T--Removing D irect Clutch Assem bly
Fig. 24T~Rem oving M anual S haft Retaining Pin from Case
CAUTION: Do not lose jam nut as it becomes free

from manual shaft.
c. Remove m anual shaft and jam nut from case (fig.

25T).
Fig. 22T~Rem oving Forward Clutch Assem bly and Turbine
Shaft NOTE: Manual shaft should NOT be removed from
the case unless replacement is required.
7. Remove direct clutch assembly (fig. 23T).
NOTE: If necessary, remove manual linkage as fol d. Remove parking actuator rod and detent lever as
lows: sembly.
a. U nthread jam nut holding detent lever to m anual e. Remove attaching screws and parking bracket (fig.
shaft. 26T).
b. Rem ove m anual shaft retaining pin from case (fig.
24T). f. Remove parking pawl return spring (fig. 27T).

RETAINING
SPRING
SHAFT
Fig. 28T-R em oving Parking Shaft Retaining Spring
Fig. 25T~Rem oving Detent Lever and Jam Nut from Manual
h. Remove parking pawl shaft cup plug by inserting a
S haft
screwdriver, between the parking pawl shaft and the
case rib, and prying outw ards (fig. 29T).
i. Remove parking pawl shaft and parking pawl (fig.

29T).
8. Remove front band assembly (fig. 30T).
9. Remove sun gear shaft (fig. 3 IT).
Fig. 26T~Rem oving Parking Bracket
RETURN SPRING
Fig. 27T--Removing Parking Pawl Return Spring
NOTE: The following steps are to be completed only

if 1 or more of the parts involved require replace
ment.
g. Remove parking pawl shaft retainer (fig. 28T). Fig. 29T~Rem oving Parking Brake Pawl, S haft and Cup Plug

DIAL INDICATOR
J-9539
Fig. 32T~C hecking Rear Unit End Play
If a different washer thickness is required to bring end

play within specification, it can be selected from the follow
ing chart.
Fig. 30T~Rem oving Front Band Identification__________
Thickness N otches a n d /or Numeral
.074 - .078 N one ......................... I
.082 - .086 1 T ab S i d e ..............2
.090 - .094 2 T ab Side ..............3
.098 - .102 1 T ab O .D ............... 4
.106 - .1 1 0 2 Tabs O .D ..............5
.114 - .118 3 Tabs O .D .............. 6
10. Remove center support to case bolt (fig. 33T), using a
3/8" 12-point thin wall deep socket.
11. Remove interm ediate clutch backing plate to case snap
ring.
Fig. 31 T~Removing Sun Gear S hift
Check Rear End Play as Follows (Fig.

32T)
a. Install J-9539 or a 3/8"-16 threaded bolt into an
extension housing attaching bolt hole (fig. 32T).
b. M ount a dial indicator on rod and index with end
of output shaft.
c. Move output shaft in and out to read end play. End
play should be from .007"-.019". Selective washer
controlling this end play is a steel washer having 3
lugs th at is located between output shaft thrust
w asher and rear face o f transm ission case. Fig. 3 3 T -C e n te r Support Locating B olt

12. Remove interm ediate clutch backing plate, three (3) 16. Place gear unit assembly, with output shaft facing down
composition, and three (3) steel clutch plates (fig. 34T). through hole in work bench or Holding Fixtures J-6116
with J-21364 adapter.
13. Remove center support to case retaining snap ring (fig.
35T). 17. Remove rear unit selective washer from transmissions
case (fig. 37T).
14. Remove entire gear unit assembly by lifting with gear
assembly installing and removing Tool J-21795 with 18. Remove support to case spacer (fig. 129T-A).
J-9539 slide ham m er (fig. 36T).
19. Remove rear band assembly (fig. 38T).
15. Remove output shaft to case thru st washer from rear of
output shaft or inside case.
Disassembly of Gear Unit Assembly
t 1. Remove center support assembly (fig. 39T).
BACKING PLATE
..
\ H
COMPOSITION PLATES (3)
STEEL PLATES (3)
Fig. 34T--Removing Interm ediate Backing Plate and Clutch

Plates
Fig. 36T -R em oving Center S upport and Gear U nit from Case
Fig. 35T-R em oving Center S upport to Case Snap Ring Fig. 37T-R em oving Selective W asher

CENTER SUPPORT
T O CASE SPACER ROLLER
CLUTCH
/ LOCATE SPACER G A P
ADJACENT TO
1 B A N D A N C H O R PIN
F ig . 3 7 T A — R e m o v in g S u p p o r t t o Case S pacer
Fig. 39T~Rem oving Center Support Assem bly

R
ID
5. Remove front internal gear ring from output carrier
assembly.
6. Remove sun gear (fig. 42T).
THRUST WASHER
Fig. 38T~Rem oving Rear Band
2. Remove center support to reaction carrier, thrust

w asher (fig. 40T).
3. Remove center support to sun gear races and thrust

bearing.
NOTE: One race may have been removed with cen

ter support.
CONSTANT BLEED
ORIFICE PLUG
4. Remove reaction carrier and roller clutch assembly (fig.

4 IT). Lift roller clutch assembly out of carrier. Fig. 40T--Removing Center S upport T hrust W asher

ROLLER CLUTCH
SNAP RING
ASSEMBLY
REACTION
CARRIER
SUN
GEAR
PLASTIC GEAR
RING
OUTPUT Fig. 43T~Rem oving O utput S haft to C arrier Snap Ring

CARRIER
13. Remove rear internal gear and m ainshaft (fig. 46T).
NOTE: Do not drop bearings.

Fig. 4 1T--Removing Reaction C arrier and Roller Clutch from
O utpu t C arrier 14. Remove rear internal gear to sun gear thrust bearing
and two ( 2 ) races.
15. If necessary, remove rear internal gear to mainshaft
snap ring, to remove m ainshaft (fig. 47T).
Speedometer Drive Gear
NOTE: If removal and installation or replacement of

the Speedometer Drive Gear is necessary, proceed
as follows:
Fig. 42T~Rem oving Sun Gear
7. Remove reaction carrier to output carrier thrust

washer.
8 . T urn assembly over.
9. Remove "O" ring from output shaft of models th at use
and "O" ring.
10. Remove output shaft to output carrier snap ring (fig.
43T).
11. Remove output shaft.
12. Remove o utput shaft to rear internal gear thru st bear
ing and two ( 2 ) races. Fig. 44T-R em oving Speedom eter Drive Gear

SPEEDOMETER DRIVE
GEAR CLIP
Fig. 45T-B --lnstalling Speedom eter Drive Gear (steel)

Fig. 45 T --lnstalling Speedom eter Drive Gear Clip
NOTE: The nylon speedometer drive gear is installed
Transm issions W ith Nylon Speedometer Drive at the factory only. ALL service replacement speed
ometer drive gears are STEEL. When replacing the
Gear nylon speedometer drive gear with a steel gear, dis
card the retaining clip and proceed as indicated in
1. D epress retaining clip and slide gear off output shaft Step" b" .
(Fig. 44T).
2. To install, place retaining clip (square end toward
flange of shaft) into hole in output shaft (fig. 45T).
Align slot in speedometer drive gear with retaining clip REAR INTERNAL GEAR
and install gear.
Fig. 45T-A--Removing Speedom eter Drive Gear (steel) Fig. 46T--Removing Rear Internal Gear and M ainshaft

Fig. 48T~G overnor~Exploded
3. Perform following inspections and replace governor

driven gear, if necessary.
Inspection
1. W ash all parts in cleaning solvent, air dry and blow out
all passages.
2. Inspect governor sleeve for nicks, burrs, scoring or gall
ing.
Ring
3. Check governor sleeve for free operation in bore of
transm ission case.
Transmissions With Steel 4. Inspect governor valve for nicks, burrs, scoring or gall
Speedometer Drive Gear ing.
a. Install speedom eter drive gear rem oving Tool J- 5. Check governor valve for free operation in bore of gov
21427-01 and J-9539 bolts with J-8105 or suitable ernor sleeve.
puller on output shaft, and remove speedometer 6. Inspect governor driven gear for nicks, burrs, or dam
drive gear (fig. 45T-A). age.
b. Install new steel speedometer drive gear and drive 7. Check governor driven gear for looseness or governor
to location (5 43/64" below end of output shaft for sleeve.
all models except "CA" and "C R ") (11 29/64 below 8. Inspect governor weight springs for distortion or dam
end o f output shaft for models "CA" and "C R ") age.
using J-5590 (fig. 45T-B). 9. Check governor weights for free operation in their re
tainers.
10. Check valve opening at entry (.020" minim um ) with a
GOVERN OR A S S E M B L Y
feeler gage, holding governor as shown with governor
All com ponents of governor assembly, with exception of weights extended completely outw ard (fig. 48T-A).
driven gear, are a select fit and each assembly is calibrated. 11. Check valve opening at exhaust (.020" minim um ) with
The governor, including the driven gear, is serviced as a a feeler gauge, holding governor as shown with gover
complete assembly. However, the driven gear can also be nor weights completely inward (fig. 48T-B).
It is necessary to disassemble governor assembly in order Governor Driven Gear Replacement
to replace driven gear. Disassembly may also be necessary
To facilitate governor repair in the field, a governor driven
due to foreign m aterial causing im proper operation. In such
gear and replacement pins are available for service use. The
cases, proceed as follows:
service package contains a nylon driven gear, two governor
weight retaining pins and one governor gear retainer split
Disassem bly
pin. Replacem ent of gear must be perform ed with care in the
1. Cut off one end of each governor weight pin and remove following manner:
pins, governor thrust cap, governor weights, and 1. Drive out governor gear retaining split pin using small
springs. Governor weights are interchangeable from punch (fig. 49T).
side to side and need not be identified, (fig. 48T). 2. Support governor on 7/64 inch plates installed in ex
2. Remove governor valve from governor sleeve. Be care haust slots of governor sleeve, place in arbor press, and
ful not to damage valve. with a long punch, press gear out of sleeve.
Fig. 48T-A~Checking Valve O pening W ith W eig hts O utward Fig. 49T--Rem oving G overnor Gear Retaining Pin
3. Carefully clean governor sleeve of chips that remain new pin hole m ust be drilled through sleeve and gear. Lo
from original gear installation. cate hole position 90 degrees from existing hole, center
punch and then, while supporting governor in press,
4. Support governor on 7 /6 4 inch plates installed in ex
drill new hole through sleeve and gear using a standard
haust slots of sleeve, position new gear in sleeve and,
( 1 /8 inch) drill.
w ith a suitable socket, press gear into sleeve until nearly
6 . Install split retaining pin.
seated. Carefully remove any chips th at may have
7. W ash governor assembly thoroughly to remove any
shaved off gear hub and press gear in until it bottom s
chips th at may have collected.
on shoulder.
Assem bly
1. Install governor valve in bore of governor sleeve, large
end first.
2. Install governor weights and springs, and thrust cap on
governor sleeve.
3. Align pin holes in thrust cap, governor weight assem
blies and governor sleeve, and install new pins. Crim p
both end of pins to prevent them from falling out.
4. Check governor weight assemblies for free operation on
pins.
5. Check governor valve for free movement in governor
sleeve.
Front Servo Parts Inspection
NOTE: See figure 50T. Do not remove the teflon oil

seal ring from the front servo piston unless the oil
seal ring requires replacement. For service, the oil
seal ring is aluminum.
CAUTION: The spring retainer, servo pin, retainer

ring and servo piston are new for 1971. These in
dividual parts are not interchangeable with pre-
Fig. 48T-B~Checking Valve O pening W ith W e ig h t Inward 1971 parts.

Fig. 5 0 T -F ro n t Servo Assem bly-E xploded V iew
1. Inspect servo pin for damage. 2. Remove "E" ring retaining rear servo piston to band
and apply servo pin (fig. 5 IT).
2. Inspect piston and oil ring for damage.
3. Remove rear servo piston and seal from band and apply
3. Check fit of servo pin in piston and case bore. servo pin (fig. 52T). (Exploded view).
4. Remove washer, spring, and retainer.

Disassembly of Rear Servo Assembly
Inspection
1. Remove rear accum ulator piston from rear servo piston
(fig. 50T-A). 1. Inspect freedom of accum ulator rings in piston.
“ E” RING
Fig. 50T-A-R em oving Rear A ccum u lato r Piston from Rear Fig. 5 1 T — Rem oving Retaining “ E ” Ring fro m
Servo Assem bly Rear Servo Pin

RETAINING
"E ” RING
SERVO PISTON \
SERVO PIN
Fig. 52T~Rear Servo and A ccum u lato r A ssem bly-E xploded V iew
2. Inspect fit of band apply pin in servo piston in case bore. 4. Remove front accum ulator piston and spring (fig. 54T).
3. Inspect band apply servo pin for scores or cracks.
4. Inspect accum ulator and servo pistons for scoring, NOTE: No front accumulator spring used in CY
cracks or porosity. model.
5. On the right side adjacent to the m anual valve, remove
Reassem bly the 1-2 valve train as follows:
1. Install spring retainer cup side down, spring and washer
on band apply pin.
2. Install band apply servo pin, retainer, spring and
washer, into bore of servo piston and secure with "E"
ring.
3. Install oil seal ring on servo piston, if removed.
4. Install outer and inner oil rings on accum ulator piston,
if removed, and assemble into bore of servo piston.
CO N TRO L V A LV E, D IS A S S E M B LY ,
IN SPECTIO N AND RE A S S E M B L Y (Fig.
55T)
Passenger Cars
Disassem bly
1. Position control valve assembly with cored face up and
accum ulator pocket nearest operator.
2. Remove m anual valve from upper bore.
3. Install Special Tool J-2 18 85, on accum ulator piston and Fig. 5 3 T -ln s ta llin g Com pressor Tool to Front A ccum ulator
remove retaining ring (fig. 53T). Piston

a. (Models CD, CK , CM and CY) Remove retaining

pin, 1-2 m odulator bushing, 1-2 valve spring, 1-2
m odualtor valve and 1-2 shift valve.
b, (Models CA, CF, CJ, C R and CS) Remove retain
ing pin, 1-2 m odulator bushing, 1-2 regulator valve,
1-2 regulator spring, 1-2 de+*nt valve, and 1-2 shift
valve.
6. From next bore down, remove retaining pin, 2-3 shift
valve spring, m odulator valve bushing, 2-3 m odulator
valve, 3-2 interm ediate spring, and 2-3 shift valve.
7. From next bore dow n remove retaining pin, bore plug,
spring, spacer, and 3-2 valve.
ACCUMULATOR PISTON
8. A t other end of assembly, top bore, remove retaining
pin and bore plug, detent valve, detent regulator valve, Fig. 54T--Front Servo A ssem bly-E xploded View
spring and spacer.
9. From the next bore down, remove the 1-2 accum ulator
Valve train as follows: valve bore and install grooved retaining pin from
a. (M odel CY) Rem ove the grooved retaining pin, the cast surface side of the valve body, with the
bore plug and 1-2 accum ulator valve. grooves entering the pin hole last. Tap pin with a
b. (M odels CM ) Rem ove the grooved retaining pin, ham m er until flush with cast surface.
bore plug, 1-2 accum ulator valve and spring. b. (M odel CM ) Install the 1-2 accum ulator spring and
c. (M odels CA, C D and C K ) Remove the grooved 1-2 accum ulator valve, stem end out, into bore.
retaining pin, bore plug, 1-2 secondary spring, 1-2 Place the bore plug into valve bore and install
accum ulator valve, 1-2 accum ulator bushing, 1-2 grooved retaining pin from the cast surface side of
prim ary accum ulator valve and prim ary spring. the valve body, with the grooves entering the pin
d. (M odels CF, CJ, C R and CS) Remove the grooved hole last. Tap pin with a ham m er until flush with
retaining pin, bore plug, 1-2 accum ulator secondary cast surface.
spring and 1-2 accum ulator valve. c. (Models CA, CD, and CK) Install the 1-2 prim ary
accum ulator spring and valve into the valve bore
using a retaining pin as a tem porary retainer to hold
Inspection the spring and valve in their operating position.
Install the 1-2 secondary accum ulator valve, stem
NOTE: See figure 54T. Do not remove the teflon oil end out, and the 1-2 secondary spring into the 1-2
seal ring from the front accumulator piston unless accum ulator valve bushing. Install the bushing into
the oil seal ring requires replacement. For service, the bore and using the bore plug, compress the
the oil seal ring is cast iron. spring until the grooved retaining pin can be in
serted from the cast surface side of the valve body
w ith the grooves entering the pin hole last. Tap the
retaining pin with a ham m er until it is flush w ith the
CAUTION: The front accumulator piston is new for cast surface of the valve body. Remove the tem po
1971, and it is not interchangeable with the pre 1971 rary retainer pin.
piston. d. (Models CF, CJ, CR and CS) Install the 1-2 ac
cum ulator valve, stem end out, and 1-2 accum ulator
1. Inspect all valves for scoring, cracks and free movement secondary spring. Install the bore plug and com
in their respective bores. press spring until grooved retaining pin can be in
2. Inspect bushings for cracks, scratches or distortion. serted from the cast surface side of the valve body.
3. Inspect body for cracks, or scored bores. Install retaining pin with the grooved end entering
4. Check all springs for distortion or collapsed coils. the pin hole last and tap in place until flush with cast
5. Inspect accum ulator piston and oil seal ring for dam surface of the valve body.
age. 4. In next bore up, install detent spring and spacer. Com
press spring and secure with small screw driver (fig.
56T).
Reassem bly 5. Install detent regulator valve, wide land first.
6. Install detent valve, narrow land first.
1. Install front accum ulator spring and piston into valve 7. Install bore plug (hole out), depress spring by pressing
body. in on plug, install retaining pin, and remove screw
2. Install Special Tool J-2 1885 and compress spring and driver.
piston and secure with retaining "E" ring. 8. In lower right hand bore, install 3-2 valve.
3. Install the 1-2 accum ulator valve train into the lower 9. Install 3-2 spring, spacer, bore plug (hole out) and re
left hand bore as follows: taining pin.
a. (M odel CY) Install the 1-2 accum ulator valve, stem 10. In next bore up, install the 2-3 shift valve, open end out,
end out, into valve bore. Place the bore plug into into the bore and install 3-2 interm ediate spring.

71-CJ-1001 thru 71-CJ-l 677 145 thru 218

' MODELS CF, CJ, CR & CS j
Fig. 55T--Control Valve Assem bly-E xploded V iew
1. Manual Valve 10. 1-2 Regulator Valve 17. 1-2 Primary 26. 3-2 Valve Spring
2. Retaining Pin Spring A ccum u lato r Spring 27. Bore Plug
3. Bore Plug 10a. 1-2 M od ula tor Valve 18. 2-3 S hift Valve 28. Retaining Pin
4. Detent Valve Spring 19. 3-2 Interm ediate 29. 1-2 A ccum ulator
5. Detent Regulator 1 1. 1-2 Regulator Valve Spring Valve Sec. Spring
Valve 12. 1-2 M od ula tor 20. 2-3 M od ula tor Valve 30. 1-2 A ccum ulator
6. Spacer Bushing 21. 2-3 S hift Valve Valve
7. Detent Regulator 13. Retaining Pin Spring 31. 1-2 A ccum ulator
Valve Spring 14. Retaining Pin 22. 2-3 M od ula tor Valve Bushing
8. 1-2 S h ift Valve 15. Bore Plug Bushing 32. 1-2 A ccum ulator
9. 1-2 Detent Valve 16. 1-2 A ccum ulator 23. Retaining Pin Primary Valve
9a. 1-2 M od ula tor Valve Valve 24. 3-2 Valve 33. 1-2 A ccum ulator
25. Spacer Prim ary Valve Spring
11. Install 2-3 m odulator valve into bushing and install

both parts into valve body bore.
12. Install 2-3 valve spring and retaining pin.
13. In next bore up, install 1-2 valve, stem end out.
14. a. (Models CB, CD , C F, CG , CK , CR, CS, CW, CY,
and CZ) Install the 1-2 valve spring and 1-2 m odulator
valve into the 1-2 m odulator bushing, aligning the
spring in the bore of the m odulator valve. Install parts
into the valve body bore.
b. (Models CA, CJ and CP) Install the 1-2 regulator
valve, large stem first, regulator spring, and 1-2 de
tent valve open hole first into the 1-2 m odulator
bushing, aligning the spring in the bore of the detent
valve. Install the parts in the valve body bore.
15. Compress bushing against spring and install retaining
pin.
16. Install m anual valve w ith detent pin groove to the right. Fig. 5 6 T -ln s ta llin g Detent R egulator Valve and Detent Valve

CLUTCHES A N D TR A N SM ISSIO N S 7-158
VENT
CONVERTER
DRIVE M ODULATOR OR
INTERMEDIATE
REVERSE
COOLER
RETURN EXHAUST
TO
COOLER
TO
COOLER INTAKE
COOLER
RETURN
BREATHER
HOLE
INTAKE
REVERSE CONVERTER
DRIVE PRESSURE REGULATOR IINip '

MODULATOR OR
FEED HOLE VENT COVER-PUMP
INTERMEDIATE
Fig. 57T~Pum p Body Oil Passages Fig. 58T~Pump Cover Oil Passages
Oil Pump Disassembly, Inspection and 10. Remove pum p to forward clutch housing selective
washer.
Reassembly
11. M ark drive and driven gears for reassembly in same
position and remove from the pum p body.
Disassem bly
Inspection of Pump Body and Pump Cover

1. Place oil pum p assembly in hole in bench or holding
fixture, J-6116 with J-21364 adapter.
2. Com press regulator boost valve bushing against pres NOTE: The 1971 solid type pressure regulator valve
does not contain oil holes and an orifice cup plug like
sure regulator spring and remove snap ring, using J-
5403 pliers (fig. 60T). the previous pressure regulator valve. The solid
style valve must only be used in the pump cover with
the squared pressure regulator boss. (Pressure
3. Remove regulator boost valve bushing and valve. boost bushing end.) See figure 64T. The previous
pressure regulator valve with the oil holes and ori
fice cup plug may be used to service either type
4. Remove pressure regulator spring. pump cover.
5. Remove regulator valve, spring retainer and spacer(s), 1. Inspect drive and driven gear pocket and crescent for
if present (fig. 6 IT). scoring, galling or other damage.
2. Place pum p gears in pump body and check pum p body

6. Remove pum p cover to body attaching bolts. face to gear face clearance, should be .0008" - .0035"
(fig. 65T).
7. Remove pum p cover from body.
3. Check face of pum p body for scores or nicks.
8. Remove retaining pin and bore plug from pressure 4. Check oil passages (fig. 57T).
regulator bore (fig. 62T.
5. Check for damaged cover bolt attaching threads.
9. Remove hook type oil rings from pum p cover. 6. Check for overall flatness of pum p body face.

RETAINING PIN
BORE PLUG
PRESSURE REGULATOR VALVE

PRESSURE REGULATOR SPACER
SPRING RETAINER WASHERn
PRESSURE REGULATOR SPRING PUMP COVER

PRESSURE BOOST VALVE THRUST WASHER
PRESSURE BOOST BUSHING PUMP OIL SEAL RINGS
SNAP RING
Fig. 59T~Pump C over-Exploded V iew
REGULATOR BOOST VALVE

SNAP RING
BUSHING A N D VALVE
REGULATOR SPRING
PUMP ASSEMBLY
Fig. 60T~Removing Pump R egulator Valve Snap Ring Fig. 61T-R em oving Pressure Regulator Valve

RETAINING
PIN
PUMP C O V ER
BORE PLUG
PUMP COVER
FOR ID E N T IF IC A T IO N -
SQ U A R ED O FF PRESSURE
REG. BO SS.
Fig. 6 2 T -ln s ta llin g Pressure R egulator Retaining Pin and Bore

Plug
Fig. 64T~Pressure Regulator Valve Id e n tifica tio n
7. Check bushing for scores or nicks. If replacem ent is 8. Inspect pum p attaching bolt seals for damage, replace
necessary proceed as follows: if necessary.
a. Using Tool J-21465-17 and driver H andle J-8092 9. Inspect pum p cover face for overall flatness.
remove bushing. 10. Check for scores or chips in pressure regulator bore.
b. F rom front side of pum p, using J-21465-17 and 11. Check th at all passages are open and not interconnected
driver H andle J 8092 install new bushing flush to (fig. 58T).
.0 1 0 " below gear pocket face. 12. Check for scoring or damage at pum p gear face.
13. Inspect stator shaft for damaged splines, or scored
bushings. If replacem ent of bushing is necessary pro
ceed as follows:
Front
a. W ith pum p cover and stator shaft properly sup
PUMP DRIVE GEAR
(TA N G S UP)
ported, using Tool J-21465-15, with slide ham m er
PUMP
PUMP DRIVEN
BODY
Fig. 63T--lnstalling Pump Drive Gear Fig. 65T~C hecking Pump Body Face to Gear Face Clearance

tool J-2619, and adapter Tool J- 2619-4 remove

bushing.
b. Using Tool J-2 1465-3 with D river H andle J-8092

press or drive replacem ent bushing into place until
tool bottoms.
Rear
c. W ith pum p and stator shaft properly supported,

using Tool J-2 1465-15, with slide ham m er Tool J-
2619 and adapter tool J-2619- 4, remove bushing.
d. Using Tool J-2 1465-2 with D river H andle J-8092,

press or drive replacem ent bushing into place until
tool bottoms.
14. Inspect oil ring grooves for dam age or wear.
15. Inspect selective w asher th ru st face for wear or damage. Fig. 6 6 T ~ ln sta llin g Pump Cover to Pump Body
16. Inspect pressure regulator and boost valve for free oper
ation in their respective bores. NOTE: Leave bolts one turn loose at this time.
17. Inspect pum p cover for open 1/8" breather hole (fig. 11. To align the pum p body and cover, place the pump
58T). assembly, less rubber seal ring, upside down into the
pum p bore of the case (fig. 66 T).
12. Tighten pum p cover bolts to 18 foot pounds. Remove

pum p assembly from case bore.
Reassem bly
13. Install pum p to case "O" ring seal.
1. Install d riv e‘and driven pum p gears with alignment
m arks up into pum p body (fig. 63T) drive gear tangs up.
2. Protect stator shaft and install pum p cover in vise.
3. Install spacer(s) if used, retainer and spring, into pres

sure regulator bore (fig. 59T).
4. Install pressure regulator valve from oppostie end of

bore, stem end first.
5. Install boost valve into bushing, stem end out, and in
stall both parts into pum p cover by compressing bush
ing against spring.
6. Install retaining snap ring.
7. Install pressure regulator valve bore plug and retaining

pin into opposite end o f bore.
8. Install previously selected front unit selective thrust

w asher over pum p cover delivery sleeve.
9. Install two (2) hook type oil seal rings.
10. Assemble pum p cover to pum p body with attaching Fig. 67T-R em oving Forward Clutch Housing to D irect Clutch
bolts. Hub Snap Ring

FORWARD
CLUTCH HUB
THRUST
WASHERS
FORWARD CLUTCH
HOUSING
Fig. 68T~Rem oving Forward Clutch Hub and T hrust W ashers
FORW ARD CLU TCH D ISA SSEM BLY,

INSPECTION AND RE-ASSEM BLY
Fig. 70T--Removing Forward Clutch Spring Retaining Snap
Disassembly Ring
1. Place forw ard clutch assembly with turbine shaft 5. If necessary place forward clutch and turbine shaft in
through hole in bench or Holding Fixture J-6 116, and arbor press and remove turbine shaft (fig. 69T).
remove forward clutch housing to direct clutch hub 6. Using J-4670 clutch spring com pressor in arbor press
snap ring (fig. 67T). with A dapter J-2 1664, compress spring retainer and
2. Remove direct clutch hub. remove snap ring (fig. 70T).
3. Remove forw ard clutch hub and thru st washers (fig. 7. Remove spring retainer and sixteen (16) clutch release
68 T). springs.
4. Remove five (5) radial grooved composition and five (5)
steel clutch plates. NOTE: Keep springs separate from direct clutch re
lease springs.
8. Remove forward clutch piston.

9. Remove inner and outer clutch piston seals (fig. 7 IT).
BOLT
FORWARD CLUTCH PISTON
TURBINE SHAFT
CLUTCH OUTER SEAL
Fig. 69T--Removing T urbine S haft from Forward Clutch

Housing Fig. 7 1T--Removing Forward Clutch Piston O uter Seal

3. Inspect clutch hubs for worn splines, proper lubrication

FORWARD CLUTCH H O U S IN G holes or scored thrust faces.
4. Inspect piston for cracks.
5. Inspect clutch housing for wear, scoring, open oil pas
sages and free operation of ball check.
6 . Inspect turbine shaft.
a. Inspect for open lubrication passages at each end.
b. Inspect splines for damage.
c. Inspect ground bushing journals for damage.
d. Inspect shaft for cracks or distortion.
NOTE: Turbine shaft and clutch housing are ser

viced separately. Shaft may be removed from hous
ing by using a suitable size socket in an arbor press
(fig. 69T).
Reassem bly
CLUTCH CENTER SEAL
NOTE: The Turbo Hydra-Matic forward and direct
Fig. 72T~Rem oving Forw ard Clutch Center Seal clutch pistons have identical inside and outside
diameters. It is possible to reverse the pistons dur
10. Remove center piston seal from forw ard clutch housing ing reasembly, therefore, care should be exercised
(fig. 72T). to make certain the proper piston be installed in the
clutch assemblies. As shown in Figure 89T, the di
Inspection rect clutch piston can be identified by the check ball.
1. Inspect com position-faced and steel clutch plates for

signs of burning, scoring or wear.
2. Inspect sixteen (16) springs for collapsed coils or signs Place new inner and outer oil seals on clutch piston, lips
o f distortion. face away from spring pockets (fig. 7 IT).
FORWARD CLUTCH
ASSEMBLY
FLAT STEEL FORWARD DIRECT SNAP

PLATES (4) CLUTCH HUB CLUTCH HUB RING
WAVED
STEEL
PLATE
COMPOSITION
PLATES (5) THRUST
WASHERS
Fig. 73T~Forw ard Clutch A ssem bly-E xploded V iew

J-21362
Fig. 7 4 T -ln s ta llin g Forward Clutch Piston Fig. 7 5 T ~ ln sta llin g Forward Clutch Com position and Steel
Plates
2. Place a new center seal on clutch housing, lip faces up CAUTION: Do not confuse the flat steel clutch plate
(fig. 72T). (plate with “ V" notch) with the waved steel clutch
plate (plate with "U" notch). (See Fig. 76T).
NOTE: Radially grooved composition clutch plates

NOTE: Apply automatic transmission oil to all seals
are installed at the factory only. All service composi
and clutch plates.
tion plates have the smooth surface configuration.
3. Place seal protector Tool J-2 1362, over clutch hub and 11. Install direct clutch hub and retaining snap ring (fig.
install outer clutch piston seal Protector J-2 1409, into 77T).
clutch drum and install piston, rotating piston on drum
until seated (fig. 74T).
4. Install sixteen (16) clutch release springs into pockets

in piston.
5. Place spring retainer and snap ring on springs.
6. Compress springs in arbor press, using clutch com pres

sor Tools J-4670 and J -2 1664, install snap ring.
7. If removed, install turbine shaft in forw ard clutch hous

ing, using arbor press.
8. Install forw ard clutch hub washers on forw ard clutch

hub. R etain with petrolatum .
9. Place forward clutch hub into forw ard clutch housing.
10. Oil and install five (5) radial grooved composition and
four (4) flat steel and one (1) waved steel clutch plate
(plate with "U" notches) starting with waved steel and
alternating composition and steel clutch plates (fig. Fig. 76T--Forw ard Clutch Plate Id e n tifica tio n
75T).

SNAP RING
CLUTCH RETAINER
FORWARD CLUTCH HOUSING
SNAP RING
Fig. 79T--Removing Interm ediate Clutch Retainer Snap Ring
Disassem bly
Fig. 77T--lnstalling Forward Clutch Housing to Direct Clutch
Hub Snap Ring 1. Remove interm ediate sprag retainer snap ring and re
tainer (fig. 79T).
12. Place forw ard clutch housing on pum p delivery sleeve 2. Remove sprag outer race, bushings and sprag assembly.
and air check clutch operation (fig. 78T). 3. T urn unit over and remove backing plate to direct
clutch housing snap ring (fig. 80T).
D IR EC T CLU TCH AND IN TERM ED IA TE 4. Remove direct clutch backing plate (five) 5 composi
tion, and (five) 5 steel clutch plates.
SP R A G D IS A S S E M B L Y , IN SPECTIO N
AND RE A S S E M B L Y NOTE: Models CF, CR, CS, and CY, have six (6) com
position and six (6) steel clutch plates. No waved
steel plate used in model CY.
V
FORWARD CLUTCH ASSEMBLY DIRECT CLUTCH BAC KIN G PLATE
PUMP ASSEMBLY
DIRECT CLUTCH
H O U S IN G
Fig. 78T--Air Checking Forward Clutch Assem bly Fig. 80T~Removing Direct Clutch Backing Plate Snap Ring

SNAP RING
INTERMEDIATE CLUTCH RETAINER
INTERMEDIATE CLUTCH OUTER RACE
INTERMEDIATE CLUTCH SPRAG ASSEMBLY
SPRAG BUSHINGS
DIRECT CLUTCH HO USING

A N D RACE ASSEMBLY
DIRECT CLUTCH CENTER SEAL
DIRECT CLUTCH OUTER SEAL
DIRECT CLUTCH INNER SEAL

DIRECT CLUTCH PISTON
DIRECT CLUTCH PISTON RELEASE SPRINGS

DIRECT CLUTCH SPRING RETAINER
SNAP RING
Fig. 81T~D irect Clutch and Interm ediate Sprag-Exploded V ie w
5. Using clutch com pressor Tool J-4670 and J-21664, 8. Remove outer seal from piston.
compress spring retainer in arbor press and remove 9. Remove inner seal from piston.
snap ring (fig. 82T). 10. Remove center piston seal from direct clutch housing.
6. Remove retainer and sixteen (16) piston release springs. Inspection

1. Inspect sprag assembly for popped or loose sprags.
NOTE: Keep springs separate from forward clutch 2. Inspect sprag bushings for wear or distortion.
release spring. 3. Inspect inner and outer races for scratches or wear.
7. Remove direct clutch piston (fig. 83T). DIRECT CLUTCH

PISTON ASSEMBLY
DIRECT
CLUTCH
HOUSING
Fig. 82 T -R em o ving or Installing Direct Clutch Snap Ring Fig. 83T-R em oving Direct Clutch Piston Assem bly

CLUTCH OUTER SEAL
Fig. 8 6 T ~ ln sta llin g Direct Clutch O uter Seal
Fig. 8 4 T ~ D ire ct Clutch A ssem bly Exploded to make certain the proper piston be installed in the
clutch assemblies. As shown in Figure 89T, the di
4. Inspect clutch housing for cracks, wear, proper opening rect clutch piston can be identified by the check ball.
of oil passages or wear on clutch plate drive lugs. On CY model, the direct clutch piston has 2 check
balls.
5. Inspect composition-faces and steel clutch plates for
sign of wear or burning. *• Install a new inner clutch piston seal on piston with lip
facing away from spring pockets (fig. 85T).
6. Inspect backing plate for scratches or other damage.
2 Install a new outer clutch piston seal with lip facing
7. Inspect clutch piston for cracks and free operation of
away from spring pockets (fig. 86 T).
ball check.
3. Install a new center seal on clutch housing with lip of

Assem bly seal facing up (fig. 87T).
NOTE: The Turbo Hydra-Matic forward and direct NOTE: Apply automatic transmission oil to all seals
clutch pistons have identical inside and outside and clutch plates.
diameters. It is possible to reverse the pistons dur
ing reassembly, therefore, care should be exercised
CAUTION: The direct clutch housing for the CF, CR,
CS, and CY models use the 6 plate clutch assembly.
CLUTCH
CENTER SEAL
Fig. 8 5T— I nsta 11i ng D irect Clutch Inner Seal Fig. 8 7 T ~ ln sta llin g Direct Clutch Center Seal

CHECK BALL
DIRECT CLUTCH H O U SIN G DIRECT CLUTCH H O U SIN G

FOR 5 PLATE CLUTCH PACK FOR 6 PLATE CLUTCH PACK
8. a. (Models CA, CD, CJ, C K and CM ) oil and install

F ig. 8 7 T A — D ire c t C lu tc h H o usin g Id e n tific a tio n
five (5) composition, four (4) flat steel plates and one (1)
waved steel plate ("U " N otch), starting with the waved
This housing can be identified by the elimination of plate and alternating composition and flat steel clutch
the inside diameter chamfer on the clutch plate end plates (fig. 90T).
and/or a groove in the face at the base of the tower b. (Model CY) oil and install six ( 6 ) composition and
(fig. 87T-A). Should replacement of the direct clutch six ( 6) flat steel plates, starting with a flat steel plate
housing become necessary, extreme care must be and alternating composition and flat steel clutch
taken in obtaining the correct part for the model plates.
involved. c. (M odels CF, CR and CS) oil and install six ( 6)
composition, five (5) flat steel plates and one (1)
4. Place seal protectors, Tools J-21362 Inner, J-21409 waved steel plate ("U " N otch), starting with the
O uter, over hub and clutch housing and install clutch waved plate and alternating composition and flat
piston, with a rotating m otion (fig. 88 T). steel clutch plates.
5. Install sixteen (16) springs into piston. See figure 76T for clutch plate identification.
6. Place spring retainer and snap ring on retainer.
7. Using an arbor press and Tool J-4670, with J-21664, NOTE: Do not use radial grooved composition plates
compress springs and install snap ring (fig. 82T). here.
Fig. 9 0 T ~ ln sta ll Direct Clutch Backing Plate, C om position

Fig. 8 8 T -ln s ta llin g D irect Clutch Piston Plates, and Steel Plates

DIRECT CLUTCH
HO U SIN G
Fig. 9 1 T—Installing D irect Clutch Housing to Backing Plate

Snap Ring
Fig. 9 2 T -ln s ta llin g Interm ediate Sprag to D irect Clutch Fig. 94 T ~ ln sta llin g Interm ediate Clutch Retainer
9. Install clutch backing plate. 14. Install sprag bushing over sprag, cup side down.
10. Install backing plate retaining snap ring (fig. 9 IT).
15. Install sprag retainer and snap ring (fig. 94T and 95T).
11. T urn unit over and install one sprag bushing, cup side
up, over inner race. 16. Place direct clutch assembly over center support and air
12. Install sprag assembly into outer race. check operation of direct clutch (fig. 97T).
13. W ith ridge or shoulder on inner cage down, start sprag

and outer race over inner race w ith clockwise turning
m otion (fig. 92T). NOTE: If air is applied through reverse passage,
(right oil feed hole) it will escape from direct clutch
passage (left oil feed hole). This is considered nor
NOTE: Outer race should not turn counter-clock mal. Apply air through left oil feed hole to actuate
wise after installation. (See Figure 93T). piston and move direct clutch.

Fig. 95T --lnstalling Interm ediate Clutch Retainer Snap Ring
CAUTION: Do not remove three (3) screws retaining

roller clutch inner race to center support.
Inspection
1. Inspect roller clutch inner race for scratches or indenta
tions. Be sure lubrication hole is open. Be sure constant
bleed plug orifice, (approx. .020 dia.), is open (fig. 40T).
2. Inspect bushing for scoring, wear or galling. If replace

m ent is necessary, proceed as follows:
a. Using Tool J-21465-6 w ith D river H andle J-8092
remove bushing.
b. From front side of center support, align elongated
slot in the bushing with drilled hole in the oil deliv-
D IS A S S E M B L Y , IN SPECTIO N AND
RE A S S E M B L Y OF CEN TER SU PPO RT
Disassem bly
1. Remove three (3) hook type cast iron oil seal rings from
the center support. D o not remove the teflon oil seal
ring unless replacem ent is required. All service center
support oil seal rings are hook type cast iron (fig. 96T).
2. Using clutch compressor, J-4670 in arbor press com

press spring retainer and remove snap ring (fig. 98T).
3. Remove spring retainer and three (3) clutch release
springs.
4. Remove interm ediate clutch piston.
5. Remove inner and outer piston seal. Fig. 98 T -R em o ving Interm ediate Clutch Piston Snap Ring

ery sleeve closest to the piston. Using Tool J-21465-

6 and D river H andle J-8092, drive bushing squarely
into the bore until the bushing is flush to .0 1 0 "
below top of oil delivery sleeve.
3. Check oil ring grooves and oil rings for damage.
NOTE: All service center support oil seal rings are

hook type cast iron.
4. A ir check oil passages to be sure they are not inter

connected.
5. Inspect piston sealing surfaces for scratches.
6. Inspect piston seal grooves for nicks or other damage.
7. Inspect piston for cracks or porosity.
8. Inspect release springs for distortion.
9. Inspect support to case for burrs or raised edges. If
present, remove with a stone or fine sandpaper.
Assem bly CLUTCH INNER SEAL

1. Lubricate and install new inner and outer seals on pis
ton with lip of seal facing away from spring pocket (fig.
100T and 101T). Fig. 100T--lnstalling Interm ediate Clutch Inner Seal

INTERMEDIATE CLUTCH PISTON
CLUTCH OUTER SEAL
Fig. 1 0 1T— Installing Interm ediate Clutch O uter Seal Fig. 10 3 T —Installing Interm ediate Clutch Piston Snap Ring
IN SPECTIO N OF REACTIO N C A R R IER ,

2. Install inner seal protector. Tool J-21363, on center
support hub, install piston, indexing spring pockets of RO LLER CLU TCH , AND O UTPUT
piston into cored areas of the center support (fig. 102T).
3. Install three (3) release springs into counterbores of C A R R IER A S S E M B L Y
piston. Space equally during assembly.
4. Place spring retainer and snap ring over springs.
5. Using C lutch Spring Compressor, J-4670, in arbor 1. Inspect band surface on reaction carrier for signs of
press compress springs and install snap ring (fig. 103T). burning or scoring.
2 . Inspect roller clutch outer race for scoring or wear.
6. Install three (3) hook type cast iron oil seal rings on the
3. Inspect thrust washer surfaces for signs of scoring or
center support if the teflon ring was not removed. If the
wear.
teflon ring was removed, install four (4) hook type cast
iron oil seal rings. 4. Inspect bushing for damage. If bushing is damaged
reaction carrier m ust be replaced.
7. A ir check operation of interm ediate clutch piston (fig.
104T). 5. Inspect reaction carrier pinions for damage, rough
bearings, or excessive tilt.
6 . Check pinion end play. Pinion end play should be
.009"-.024" (fig. 105T).
J-21363
CENTER
SUPPORT
Fig. 102T --lnstalling Interm ediate Clutch Piston Fig. 1 0 4 T -A ir Checking Interm ediate Clutch Piston

P IN IO N PIN
B R O N ZE W A S H ER
Fig. 105T--C hecking Pinions End Play

Fig. 108T--Planet Pinion Assembly-Exploded V iew
12. Inspect parking pawl lugs for cracks or damage.
13. Inspect output locating splines for damage.
14. Inspect front internal gear ring for flaking (fig. 41).
Pinion Replacement Procedure
1. Support carrier assembly on its front face.
2. Using a 1/2 inch diam eter drill, remove stake m arks

Fig. 106T~C hecking O utpu t C arrier Pinion End Play from the end of the pinion pin, or pins, to be replaced.
This will reduce the probability of cracking the carrier
when pinion pins are pressed out.
CAUTION: Do not allow drill to remove any stock

from the carrier.
3. Using a tapered punch, drive or press pinion pins out

of carrier (fig. 107T).
4. Remove pinions, thrust washers and roller needle bear

ing.
5. Inspect pinion pocket thrust faces for burrs and remove

if present.
Fig. 107T~Removing Planent Pinion Pin
6. Install eighteen (18) needle bearings into each pinion

7. Inspect roller clutch for dam aged rollers.
using petrolatum to hold bearings in place. Use pinion
8. Inspect roller clutch cage and springs for damage. pin as guide (fig. 108T).
9. Inspect front internal gear (output carrier) for damaged 7. Place a bronze and steel washer on each side of pinion
teeth. so steel washer is against pinion, hold them in place
with petrolatum .
10. Inspect output carrier pinions for damage, rough bear
ings or excessive tilt.
8. Place pinion assembly in position in carrier and install
11. Check pinion end play. Pinion end play should be a pilot shaft through rear face of assembly to hold parts
.009 "-.024" (fig. 106T). in place.

Inspection of Sun Gear Shaft

1. Inspect shaft for cracks or splits.
2. Inspect splines for damage.
3. Inspect bushings for scoring or galling. If necessary to
replace, proceed as follows:
Sun Gear Shaft Bushing-Front and Rear
Remove
W ith sun gear shaft properly supported, using Tool J-
21465-15, with slide ham m er and A dapter J-2619, remove
bushing.
Fig. 1 0 9T ~ lnstalling Planet Pinion Pin Replace

Using Tool J-2 1465-5 with D river H andle J-8092 press or
9. Drive a new pinion pin into place while rotating pinion drive replacem ent bushing into place until tool bottoms.
from front, being sure th at headed end is flush or below
face of carrier (fig. 109T).
10. Place a large punch in a bench vise to be used as an anvil IN SPECTIO N OF MAIN SH A FT
while staking opposite end of pinion pin in three places. 1. Inspect shaft for cracks or distortion.
2. Inspect splines for damage.
3. Inspect ground bushing journals for damage.
NOTE: Both ends of pinion pins must lie below face 4. Inspect snap ring groove for damage.
of carrier or interference may occur. 5. M ake sure that lubrication holes are open.
NOTE: If replacement of mainshaft is required,

O UTPUT SH A FT, REA R IN TERN AL make sure that the orifice cup plug in the service
G EA R , SUN G EA R AND SH A FT mainshaft is removed.
Output Shaft IN SPECTIO N OF FRONT AND REAR

1. Inspect bushing for wear or galling. If replacem ent is
necessary, proceed as follows:
BAN DS, SU P PO R T TO C A S E S P A C ER
a. T hread Tool J-21465-16 into bushing and using
1. Inspect lining for cracks, flaking, buring, or looseness.
Slide H am m er J-2619, remove bushing.
2. Inspect bands for cracks or distortion.
b. Using Tool J-2 1465-1 w ith drive handle J-8092,, in
3. Inspect end for damage at anchor lugs or apply lugs.
stall bushing into place until tool bottoms.
2. Inspect bearing and th ru st washer surfaces for damage.
IN SPECTIO N OF C A S E EXTENSIO N
3. Inspect governor drive gear for rough or damaged
teeth. 1. Inspect bushing for excessive wear or damage. If re
4. Inspect splines for damage. placement is necessary proceed as follows:
5. Inspect orificed cup plug in lubrication passage. a. W ith rear seal removed and the extension housing
6. Inspect drive lugs for damage. properly supported, using tool J-8400-1, remove
bushing.
Inspection of Rear Internal Gear All Models Except CM

1. Inspect gear teeth for dam age or wear. b. Using tool J-22419, with D river H andle J-8092,
2. Inspect splines for damage. drive or press replacement bushing into place, flush
3. Inspect gear for cracks. to .010 below oil seal counter bore area. Stake bush
ing, using tool J-21465-10. Stake m arks to be in
bushing lubrication grooves.
Inspection of Sun Gear
CM Models
1. Inspect gear teeth for dam age or wear.
2. Inspect splines for damage. c. Using Tool J-8400-19 (or J-9640) with D river H an
3. Be sure oil lubrication hole is open. dle J-8092, drive or press replacement bushing into

IN SPECTIO N OF M ODULATOR AND

V A LV E
1. Inspect m odulator assembly for any signs of bending or
distortion (fig. 110T).
2. Inspect "O" ring seal seat for damage.
3. Apply suction to vacuum tube and check for diaphragm
MODULATOR VALVE leaks.
4. Check m odulator bellows as outlined in Section 7 of
Service M anual (m odulator plunger is under pressure -
16 lbs.). If bellows is damaged plunger will have very
MODULATOR ASSEMBLY little pressure.
OIL RING 5. Inspect m odulator valve for nicks or damage.
6. Check freeness of valve operation in case bore.
Fig. 1 10T --M odulator A ssem bly and Valve

IN SPECTIO N OF M ANUAL AND
place flush to .010 below oil seal counter bore area.
PARKIN G LIN KAGE
Stake bushing, using tool J-21465-10 (or J-8400-22).
Stake m arks to be in bushing lubrication grooves. 1. Inspect parking actuator rod for cracks, or broken
2. Inspect gasket m ounting face for damage. spring retainer lugs (fig. 11 IT).
3. Inspect housing for cracks or porosity. 2. Inspect actuator spring for damage.
4. Be sure rear seal drain back port is not obstructed. 3. Inspect actuator for free fit on actuator rod.
Fig. 111T~M anual and Parking Linkage-E xploded V iew

4. Inspect parking pawl for cracks or wear. DRIVE i ETENT

5. Inspect m anual shaft for damaged threads, rough oil REVERSE
EXHAUST
INTERMEDIATE
surface or loose lever.
6. Inspect inside detent lever for cracks or a loose pin.
V \ .REVERSE
7. Inspect parking pawl shaft if removed for damaged
retainer groove.
8. Inspect parking pawl return spring for deformed coils EVERSE
or end. Im odulator T«JP
>R LO
9. Inspect parking bracket for cracks or wear. mmoR & £ $

INTERMEDIATE
10. Inspect detent roller and spring assembly. HHP®*® F jn
■ y N E -------- INTERMEDIATE
B m OPULMOR X LU TC H
IN SPECTIO N OF C A S E A S S E M B L Y
GOVERNOR
{FIGS. 112T AND 113T) 7A C C U M U LA fO R
[INTERMEDIATE
CLUTCH
CAUTION: If the case assembly requires replace

ment make sure the center support-to-case spacer
is removed from the old case and reinstalled in the SERVO DIRECT
CLUTCH
new case.
Fig. 1 13T~lnspect Transm ission Case
1. Inspect case assembly for cracks, porosity or inter-con-
nected passages.
2. Check for good retention of band anchor pins. Case Bushing
3. Inspect all threaded holes for thread damage.
4. Inspect interm ediate clutch driven plate lugs for dam
Remove
age or brinneling. W ith case properly supported, using tool J-21465-8, with
5. Inspect snap ring grooves for damage. D river H andle J-8092, remove bushing.
6 . Inspect bore for governor assembly for scratches or
scoring.
7. Inspect m odulator valve bore for scoring or damage. Replace
8 . Inspect cup plug inside case for good staking and seal
Using tool J-21465-8 adaptor ring J-21465-9, D river H an
ing.
dle J- 8092, and extension J-21465-13, with lube passage
9. Inspect case bushing. If necessary to replace,proceed as
facing front of transmission case, drive replacem ent bushing
follows:
into case until .040 to .055 above selective thrust washer face.
Stake bushing with tool J-21465-10. Stake m arks to be in
bushing lubrication grooves.
IN SPECTIO N OF CO N VERTER
1.
Check converter for leaks as follows (fig. 114T):
a. Install Tool J-21369 and tighten.
b. Apply 80 psi air pressure to tool.
c. Submerge in w ater and check for leaks.
2. Check converter hub surfaces for signs of scoring or
wear.
Converter End Clearance Check (Figs.

114A and 114B)
1. Fully release collet end of Tool J-21371-8.
2. Install collet end of Tool J-21371-8 into converter hub
until it bottoms; then tighten cap nut to 5 lb. ft. (fig.
114A).
3. Install Tool J-21371-3 and tighten hex nut to 3 lb. ft.
(fig. 114B).
4. Install D ial Indicator J-8001 and set it at "zero", while
Fig. 1 1 2T~Case~Front V iew Passage Ide ntification its plunger rests on the cap nut of Tool J-21371-8.

Fig. 114TB— Checking C o nve rte r end Clearance
A S S E M B L Y OF REA R UNIT
Fig. 1 14T--Air Checking Converter
1. Install rear internal gear on end of mainshaft.
5. Loosen hex nut while holding cap n u t stationary. W ith 2. Install internal gear retaining snap ring (fig. 116T).
the hex nut loosened and holding Tool J-21371-3 firmly
against the converter hub, the reading obtained on the 3. Install sun gear to internal gear thrust races and bear
dial indicator will be the converter end clearance. End ings against innner face of rear internal gear as follows,
clearance should be less than .050". If the end clearance and retain with petrolatum .
is .050" or greater, the converter m ust be replaced. a. Place large race against internal gear with outer
flange facing forward or up (fig. 117T).
b. Place thrust bearing against race.
c. Place small race against bearing with inner flange
facing into bearing or down.
4. Install output carrier over mainshaft so that pinions

mesh with rear internal gear.
5. Place above portion of "build-up" through hole in

bench so th at m ainshaft hangs downward.
6. Install rear internal gear to output shaft thrust races

and bearings as follows and retain with petrolatum (fig.
118T).
a. Place small diam eter race against internal gear with
center flange facing up.
b. Place bearing on race.
c. Place second race on bearing with outer flange
cupped over bearing.
7. Install output shaft into output carrier assembly (fig.

119T).
8. Install output shaft to output carrier snap ring.
9. Install "O" ring on output shaft of models that use an

Fig. 1 1 4 T A — Loosening C ollet on T o o l J-21371-8 "O" ring.

I.D . FLANIGE
RACE
O' R IN G
M A IN SHAFT
FRO NT IN TE R N A L
RE A C TIO N G EAR R|N G
CARRIER
A SSEMBLY
Fig. 1 15T~Gear Unit A ssem bly-E xploded V iew
10. T urn assembly over and support so th at output shaft 11 Install reaction carrier to output carrier thrust washer
hangs downward. with tabs facing down in pockets of output carrier and
retain with petrolatum .
12. Install sun gear I.D . splines with cham fer down.
13. Install composition ring over output carrier (fig. 120T).
INTERNAL GEAR
O.D. FLANGED RACE
SNAP RING I.D. FLANGED RACE

MAIN SHAFT THRUST BEARING
Fig. 116T --lnstalling Rear Internal Gear to M ain S haft Snap Fig. 1 17 T -ln s ta llin g Rear Internal Gear to Sun Gear Bearing
Ring and Races

.D. FLANGED RACE
THRUST
BEARING
I.D. FLANGED
RACE
Fig. 12 0 T -ln s ta llin g Front Internal Gear Ring to O utput C arrier
14. Install sun gear shaft w ith long splined end down.
15. Install reaction carrier (fig. 12IT ).
NOTE: When a new output carrier and/or reaction

Fig. 1 1 8T— in sta llin g Rear internal Gear to O utput S haft carrier is being installed and if the front internal
Bearing and Races
Fig. 1 19T— Installing O utput S haft Fig. 1 2 I T — Installing Reaction C arrier and R o lle r Assem bly

ROLLER CLUTCH
ASSEMBLY
Fig. 124T--lnstalling Roller Clutch to Reaction C arrier
17. Install rollers that may have .come out of the roller
clutch cage, by compressing the energizing spring with
forefinger and inserting roller from the outer edge (fig.
Fig. 122 T — Installing Center S upport to Sun Gear T hrust 123T).
Bearing and Races
18. Install roller clutch assembly (fig. 124T) into reaction
carrier.
gear ring prevents assembly of the carriers, replace
the front internal gear ring with the SERVICE ring. 19. Install center support to reaction carrier thrust washer
into recess in center support. Retain with petrolatum
(fig. 40T).
16. Install center support to sun gear th ru st races and bear
ings as follows: (R etain with petrolatum .) 20. Install center support into roller clutch in reaction car
a. Install large race, center flange up over sun gear rier (fig. 125T).
shaft.
b. Install thrust bearing against race. NOTE: With reaction carrier held, center support
c. Install second race, center flange up (fig. 122T). should only turn counter-clockwise after installa
tion.
Fig. 12 3 T -ln s ta llin g Roller into Roller Cage Fig. 12 5 T -ln s ta llin g Center S upport to Reaction Carrier

THRUST WASHER
Fig. 12 6 T --lnstalling Case to O utpu t S haft T hrust W asher
21. Install J-2 1795 on gear unit assembly to hold units in

Fig. 1 27T — Installing Parking Brake Pawl S haft Cup Plug
place.
22. Install output shaft to case th ru st washer tabs in pock
ets (fig. 126T), and retain w ith petrolatum . Using a hacksaw, remove the two front m anufacturing
lugs (one on each side), as close to the wall of the case as
C A S E M O D IFIC A TIO N -C O R V ETTE possible, using caution not to cut into the wall of the case.
NOTE: Due to the configuration of the body floor

pan, it is necessary to modify the standard Service A S S E M B L Y OF UNITS TO
Case when used as a replacement part for the Cor
vette.
TRA N SM ISSIO N C A S E
Using a "C" Clamp, clam p the transm ission case firmly to

NOTE: The first three steps can be omitted if the
a suitable bench, with the converter under pan attaching face
parts involved were not removed on disassembly.
down, as shown in Figure 126T-A ,(do not damage m achined
surface o f the case).
1. Install parking pawl tooth toward inside of case,
and parking pawl shaft (fig. 127T).
2. Install parking pawl shaft retainer clip (fig. 128T).
3. Install parking pawl shaft cup plug and drive into the
case, using a 3 /8 dia. rod, until the parking pawl shaft
bottom s on the case rib (fig. 127T).
4. Install parking pawl return spring, square end hooked

on pawl and other end on case.
5. Install parking brake bracket with guides over parking

pawl using two attaching bolts, torque to 18 ft. lbs.
6. Install rear band assembly so th at two lugs index with

two anchor pins. Check to make sure band is seated on
Fig. 1 2 6 T -A — M o d ific a tio n of Service Case fo r C orvette Models lugs (fig. 129T).

u CENTER S U P P O R fi
RETAINING
SPRING
f I t o CASE SPACER U
7 LOCATE SPACER GAp|

4 ADJACENT TO
BAND ANCHOR PIN
SHAFT
Fig. 1 2 8 T -ln s ta llin g Parking S haft Retaining Spring Fig. 12 9 T -A -ln s ta llin g Support to Case Spacer
7. Install the support to case spacer against the shoulder

at the bottom of case splines and the gap located adja
cent to the band anchor pin (fig. 129T-A). 11. Install case to center support bolt by placing the center
support locating tool into the case direct clutch passage,
CAUTION: Do not confuse this spacer (.040"thick with the handle of the tool pointing to the right as
and both sides flat) with either the center support to viewed from the front of the transm ission and parallel
case snap ring (one side beveled) or the intermediate to the bell housing m ounting face. Apply pressure
clutch backing plate to case snap ring (.093"thick
and both sides flat).
8. Install proper rear selective washer (proper washer de

term ined by previous end play check) into slots prov
ided inside rear of transm ission case.
9. Install complete gear unit assembly into case, using
Tool J-21795 (fig. 130T).
10. Install center support to case retaining snap ring with
bevel side up (flat surface against the center support)
and locating gap adjacent to band anchor pin. Make
certain ring is properly seated in case (fig. 13IT).
X* ' !
REAR
BAND
Fig. 1 2 9 T ~ ln sta llin g Rear Band Fig. 13 0 T -ln s ta llin g Center S upport and Gear U nit

SNAP RING
BACKING PLATE
COMPOSITION PLATES (3)i

STEEL PLATES (3)
Fig. 13 1T—Installing Center S upport to Case Snap Ring
dow nw ard on the tool handle which will tend to rotate

the center support Counterclockwise as viewed from the
Fig. 132T--lnstalling Interm ediate Back Plate and Clutch
front of the transm ission. W hile holding the center sup
port firmly counter clockwise against the case splines, Plates
torque the case to center support bolt to 20-25 ft. lbs.,

using a 3 /8 " 12-point thin wall deep socket (fig. 131T- NOTE: No waved steel plate is used in the CY model.
A). Three flat steel plates are used.
CAUTION: When using the locating tool, care

should be taken not to raise burrs on the case valve 13. Install interm ediate clutch backing plate, ridge up.
body mounting face.
14. Install interm ediate clutch backing plate to case snap
ring, locating gap opposite band anchor pin.
12. Oil and install three (3) steel and three (3) composition
interm ediate clutch plates. Start w ith the waved steel
plate and alternate com position and steel clutch plates NOTE: Both sides of this snap ring are fla t and it is
(fig. 132T). .093" thick.
15. Check rear end play as follows:
a. Install a 3/8"-16 bolt or J-9539, into an extension

housing attaching bolt hole (fig. >2T).
CEN TER SUPPORT b. M ount a Dial Indicator on a rod and index with end
LO C A T IN G T O O L
of output shaft.
c. Move output shaft in and out to read end play. End
play should be from .007"-.019". The selective
washer controlling this end play is steel washer hav
ing 3 lugs that is located between thrust washer and
rear face of transm ission case.
If a different washer thickness is required to bring end

play within specifications, it can be selected from the follow
ing chart:
Identification
Thickness Notches a n d /o r Numerals
.074-.078 N one ............................1
.082-.086 1 Tab Side ................ 2
.090-.094 2 Tabs Side ...............3
.098-. 102 1 T ab O .D ...................4
.106-.110 2 T abs O .D .................5
Fig. 131T-A— Installing Center S upport Bolt .1 14-.118 3 T abs O .D ................. 6

CLUTCHES A N D TR A N SM ISSIO N S 7 -1 84
16. Install front band with anchor hole placed over band
anchor pin and apply lug facing servo hole (fig. 133T).
Install Manual Linkage
a. If necessary, install a new m anual shaft seal into

transm ission case using a 3 /4 inch dia. rod to seat
the seal.
b. If removed, insert actuator rod into m anual detent

lever from side opposite pin.
c. Install actuator rod plunger under parking bracket

over parking pawl.
d. Install m anual shaft through case and detent lever

(fig. 134T).
e. Install detent retaining hex locknut on m anual

shaft, and tighten to 18 ft. lbs. (fig. 135T).
Fig. 134T--lnstalling M anual S haft to Case
f. Install retaining pin indexing with groove in m anual
shaft. R otate transm ission to vertical position and
remove J-21795.
of housing hub splines. It also may be helpful to
remove the direct clutch plates while installing
17. W ith converter end of transm ission up, carefully install housing.
direct clutch and interm ediate sprag assembly. It will be
necessary to shake and slightly twist housing to allow
sprag outer race to index with composition plates.
Housing hub will bottom on sun gear shaft (fig. 136T). 18. Install forward clutch hub to direct clutch housing
thrust washer on forward clutch hub. Retain with pe
trolatum .
NOTE: First visually line up the intermediate clutch
drive lugs, one above the other to help engagement 19. Install forward clutch assembly and turbine shaft; in
dexing direct clutch hub so end of m ainshaft will bot
tom on end of forward clutch hub. W hen forward
clutch is seated it will be approximately 1-1/4" from
pum p face in case (fig. 137T).
SHAFT DETENT
LEVER
Fig. 13 5 T —Installing Detent Lever and Jam Nut to M anual

Fig. 133T — Installing Front Band
Shaft

CLUTCHES A N D TRAN SM ISSIO N S 7 -1 8 5
FRONT SEAL
Fig. 136T--Installing D irect Clutch Assem bly Fig. 13 8 T ~ ln sta llin g Pump Seal
20. Install front pum p assembly and gasket. 23. Check front unit end play as follows (fig. 139T).
NOTE: If turbine shaft cannot be rotated as pump is

being pulled into place, forward or direct clutch a. Install a 3/8"-16 threaded bolt or a Slide Ham m er
housing have not been properly installed to index Bolt J 9539 into bolt hole in pump.
with all clutch plates. This condition must be cor b. M ount a dial indicator on rod and index indicator
rected before pump is pulled fully into place. to register with end of turbine shaft.
c. Push turbine shaft rearward.
21. Install all but one pum p attaching bolts and seals. d. Push output shaft forward.
T orque to 18 ft. lbs. (See Figure 139T for location of e. Set dial indocator to zero.
om itted bolt.) f. Pull turbine shaft forward.
22. If necessary to install a new front seal, use a non-hard
ening sealer on outside of seal body; and using Tool
Read resulting travel or end play which should be .003"-
J-2 1359, drive seal in place (fig. 138T).
.024". Selective washer controlling this end play is located
between pum p cover and forw ard clutch housing. If more or
less washer thickness is required to bring end play within
speciations, select proper washer from the chart below:
DIAL
IN D IC A T O R
Fig. 1 3 7 T -ln s ta llin g Forward Clutch Assem bly and Turbine

Shaft Fig. 139T~Checking Front U nit End Play

Thickness Color Installation of Check Balls, Control

.060-.064 Yellow
Valve Spacer Plate and Gasket, Detent
.071 -.07 5 Blue
.082-.086 Red Solenoid, Front Servo Assembly, and
.093-.097 Brown
Electrical Connector
.104-. 108 G reen
.115-.119 Black
.126-.130 Purple 1. Install two control valve assembly attaching bolts with
heads cut off as guide pins as shown in figure 15 IT.
NOTE: An oil soaked washer may tend to discolor.

It will be necessary to measure washer for its actual 2. Install six check balls into ball seat pockets in transm is
thickness. sion case. Figure 142T.
24. Install rem aining front pum p attaching bolt and seal.
Torque 18 ft. lbs.
NOTE: If transmission is in the vehicle, install check
balls into ball seat pockets on spacer plate (Fig.
142T-A.
Rear Extension Assem bly
3. Install control valve spacer plate-to-case gasket (gasket
1. Install new extension housing to case gasket on exten with extension for detent solenoid). Fig. 143T.
sion housing.
2. A ttach extension housing to case using attaching bolts. 4. Install control valve spacer plate.
Torque bolts to 20-25 ft. lbs.
5. Install detent solenoid gasket.
3. If necessary, install a new seal as follows:
a. A ll models except " C M " - Use a non-hardening 6. Install detent solenoid assembly with connector facing
sealer on outside of seal body; and using Tool outer edge of case (fig. 144T). Do not tighten bolts at
J-21359, drive seal in place (fig. HOT). this time.
b. M odel " C M " - Use a non-hardening sealer on
outside of seal body; and using Tool J-2 1464, drive 7. Install front servo spring and spring retainer into trans
seal in place (fig. HOT). mission case.
8. Install retainer pins in front servo pin groove and install

pin into case so that tapered end contacts band. Make
certain retainer ring is installed in servo pin groove.
9. Install seal ring on servo piston, if removed, and install

on servo pin with flat side of piston positioned toward
bottom pan. Fig: 14IT.
NOTE: The teflon ring allows the front servo piston

to slide very freely in the case. The free fit of the ring
in the bore is a normal characteristic and does not
indicate leakage during operation. The teflon ring
should only be replaced if it shows damage or if
evidence of leakage during operation exists.
NOTE: If transmission is in the vehicle, assemble

front servo group as shown in figure 50T and install
this group of parts into front servo bore in case and
hold. Slip a length of straight, clean feeler gauge or
shim stock (about .02(0 between spacer plate and
front servo piston to temporarily retain front servo
group. Figure 144T- A.

SPACER PLATE
Fig. 1 4 1T--lnstalling Front Servo Piston, W asher, and Pin
10. Install "O" ring seal on electrical connector.

Fig. 1 4 2 T A — L o c a tio n o f C h eck Balls in
11. Lubricate and install electrical connector with lock tabs Car In s ta lla tio n
facing into case, positioning locator tab in notch on side
of case (fig. 145T). a. A ttach band apply pin selection Gauge J-21370-6
and J-21370- 5 to transmission case (lever pivot pin
to rear) with attaching screws.
12. Install detent wire and lead wire to electrical connector
Figure 9T-A.
NOTE: Attach tool attaching screws finger tight
and check freeness of selective pin. Torque attach
Installation of Rear Servo Assembly ing screws to 15 ft. lbs. and recheck pin to make
certain it does not bind.
NOTE: Before installing rear servo assembly, check
band apply pin using Tool J-21370-5 and 6 as fol b. Apply 25 ft. lb. torque and select proper servo pin
lows (fig. 146T). to be used from scale on tool.
Fig. 143T —Installing Control Valve Assem bly Spacer Plate and
Fig. 142T--Location of Check Balls Gasket

Fig. 1 4 4 T -ln s ta llin g Detent Solenoid and Gasket Fig. 145T— Installing Electrical Connector
and “ O ” Ring
Selecting proper length pin is equivalent to adjusting
band. The band lug end of each selective apply pin bears
identification in the form of one, two or three rings.
There are three selective pins identified as follows:
c. If both steps are below the gauge surface, the long 3. Install rear servo gasket and cover (fig. 149T).
pin, identified by 3 rings, should be used.
4. Install attaching screws. Torque bolts to 15-20 ft. lbs.
d. If the gauge surface is between the steps, the
m edium pin, identified by 2 rings, should be used.
IN STALLATION OF CON TRO L V A LV E
e. If both steps are above the gauge surface, the short
pin, identified by 1 ring, should be used.
A S S E M B L Y , GOVERNOR P IP ES AND
GOVERNOR SCR EEN A S S E M B L Y
1. Install rear accum ulator spring into case (fig. 147T).
1. Install governor pipes on control valve assembly. Gov
2. Lubricate and install rear servo assembly into case (fig. ernor pipes are interchangeable.
148T).
Fig. 1 4 4 T A — F rong Servo G ro u p — In

Car In sta lla tio n Fig. 1 46T~Checking Rear Band Pin

REAR SERVO COVER
REAR
SERVO
GASKET
Fig. 1 4 7 T -ln s ta llin g Rear A ccum u lato r Spring Fig. 14 9 T ~ ln sta llin g Rear Servo Cover and Gasket
2. Install governor screen assembly, open end first, into NOTE: Check manual valve to make sure it is in
governor feed pipe hole in case (hole nearest the center dexed properly with pin on detent lever and check
of the transmission). Fig. 150 governor pipes to make certain they are properly
seated in case holes.
NOTE: If transmission is in vehicle, before installing
the control valve assembly and governor pipes as
4.Start control valve assembly attaching bolts and make
outlined in Step 3 below, insert the governor screen,
certain lead wire assembly clip is installed.
closed end first, into governor feed pipe. (This pipe
locates in the governor feed pipe hole in the case
nearest the center of the transmission). SEE figure
NOTE: If transmission is in the vehicle, remove
150T.
feeler stock before tightening any control valve
bolts.
3. Install control valve assembly and governor pipes on

transm ission, while carefully aligning the governor feed
5. Remove guide pins and install detent roller and spring
pipe over the governor screen, Fig. 15 IT. M ake certain
assembly and remaining bolts, Fig. 152T.
gasket and spacer do not become mispositioned.
REAR SERVO
ASSEMBLY X
GOVERNOR SCREEN
ASSY.
GOVERNOR FEED
PIPE HOLE
Fig. 1 4 8 T -ln s ta llin g Rear Servo Assem bly Fig. 15 0 T -ln s ta llin g Governor Screen Assem bly

CLUTCHES A N D TR A N SM ISSIO N S 7 -1 9 0
MODULATOR VALVE
GUIDE PINS
Fig. 1 5 1T -ln s ta llin g C ontrol Valve Assem bly and Governor

Pipes
VACUUM MODULATOR
6. If removed, install the pressure switch assembly.
NOTE: Model CM does not contain a pressure Fig. 1 5 3 T -ln s ta llin g Vacuum M od ula tor and Valve
switch assembly.
7. Connect the lead wire to the pressure switch assembly.
Installation of Modulator Valve and
Installation of Filter and Intake Pipe Vacuum Modulator
1. Install case to intake pipe "O" ring seal on intake pipe
and assemble into filter assembly. 1. Install m odulator valve into case, stem end out (fig.
2. Install filter and intake pipe assembly (fig. 8T). 153T).
2. Install "O" ring seal on vacuum m odulator.
NOTE: It is recommended that the filter be replaced, 3. Install vacuum m odulator into case.
rather than cleaned, whenever the transmission is 4. Install m odulator retainer and attaching bolt. Torque
disassembled because of a major failure. bolt 18 ft. lbs.
3. Install filter retainer bolt (fig. 7T).

Installation of Governor Assembly
4. Install new bottom pan gasket and bottom pan, with
attaching screws. Torque to 12 ft. lbs.
1. Install governor assembly into case (fig. 1 54 T ).
DETENT ROLLER AND

CDDIKir^ ACCCUDI V
Fig. 1 5 2 T -ln s ta llin g Detent Roller and Spring Assem bly Fig. 154 T —Installing Governor Assem bly

CLUTCHES A N D TRA N SM ISSIO N S 1-191
2. A ttach governor cover and gasket with four (4) attach

ing bolts. Torque bolts to 18 ft. lbs.
Installation of Speedometer Driven Gear

Assem bly
1. Install speedometer driven gear assembly (fig. 155T).
2. Install speedometer driven gear retainer and attaching

bolt.
Install Converter Assem bly

W ith the transm ission in cradle or portable jack, install
the converter assembly into the pum p assembly making cer
tain th at the converter hub drive slots are fully engaged with
the pum p drive gear tans and the converter installed fully
tow ards the rear of the transm ission.
NOTE: The converter used in the CM and CY models

has six (6) mounting lugs. Fig. 1 5 5T— Installing S peedom eter Driven Gear and Sleeve

CLUTCHES A N D TR A N SM ISSIO N S 7-1 9 2
SPECIAL TOOLS
Fig. IST-Clutch Special Tools
1. J-6456 Height Gauge

2. J-1048 Gauge Plate
3. J-1522 Pilot Bearing Driver
4. J-5824 Clutch Pilot Tool
5. J-1448 Pilot Bearing Puller

CLUTCHES A N D TRA N SM ISSIO N S 7-193
Fig. 2ST-3-Speed and 4-Speed Passenger and 10-30 Series Truck Manual Transmissions
1. J-1126 Transmission Guide Pins 9. J-1453-01 Speedometer Drive Gear Press Plates
2. J-8059 Retainer Snap Ring Pliers Press Plate Holder J-358-1
3. J-5589 Countergear Loading Tool 10. J-2228 Rear Bearing Press Plates
4. J-21629 Countergear Loading Tool 11. J-0433 Main Drive Gear Wrench
5. J-22246 Countergear Loading Tool 12. J-5590 Clutch Gear Bearing Installer
6. J-5778 Extension Bushing Remover and Installer 13. J-9772 Clutch Gear Bearing Installer
7. J-5154 Extension Seal Installer 14. J-23096 Clutch Gear Retainer Seal Installer
8. J-5814-01 Speedometer Drive Gear Remover 15. J-5752 Transmission Holding Fixture
and Adapter J-5814-15

CLUTCHES A N D TR A N SM ISSIO N S 7-1 94
Fig. 3ST-Four Speed Muncie Truck Transmission Model 465
1. J-22832 Countergear Rear Bearing Remover 8. J-22874-1 Bearing Installer

2. J-8433-1 Bearing Puller 9. J-22874-5 Mainshaft Support Tool
3. J-22872 Clutch Gear Bearing Remover and Installer 10. J-22874-2 Countershaft Support Tool
4. J-22833 Front Bearing Retainer Seal Installer 11. J-22834-2 Rear Bearing Retainer Seal Installer
5. J-22873 2nd Speed Bushing Installer 11a . J-22834-1 Adapter
6. J-22875 3rd Speed Bushing Installer 12. J-23070 Mainshaft Rear Bearing Lock Nut Installer
7. J-22830 Snap Ring Installer

Fig. 4ST-New Process Transmission
1. J-2680 Reverse Idler Gear Bushing Staking Tool 10. J-1453 Clutch Gear Bearing Replacer
2. J-1619 Transm ission M ainshaft Bearing Puller 11. J-2228 Clutch Gear Bearing Remover Plate
3. J-8109 (K -353)— Gear S hift Lever Remover and Replacer 12. J-8106 (K 342) Clutch Gear Bearing Replacer
4. J-8107 (TR-278-R)— C ountershaft Rear Bearing Remover 13. J-1614 Reverse Idler Gear Bushing Remover and Replacer
5. J-1126 Transm ission Guide Pin Set (2) 14. J-1488 Rear Bearing Retainer Oil Seal Driver
6. J-2671 Third Speed Gear Bushing Installer 15. J-4869 Speedom eter Gear Replacer
7. J-7785 Oil Seal Installer 16. J-0358 (J-358-1)— Press Plate Holder
•8. J-2667 M ainshaft and Bearing Assem bly R em overand Replacer 17. J-6416 Rear Bearing Retainer Seal Installer
9. J-6382 Reverse Idler S haft Remover

CLUTCHES A N D TR A N SM ISSIO N S 7 -1 9 6
Fig. 5ST New Process Transfer Case Special Tools
1. J-23432-1 Snap Ring Picks.

2. J-23432 Snap Ring Pliers.
3. J-8092 Handle.
4. J-23429 Intermediate Shaft Remover and Installer.
5. J-22836 Front Output Shaft Bearing Retainer Seal Installer.
6. J-21359 Rear Output Shaft Bearing Retainer Seal Installer.
1. J-23431 Rear Output Shaft Housing Bearing Remover and Installer.
8. J-7137 Adapter Seal Installer.
9. J-9276-2 Intermediate Gear Bearing Cup Installer.
10. J-22875 Rear Output Shaft Rear Bearing Installer.

Fig. 6ST Dana--Transfer Case Special Tools
1. J-8092 Handle.
2. J-8331 Rear Output Shaft Front Bearing Remover.
3. J-23422 Rear Output Shaft Front Bearing Cup Installer.
4. J-23423 Rear Output Shaft Rear Bearing Cup Installer.
5. J-5590 Bearing Installer.
6. J-23419 Intermediate Shaft Remove and Installer.
7. J-22833 Output Shaft Housing Seal Installer.
8. J-23420 Pilot Bearing Installer.
9. J-7137 Adapter Seal Installer.
10. J-6219 Front Output Shaft Bearing Installer.

Fig. 7ST~Alum inum Pow erglide Special Tools
1. J-9506 H o ld in g F ix tu re A dapters 15. J-7079 Handle

2. J-3289-01 H o ld in g F ix tu re (Use w ith J -3 2 8 9 -2 0 Base) 16. J-65 82 G ove rn or S u p p o rt Bushing Installer
3. J-95 49 C o nve rte r S afe ty Strap 17. J-95 43 V acuum M o d u la to r W rench
4. J-2 1 8 6 7 T ransm ission Pressure Gauge and Hose 18. J-57 78 Extension Bushing Rem over and Installer
6. J-33 87 P ilo t S tud Set 19. J-5154 Extension O il Seal Installer
7. J-95 39 O il Pum p Puller B olts (Use w eights fro m 20. J-5403 Snap Ring Pliers
J-6 5 8 5 ) 21. J-58 53 T orqu e W rench
8. J-6839 O il Pum p Seal Driver 22. J-80 39 Snap Ring Pliers
9. J-9546 C lu tch D ru m Bushing Rem over and Installer 23. J-21 84 8 L o w Band A d ju s tin g T ool
10. J-77 82 C lutch S pring Com pressor A d a p te r Plate J-8001 Dial In d ic a to r (N o t Illu s tra te d )
11. J-5133 C lu tch S pring Com pressor J-5492 Dial In d ic a to r S u p p o rt S trap
12. J-45 99 Planet Pinion Assem bly T o o l Set (N o t Illu s tra te d )
13. J-9542 Reverse Piston Spring Com pressor J-6585 Side Hamm ers (N o t Illu s tra te d )
14. J-95 57 Trans. Case Rear Bushing Rem over and J-6585-3 Slide H am m er A da pters (N o t Illu s tra te d )
Installer J-9534 Bushing Rem over (N o t Illu s tra te d )

Fig. 8ST~Turbo H ydra-M atic 3 5 0 Special Tools
1. J-8 7 6 3 T ransm ission Holding Fixture 15. J - 2 1424-7 S tator Shaft Front Bushing
(M od ified fo r THM 350) Installer
2. J-3289-1 4 T ransm ission Holding Fixture 16. J-2 3 0 6 2 -5 Inp ut Ring Gear Bushing
Base Installer
3. J -2 3 1 0 3 P ropeller S haft Yoke Seal 17. J-5 1 5 4 or Extension Housing Seal
Remover and Installer J-21426 Installer
4. J-8 0 9 2 Driver Handle 18. J - 2 1359 Pump Seal Installer
5. J-2 1465-13 Driver Handle Extension 19. J-6 5 8 5 Slide Hammer W eights
6. J-2 3 0 6 2 -3 Sun Gear and Reaction Carrier 19a. J-9 5 3 9 Slide Hammer Screw
Bushing 20. J - 2 1885 2-3 A ccum u lato r Piston
7. J -2 3 0 6 2 -7 O utpu t S haft Bushing Installer Com pressing Tool
8. J - 2 1465-15 S tator S haft Front Bushing 21. J-23071 Interm ediate Band A p p ly Pin
Remover Gauge
9. J -2 3 3 2 9 D irect Clutch Bushing Installer 22. J-2 3 0 6 9 1-2 A ccum ulator Cover
10. J-9534-01 O utput S haft Bushing Remover Remover and Installer
1 1. J -2 3 3 2 7 Clutch Spring Com pressor 23. J-2 6 1 9 Slide Hammer (Used w ith
12. J-2 3 0 6 2 -2 S tator S haft Rear Bushing J-26 19 -4 A dapter and
Installer J-21465-15 Stator Shaft Front
13. J-23 06 2-1 Case Bushing Installer Bushing Remover
14. J - 2 1424-9 Extension Housing Bushing
Installer

Fig. 9ST--Turbo Hydra-M atic 4 0 0 Special Tools
1. J-8 7 6 3 Transm ission H olding Fixture 9. J - 2 1363 Seal P rotector - Interm ediate
2. J -3 2 8 9 -1 4 H olding Fixture Base Clutch - Inner
3. J - 2 1427-1 Speedo Gear Remover 10. J - 2 1409 Seal P rotector - Forward Clutch
4. J -9 5 3 9 Slide Hammer Bolts ( 3 /8 " - 16 - Outer
Threads) 11. J -2 1664 Clutch Spring Com pressor
5. J-81 05 Speedo Gear Remover Puller A da pter Ring
6. J - 2 1885 A ccum u lato r Piston Installer 12. J -4 6 7 0 Clutch Spring Com pressor
7. J - 2 1369 Converter Pressure Check 13. J-8 0 5 9 Snap Ring Pliers
Fixture 14. J -5 5 8 6 Snap Ring Pliers
8. J -2 1362 Seal Protector - Forward and 15. J-5 4 0 3 Snap Ring Pliers
D irect Clutch - Inner 16. J -1 3 1 3 Torque W rench 0 -1 4 0 Ft. Lbs.

17 18 19 20 21 22
Fig. 10ST--Turbo Hydra-M atic 40 0 Special Tools

1. J - 6 116-01 Rear U nit Holding Fixture 14. J - 2 1795-2 Part of Above Holding Tool
2. J-8 0 9 2 Driver Handle 15. J-5 3 8 4 Converter Holding Strap
3. J -2 1 3 5 9 Pump Oil Seal Installer 16. J-21 46 5-01 Bushing Tool Set
4. J -2 1 3 6 4 H olding Fixture A da pter (Used 17. J - 2 1465-5 P a rto f Bushing Tool Set
w ith J - 6 116-01 Fixture) 18. J - 2 1465-3 Part of Bushing Tool Set
5. J-2 6 1 9 Slide Hammer (Used w ith 19. J - 2 1465-2 Part of Bushing Tool Set
2 6 1 9 -4 A da pter 20. J - 2 1 465-1 Part o f Bushing Tool Set
and Remover Tools J-2 1 4 6 5 -0 1 ) 21. J - 2 1465-17 Part o f Bushing Tool Set
6. J -5 1 5 4 Extension Oil Seal Installer 22. J - 2 1465-8 Part of Bushing Tool Set
7. J -6 5 8 5 Slide Hammer W eights 23. J - 2 1455-13 Part of Bushing Tool Set
8. J -9 5 3 9 Slide Hammer Bolts (3 /8 " - 16 24. J - 2 1465-6 Part of Bushing Tool Set
Threads) 25. J - 2 1465-15 Part of Bushing Tool Set
9. J -5 5 9 0 Speedo Gear Installer 26. J - 2 1465-16 Part of Bushing Tool Set
10. J -2 1 8 6 7 Pressure Gauge and Hose 27. J - 2 1465-9 Part of Bushing Tool Set
11. J -2 1 3 7 0-6 Rear Band A p p ly Fixture 28. J -2 1 4 6 5 -1 0 Part of Bushing Tool Set
12. J -2 1 370-5 Rear Band A pp ly Pin 29. J-2 2 1 8 2 Ext. Bushing Rem. and Inst.
13. J - 2 1795-1 Gear U nit Assem bly Holding (Not Illustrated)
Tool

— ■— ...... ......... , ■ ..... — .......... .............
SECTION 9
STEERING
Manual Steering Gears.................................... 9-1 Control Valve - Corvette....................... ........... 9-24

Power Steering Pu m p..................................... 9-8 Power Cylinder-Corvette................................. 9-28
Integral Power Steering G ear............................. 9-13 Special Tools................................................ 9-30
MANUAL STEERING GEARS

INDEX
Overhaul O perations............................................................... 9-2 Pitm an Shaft Bushing R eplacem ent................... .......9-3

D isassem bly................................................................... ....... 9-2 Side Cover Bushing R eplacem ent...............................9-4
Inspection ..................................................................... ....... 9-2 W orm shaft Bearing Race R eplacem ent....................9-4
R ep airs............................................................................ ....... 9-3 Ball N ut Servicing................................................... .......9-4
Pitm an Shaft a n d /o r W orm shaft Seal A ssem bly ..................................................................... .......9-5
R ep lacem en t............................................................ ....... 9-3 A djustm ent on B e n c h .............................................. .......9-8
Fig. 2 -S te e rin g Gear (Except Corvette and

Fig. 1--Steering Gear (E xce p t C o rvette ) G 10-30 Series Trucks)

STEERING 9-2
OVERHAUL OPERATIONS
Disassembly (Figs. 1 through 4)
As with any ball bearing unit the steering gear parts must CAUTION: Use care that the ball nut does not run
be kept free of dirt. Clean paper or rags should be spread on down to either end of the worm. Damage will be
the workbench before starting disassembly of the steering done to the ends of the ball guides if the nut is al
gear. lowed to rotate until stopped at the end of the worm.
1. Place the steering gear in a vise, clamping onto one of
the m ounting tabs. The w orm shaft should be in a hori
zontal position. 7. All Except Corvette-Remove the upper bearing from the
2. R otate the w orm shaft from stop to stop, counting the wormshaft.
total num ber of turns. Then tu rn back exactly half way, Corvette- Remove lower bearing from inside the gear
placing the gear on center (the w orm shaft flat should be housing.
at the 12 o’clock position). 8. All except Corvette-Using a suitable size screw driver,
3. Place a pan under the assembly to catch the lubricant pry the lower bearing retainer from the adjuster plug
and remove the three self locking bolts attaching the housing and remove the bearing (fig. 7).
side cover to the housing.
9. Remove the locknut from the lash adjuster screw in the
4. Tap lightly on the end of the pitm an shaft with a plastic
side cover. Remove the lash adjuster screw from the
ham m er and lift the side cover and pitm an shaft assem
side cover by turning the screw clockwise. Slide the
bly from the gear housing (fig. 5).
adjuster screw and shim out of the slot in the end of the
pitm an shaft.
NOTE: If the pitman shaft sector does not clear the 10. Pry out and discard both the pitm an shaft and worm
opening in the housing easily, turn the wormshaft shaft seals.
by hand until the sector will pass through the open
ing in the housing. Inspection
W ith the steering gear completely disassembled, wash all
parts in cleaning solvent. D ry them thoroughly with air.
5. Remove the adjuster plug and locknut assembly (incor W ith a magnifying glass inspect the bearings and bearing
porates the lower w orm shaft bearing and race on all races for signs of indentation. Also check for any signs of
except C orvette - upper worm shaft bearing race on C or chipping or breakdown of the surface. A ny parts that show
vette). signs of damage should be replaced
6. D ra w th e w o rm s h a ft a n d b all n u t a sse m b ly fro m Inspect all seals. Any seal that is worn or has been removed
the h o u sin g (fig. 6 ). should be replaced.
W O R M BEARING SECTOR BALL NUT SIDE COVER

(LOW ER)
BALL NUT
W OR M SH AFT
W O R M BEAR IN G LOCKNUT
(UPPER)
ADJUSTER
PLUG
SEAL
BEARING
CUP
LASH ADJUSTER PITMAN ARM SEAL

E XP A N SIO N BEARING C LAM P BALL BALL ‘ LO C K NUT SCREW
PLUG CUP GUIDE BEARINGS
Fig. 3 -S te e rin g G ear-C orvette Fig. 4--Steering Gear (Corvette and G 10-30 Series Trucks)

STEERING 9-3
Fig. 5--Removing Pitman S h a ft A s s e m b ly - T y p i c a l
Inspect the fit of the pitm an shaft in its bushing in the side CAUTION: Before installing new seals, check the
cover. If this bushing is worn, a new side cover and bushing con d itio n of the p itm a n s h a ft b u s h in g ( s ) an d the
assembly should be installed. upper w orm shaft bearing race.
Check steering gear w orm shaft assembly for being bent or
dam aged in any way. Never attem pt to salvage steering parts 2. A su ita b le size socket, p ressin g o n th e o u te r
by welding or straightening. d ia m e te r o f th e seal, m ay be u se d to in s ta ll new
seals.
Repairs NOTE: Care should be taken to insure that the new

seals are not assembled in a cocked position.
Pitman Sh a ft and/or W orm shaft Seal
Replacement
Pitman Sh aft Bushing Replacement
The double lipped pitm an shaft and worm shaft seals 1. Support the steering gear housing in an arbor press and
should be replaced each time a defective seal is indicated or press the pitm an shaft bushing (2 bushings on Corvette
the steering gear is disassembled. and G 10-30 Series Trucks) from the housing using Tool
1. If the seals were not removed at disassembly, pry out J-1614, inserted from the lower end of the housing (fig.
the old seals using a suitable size screw driver. 8).
HOLD ASSEMBLY
J0r
w'
Fig. 8-R em oving Pitman Shaft Bushing Using Tool

Fig. 6--Removing the W orm sha ft and Ball Nut--Typical J-1 61 4 -T yp ica l

STEERING 9-4
2. Press the new bushing(s) into position using Tool J-

1614. Position the Corvette and G10-30 Series Truck
bushings as shown in Figure 4.
NOTE: Service bushings are diamond bored to size

and require no further reaming.
Side Cover Bushing Replacement

The entire side cover assembly, including bushing, is ser
viced as a unit and should be replaced when it is desired to
replace the bushing. J-5755
W orm shaft Bearing Race Replacement
WORM
Adjuster Plug Races BEARING RACE
1. All Except Corvette- Remove the w orm shaft bearing
race using Tool J-5822 and Slide H am m er J-2619 as Fig. 10— Installing W orm sha ft Bearing Race in Housing Using
shown in Figure 9. Tool J-5755--Typical
Corvette- Using a ham m er and punch, drive the bear
ing race out of the adjuster plug. to deform it inward and secure it in the housing. Make
2. Press the new bearing race into position using Tool sure the plug is tight or lubricant leakage could result.
J-5755.
Ball Nut Servicing
Housing Races
As a rule, disassembly of the ball bearing nut will not be
1. Corvette only- Using a drift or punch (inserted into the
necessary if it is perfectly free with no indication of binding
housing from the adjuster plug end) drive the sheet
or tightness when rotated on the worm. However, if there is
metal expansion plug out of the lower end of the hous
any indication of binding or tightness, the unit should be
ing.
disassembled, cleaned and inspected as follows:
2. Using a drift or punch, drive the bearing race out of the
1. Remove screws and clamp retaining the ball guides in
housing.
nut. Draw guides out of nut.
3. Press the new bearing race into position using Tool
2. T urn the nut upside down and rotate the wormshaft
J-5755 (fig. 10).
back and forth until all the balls have dropped out of
4. Corvette only- Install a new expansion plug into the the nut into a clean pan. W ith the balls removed, the nut
lower end of the housing. Press on the center of the plug can be pulled endwise off the worm.
3. W ash all parts in cleaning solvent and dry them
thoroughly with air. Using a magnifying glass inspect
the worm and nut grooves and the surface of all balls
for signs of indentation. Check ball guides for damage
at ends where they deflect or pick up the balls from the
helical path. Any parts that show signs of damage
should be replaced.
4. All Except Corvette (fig. 11):
a. Place the worm shaft flat on the bench and slip the
nut over the worm with the ball guide holes up and
the shallow end of the ball nut teeth to the left from
the steering wheel position. Align the grooves in the
worm and nut by sighting through the ball guide
holes.
b. Place two ball guide halves together and insert them
into the upper circuit in the ball nut. Place the
remaining two guides together and insert them in
the lower circuit.
c. Count 24 balls into a suitable container. This is the
proper num ber of balls for one circuit.
Fig. 9--Removing A djuster Plug Bearing Race Using Tools d. Load the balls into one of the guide holes while
J -5 8 2 2 and J-2 6 1 9 turning the wormshaft gradually away from that

STEERING 9-5
Fig. 13— Filling Ball G uides-C orvette
hole. W hen all of the balls have been installed, the d. Close this half of guide with the other half. Hold the
circuit is complete. two halves together and plug each open end with
e. Fill the rem aining ball circuit in the same m anner petroleum jelly so that balls will not drop out while
as described for the first circuit in Steps c and d installing the guide.
above. e. Push the guide into the guide holes of the nut. This
5. Corvette only (figs. 12 and 13): completes one circuit of balls. If the guide does not
a. Place the worm shaft flat on the bench and slip the push all the way down easily, tap it lightly into place
nut over the worm with the ball guide holes up and with the wooden handle of a screw driver.
the shallow end of the rack teeth to the left from the f. Fill the second ball circuit in the same manner. Con
steering wheel position. Align the grooves in the tinue until the ball circuit is full from the bottom of
w orm and nut by sighting through the ball guide one guide hole to the bottom of the other or until
holes. stopped by reaching the end of the worm.
b. C ount 27 balls into a suitable container. This is the
proper num ber of balls for half the circuit. Place NOTE: In cases where the balls are stopped by the
these balls into one of the guide holes while turning end of the worm, hold down those balls already
the worm gradually away from th at hole. dropped into the nu;t with the blunt end of a clean
c. Lay one-half of the ball guide, groove up, on the rod or punch (fig. 12) and turn the worm in the re
bench and place the rem aining balls from the count verse direction a few turns. The filling of the circuit
container in it. can then be continued. It may be necessary to work
the worm back and forth, holding the balls down
first in one hole and then the other, to close up the
spaces between the balls and fill the circuit com
pletely and solidly.
6. Assemble the ball guide clamp to the ball nut and

tighten the screws to specified torque.
Check the assembly by rotating the nut on the worm to
see that it moves freely. D o not rotate the nut to the end of
the worm threads as this m ay damage the ball guides. If there
is any "stickiness" in the motion of the nut, some slight
damage to the ends of the ball guides or to other gear com po
nents may have been overlooked.
Assembly (Fig. 14 and 15)

LOWER CIRCUIT
After a major service overhaul, steering gear lubricant
meeting G M Standard G M 4673M (or equivalent) should be
applied to the pitman shaft and bearings, wormshaft and
Fig. 1 2—Filling Ball C ircu its-C orve tte bearings and the ball nut teeth.

STEERING 9-6
Fig. 14 -S teering G ear-Except Corvette
1. W orm Bearing A djuster 9. Upper W orm Bearing Race 16. Lash A d ju ste r
Locknut 10. Pitman S haft Seal 17. Lash A d ju ste r Shim
2. W orm Bearing A djuster 11. Housing 18. Housing Side Cover and
3. Lower W orm Bearing Race 12. W o rm sh a ft Seal Bushing Assem bly
4. Low er Ball Bearing 13. Side Cover Gasket 19. Lash A d ju ste r Locknut
5. Low er Bearing Retainer 14. Pitman S haft Bushing (2 20. Side Cover Bolts
6. Ball Nut Bushings on G 10-30 Series 21. Ball Guide Clamp Screws
7. W o rm sh a ft Trucks) 22. Ball Guide Clamp
8, U pper Ball Bearing 15. Pitman Shaft 23. Ball Guides
24. Balls
1. Place the steering gear housing in a vise w ith the w orm 4. Corvette-
shaft bore horizontal and the side cover opening up. a. Place a w orm shaft bearing in the housing race. Slide
2. W ith the pitm an shaft and worm shaft seals, pitm an the other bearing and the adjuster plug assembly
shaft bushings and w orm shaft bearing races installed, over the upper end of the wormshaft.
and the ball n u t installed on the worm shaft, proceed to b. Insert the wormshaft, nut and adjuster assembly
Step 3 or 4. into the housing, guiding the lower end of the
3. All Except Corvette-- worm shaft into the housing bearing.
a. Slip the upper ball bearing over the w orm shaft and c. Thread the adjuster into the housing until nearly all
insert the w orm shaft and nut assembly into the end play is removed from the wormshaft.
housing, feeding the end of the shaft through the 5. Position the lash adjuster (with shim) in the slotted end
upper ball bearing race and seal. of the pitm an shaft. Check the end clearance, which
b. Place a ball bearing in the adjuster race and press should not be greater than .002" (fig. 16). If clearance
the stam ped retainer into place with a suitable is greater than .0 0 2 ", a steering gear lash adjuster shim
socket. unit is available. It contains four shim s-.063", .065",
c. Install the adjuster and locknut into the lower end .067" and .069" thick,
of the housing (being careful to guide the end of the 6 . Lubricate the steering gear with 11 oz. of lubricant
w orm shaft into the bearing) until nearly all end play meeting G M Specification G M 4673 (or equivalent).
has been removed from the wormshaft. R otate the worm sahft until the ball nut is at the end of

STEERING 9-7
Fig. 15 -S teering G ear-C orvette
1. Side Cover Screws 9. Expansion Plug 17. W orm Bearing R ace-U pper
2. Lash A d ju ste r Locknut 10. Steering Gear Housing 18. A d ju ste r Plug
3. Side Cover and Bushing 1 1. Pitman S haft Seal 19. W orm sha ft Seal
4. Lash A d ju ste r Shim 12. W orm Bearing R ace-Low er 20. A d ju ste r Plug Locknut
5. Lash A d ju ste r Screw 13. W orm B ea rin g -L o w e r 21. Clamp Screw
6. Side Cover Gasket 14. Ball Nut 22. Ball Guide Clamp
7. Pitman Shaft 15. W orm sha ft 23. Balls
8. Pitman S haft Bushings 16. W orm B ea rin g -U p p e r 24. Ball Guides
its travel and then pack as m uch new lubricant into the 7. R otate the w orm shaft until the ball nut is about in the
housing as possible w ithout losing it out the pitm an center of travel. This is to make sure th at the pitm an
shaft opening. R otate the w orm shaft until the ball nut shaft sector and ball nut will engage properly, with the
is at the other end of its travel and pack as m uch lubri center tooth of the sector entering the center tooth
cant into the opposite end as possible. space in the ball nut.
8. Insert the pitm an shaft assembly (with lash adjuster
screw and shim but w ithout side cover) into the housing
as that the center tooth of the pitm an shaft sector enters
the center tooth space of the ball nut.
9. Pack the remaining portion of lubricant into the hous
ing.
10. Place the side cover gasket on the housing.
11. Install the side cover onto the pitm an shaft by reaching
through the side cover with a screwdriver and turning
the lash adjuster screw counterclockwise until the screw
bottoms; back the screw off one half turn. Loosely in
stall a new locknut onto the adjuster screw.
12. Install and tighten the side cover bolts to specifications.
NOTE: If new side cover bolts are used at installa

tion, be sure to use specified bolts which are self
locking.
Fig. 16-C hecking Lash A d ju ste r End Clearance

STEERING 9-8
Adjustment on Bench th e sh a ft b a c k exactly h a lf th e n u m b e r o f tu rn s to

the cen te r position.
1. Tighten the adjuster plug until all end play has been 5. T urn the lash adjuster screw clockwise to remove all
removed and then loosen one-quarter turn. lash between the ball nut and sector teeth. Tighten the
2. Using an 11/16" 12-point socket and an in. lb. torque locknut.
wrench, carefully tu rn the w orm shaft all the way to the 6 . Again using the 11/16" 12-point socket and an in. lb.
right turn stop and then tu rn back about one-half turn. torque wrench, observe the highest reading while the
3. Tighten the adjuster plug until the proper th ru st bear gear is turned through center position. See the Specifi
ing preload is obtained; (See the Specifications at the cations Section for proper over center adjustment.
rear of this M anual). Tighten the adjuster plug locknut 7. If necessary, readjust lash adjuster screw to obtain
to specifications. proper torque. Tighten the locknut to 23 ft. lb. torque
4. T u rn th e w o rm sh a ft fro m o n e sto p all th e w ay to and again check torque reading through center of
th e o th er, c o u n tin g the n u m b e r o f tu rn s. T h e n tu rn travel.
POWER STEERING PUMP

INDEX
Overhaul O perations........................................ ............... 9-9 --In sp ectio n ........................................................................ 9-9

--Disassembly...................................................................... 9-9 --Assem bly.......................................................................... 9-10
18 19 20
■&u 6
1 2 3 4 6 7 8 9 10 1 1 12 13 14 15 16 17 21 22 23 24 25 26 27
Fig. 17--Power Steering Pump--Exploded V iew

1. Union 11. Pressure Plate 20. M ounting Stud Square Ring
2. Union " 0 " Ring Seal 12. Pump Ring Seals
3. M ounting Studs 13. Vanes 21. Flow C ontrol Valve
4. Reservoir 14. Drive S haft Retaining Ring 22. Flow C ontrol Valve Spring
5. Dip S tick and Cover 15. Rotor 23. Flow C ontrol Valve Square
6. Element (Corvette only) 16. T hrust Plate Ring Seal
7. F ilter Assem bly (Corvette only) 17. Dowel Pins 24. Pump Housing
8. End Plate Retaining Ring 18. End Plate "O " Ring 25. Reservoir " 0 " Ring Seal
9. End Plate 19. Pressure Plate " 0 " Ring 26. Shaft Seal
10. Spring 27. Shaft

STEERING 9-9
OVERHAUL OPERATIONS
Disassembly (Fig. 17) 10. Separate the parts removed in Step 9 above. If inspec
tion shows the shaft to be defective, separate it from the
Clean the outside of the pum p in a Nontoxic Solvent rotor by removing the retainer snap ring. D iscard the
before disassembly. snap ring.
1. Remove the pulley retaining nut and remove the pulley 11. Remove the end plate and pressure plate "O" rings
using Tool J-2 1239-1. from the pum p housing and discard "O" rings.
2. Place the pum p in a vise and remove the union and "O" 12. Remove the dowel pins.
ring seal assembly. 13. Remove the flow control valve and spring assembly.
14. Pry the shaft seal out of the pump housing being careful
CAUTION: In clamping pump in vise, be careful not not to damage the housing bore, discard the shaft seal.
to exert excessive force on the pump front hub as
this may distort the shaft bushing.
Inspection
3. Remove the pum p reservoir retaining studs. Clean all metal parts in a nontoxic solvent and inspect as
4. Remove the reservoir from the pum p housing by tap follows:
ping lightly on the outer edge of the reservoir with a soft 1. Flow control valve m ust slide freely in housing bore. If
ham m er. Remove the "O" ring seal from the pump sticking is observed, check for dirt and burrs.
housing and discard seal. 2. Check cap screw in the end of the flow control valve for
5. Remove the m ounting stud square ring seals and the looseness; if loose, tighten, being careful not to damage
flow control valve square ring seal and discard. machined surfaces.
6 . On Corvette, remove filter and filter cage; discard filter 3. Be sure that pressure plate and pum p plate surfaces are
element. flat and parallel with pum p ring. Check all of these
7. Remove the end plate retaining ring. Compress the end parts for cracks and scoring.
plate retaining ring by inserting a small punch in the
1/8" diam eter hole in the pum p housing. W hen the ring NOTE: A high polish is always present on rotor pres
is in compressed position, remove with a screw driver sure plate and thrust plate as a result of normal
as shown in Figure 18. wear. Do not confuse this with scoring.
8 . Remove the end plate. The end plate is spring loaded
and will generally sit above the housing level. If sticking 4. M ake certain vanes were installed with rounded edge
should occur, a slight rocking action or light tapping tow ard pum p ring and see that they move freely in rotor
w ith a soft ham m er will free the plate. Remove the end slots.
plate spring. 5. If the flow control plunger is determ ined to be faulty,
9. W ith the pum p still in a vise, remove the shaft w oodruff install a new part. This part is serviced as a unit only
key and tap end of shaft gently with a soft ham m er until and is factory calibrated.
the shaft, pressure plate, pum p ring, rotor assembly and 6. Check drive shaft for worn splines, breaks, bushing
th ru st plate can be removed as a unit (fig. 19). material pickup, etc.
Fig. 18-R em oving End Plate Ring Fig. 1 9 -Im p e lle r U nit Removal

STEERING 9-10
Fig. 21 —I nsta I ling Seal Using Tool J -2 2 6 7 0
2. Install both dowel pins in the pum p housing and install

a new pressure plate "O" ring lubricated with Power
Steering Fluid.
Fig. 20~Power Steering Pump--Typical 3. Install the thrust plate on the shaft with the ported face
towards the splined end of the shaft (fig. 22 ).
1 . Shaft 4. Install the rotor, which must be free on the shaft

13. F ilter (Corvette Only)
2 . W o o d ru ff Key 14. Pressure Plate Spring splines, with the countersunk side towards the thrust
3. Shaft Seal 15. Pump Inlet Tube plate.
4. Pump Housing 16. Rotor-to-Drive Shaft 5. Install a new shaft retaining ring by placing the ring on
5. T hrust Plate Retaining Ring the end of the shaft and using first a drift and then a
6 . Vanes 17. Pump O utlet Union 3/8" socket to tap the NEW ring into place (fig. 23).
7. Pump Ring 18. Reservoir
8 . Reservoir " 0 " Ring 19. Flow C ontrol Valve CAUTION: Do not use a"C"ring to replace the full
Seal 20. Flow C ontrol Valve diameter ring. Be sure the retaining ring is firmly
9. Pressure Plate Spring seated in the shaft groove before proceeding.
10 . End Plate 21. Pressure Plate " 0 "
1 1. End Plate Retaining Ring 6. Place pum p housing in a vise and install shaft, thrust
Ring 22. Rotor plate and rotor assembly into housing, aligning the
12 . Cage Assem bly holes in the thrust plate with the dowel pins as shown
(Corvette Only) in Figure 24.
Assembly (Fig. 20)

7. Always replace all rubber seals and "O" rings when
pum p is dismantled.
8. Check reservoir, studs, casting, etc. for burrs and other
faults which would im pair proper operation.
Be sure all parts are clean during reassembly.
NOTE: In the following text, Power Steering Fluid is

noted for use in lubricating components upon reas
sembly. If Power Steering Fluid is not available,
Transmission Fluid bearing the mark Dexron may be
used as a substitute.
1. Install a new shaft seal in the pump housing, using Tool

J- 22670 as shown in Figure 21. Fig. 22-1 nstalling T hrust Plate

STEERING 9-11
Fig. 2 3 ~ ln sta llin g Shaft Snap Ring Fig. 2 6— 1nsta 11i ng Vanes
7. Install the pum p ring onto the dowel pins with the
direction of rotation arrow to the rear of the housing
(fig. 25). Rotation is clockwise as viewed from the pul
ley end of the shaft.
8. Install the vanes into the rotor slots with the radius edge
tow ards the pum p ring and the square edge towards the
rotor as shown in Figures 26 and 27.
9. Lubricate the outside diam eter and cham fer of the pres
sure plate with Power Steering Fluid, to ensure against
damaging the pressure plate "O" ring, and install the
pressure plate onto the dowel pins with the ported face
towards the pump ring. Seat the pressure plate by plac
ing a large socket on top of the plate and pressing down
DOWEL CROSS-OVER HOLE PUMP

PIN RING
Fig. 2 4 -ln s ta llin g Shaft, T hrust Plate, and Rotor Assem bly HOLE
PUMP
ROTOR
PUMP
VANES
Fig. 2 5--I nsta 11i ng Pump Ring Fig. 2 7 -C o rre c t Vane Assem bly

STEERING 9-12
Fig. 2 8 ~ ln sta llin g Pressure Plate Spring Fig. 3 0 — 1nsta 11ing Flow Control Valve
by hand (pressure plate will travel approxim ately 1/16" maging the "O" ring, and install into the housing using
to seat). an arbor press as shown in Figure 29.
10. Install the pressure plate spring in the center groove of
the pressure plate (fig. 28). NOTE: Place the end of the ring so that it is near the
11. Lubricate a new end plate "O" ring with Power Steering valve bore in the housing.
Fluid and install in housing groove.
12. Lubricate the outside diam eter and cham fer of the end 13. Install the flow control spring and flow control plunger.
plate w ith Power Steering Fluid, to ensure against da Be sure the hex head screw goes into the bore first (fig.
30).
14. On Corvette, install cage and a new filter.
VALVE BORE 15. Install new m ounting stud and union square ring seals.
16. Install a new reservoir "O" ring seal, lubricated with

Pow er Steering Fluid, onto housing.
17. Lubricate reservoir sealing edge with Power Steering
Fluid and place reservoir onto housing in the normal
position. Press down on reservoir until it seats onto
housing; check position of stud and union seals.
18. Place a new "O" ring seal, lubricated with Power Steer
ing Fluid, onto union and install union assembly and
studs.
19. Support the drive shaft on the opposite side of the key
way and tap the w oodruff key into place.
20. Slide the pulley onto the shaft. Do not ham m er on the
pulley.
21. Install the pulley nut and torque to 60 ft. lbs.
NOTE: Always use a new pulley nut.

Fig. 2 9 —Installing End Plate Retaining Ring

STEERING 9-13
INTEGRAL POWER STEERING GEAR
INDEX
O verhaul O perations........................................................ ... 9-13 Hose C onnector Inverted Flares.......................... .......9-20

D isassem bly................................................................... ... 9-13 Pitm an Shaft Needle Bearing and Seals............ .......9-20
O verhauling Individual U n its................................... ... 9-16 Pitm an Shaft Seal Removal W ith G ear In
Valve and Stub Shaft A ssem bly .......................... ... 9-18 Vehicle ..................................................................... .......9-21
Pitm an Shaft and Side C o v e r...................................9-19 A ssem bly...............................................................................9-22
R a c k -P isto n ...................................................................9-19
OVERHAUL OPERATIONS
NOTE: In the following te x t Power Steering Fluid is piston just forces end cover out of housing. Remove
noted for use in lubricating components upon reas cover and discard "O" ring.
sembly. If Power Steering Fluid is not available,
Transmission Fluid bearing the mark DEXRON may
be used as a substitute. CAUTION: DO NOT turn the stub shaft any further
than absolutely necessary to remove the end plug,
or balls from rack-piston and worm circuit may es
Disassembly (Fig. 31) cape and lay loose inside the rack-piston chamber.
In m any cases, complete disassembly of the gear will not 3. Remove the rack-piston end plug as shown in Figure
be necessary since most of the com ponents can be removed 33.
w ithout complete disassembly.
NOTE: To aid in loosening end plug, tap end plug
with a brass drift.
NOTE: Disassembly of the major components
within the gear must be performed on a clean work
bench. The work area, tools and parts must be kept 4. Remove the pitm an shaft and side cover as follows:
clean at all times. a. Loosen the over-center adjusting screw locknut and
remove the 4 side cover attaching bolts and lock
washers.
b. R otate the side cover until the rack-piston and pit
1. R otate end cover retainer ring so that one end of the
man shaft teeth are visible, then turn the stub shaft
ring is over the hole in the side of the housing. Force
until the pitm an shaft teeth are centered in the hous
the end of the ring from its groove and remove ring (fig.
ing opening. Tap the pitm an shaft with a soft ham
32).
m er and remove the pitm an shaft and side cover
from the housing. Remove the side cover "O" ring
2. T urn the stub shaft counter-clockwise until the rack- and discard.

9-14 STEERING
INLET OUTLET
STUB SHAFT
•TORSION BAR
SEAL
RACK PISTON NUT

-ADJUSTER PLUG
PITMAN SHAFT THRUST BEARING
Fig. 31~Pow er Steering G ear-T ypical
Fig. 3 2 -R e m o vin g End Cover Retaining Ring Fig. 33~Removing End Plug

STEERING 9-15
Fig. 34~Pow er Steering G ear-Exploded V iew
1. Locknut 17. Valve Body 33. Balls

2. Retaining Ring 18. Stub Shaft 34. Rack-Piston
3. Dust Seal 19. " 0 " Ring 35. Teflon Oil Seal
4. Oil Seal 20. W orm sha ft 36. " 0 " Ring
5. Bearing 21. T hrust W asher 37. Plug
6. A d ju ste r Plug 22. T hrust Bearing 38. " 0 " Ring
7. " 0 " Ring 23. T hrust W asher 39. Housing End Cover
8. T hrust W asher (Large) 24. Housing 40. Retainer Ring
9. T hrust Bearing 25. Locknut 41. Needle Bearing
10. T hrust W asher (Small) 26. A tta chin g Bolts and W ashers 42. Oil Seal
11. Spacer 27. Side Cover 43. Back Up W asher
12. Retainer 28. " 0 " Ring 44. Oil Seal
13. " 0 " Ring 29. Pitman Shaft 45. Back Up W asher
14. Spool Valve 30. Screws and Lock W ashers 46. Retaining Ring
15. Teflon Oil Rings 31. Clamp
16. " 0 " Rings 32. Ball Return Guide
5. Remove the rack-piston as follows: b. Remove the rack-piston with Ball Retainer Tool
a. Insert Ball R etainer Tool J-7539 into the rack-pis J-7539 from gear housing.
ton bore with pilot of tool seated in the end of the
worm (fig. 35). T urn the stub shaft counter-clock 6. Remove the adjuster plug as follows:
wise while holding tool tightly against worm. The a. Loosen the adjuster plug locknut and remove.
rack-piston will be forced onto the tool. b. Remove adjuster plug assembly with Spanner

STEERING 9-16
Fig. 3 5 -R e m o vin g Rack-Piston Fig. 37--A djuster P lug-E xploded View
1. Retaining Ring 7. T hrust W asher (Large)

W rench J-7624 (fig. 36). Remove and discard the 2. Dust Seal 8. T hrust Bearing
plug "O" ring. 3. Oil Seal 9. T hrust W asher (Small)
7. G rasp the stub shaft and pull the valve and shaft assem 4. Needle Bearing 10. Spacer
bly from the housing bore. Separate worm and shaft and 5. A d ju ste r Plug 11. Retainer
remove the stub shaft cap "O" ring and discard. 6. " 0 " Ring
8. If the worm or the lower thrust bearing and race re
mained in the gear housing, remove them at this time. to score the needle bearing bore (fig. 37). Discard the
oil seal.
O VERHAULIN G IN DIVIDUAL UNITS If the thrust bearing O N LY is to be removed, pry the
thrust bearing retainer at the two raised areas with a
small screw driver (fig. 38). Remove the spacer, thrust
Adjuster Plug Assembly bearing washer, thrust bearing and washer. Discard the
retainer.
Disassem bly
If the needle bearing is to be replaced, remove the re
1. If the oil seal O N LY is to be replaced, and not the taining ring using Internal Pliers J-4245. Remove thrust
bearing, install the adjuster plug loosely in the gear bearing as outlined in Step 2 above. Drive needle bear
housing. Remove the retaining ring with Internal Pliers ing, dust seal and oil seal from adjuster plug using
J-4245. W ith a screw driver, pry the dust seal and oil Bearing Remover J-8524-2 and D river J-7079-2 as
seal from the bore of the adjuster plug being careful not shown in Figure 39. Discard the oil seal.
BEARING SCREW DRIVER
RETAINER
Fig. 36 -R em oving A djuster Plug Fig. 38--Removing Retainer

STEERING 9-17
SEAL
s ■>;r*»*
.. ______ Li______
Fig. 39--Removing Bearing and Seal Fig. 4 1— Installing A d ju ste r Plug Seal
4. W ash all parts in clean solvent and dry parts with com drive the bearing into the adjuster plug until the tool
pressed air. bottom s in the housing (fig. 40).
5. Inspect thru st bearing spacer for wear or cracks. R e 2. Place dust seal and a new oil seal on Tool J-8524-1 (lip
place if damaged. of seal away from tool). Lubricate seal with Power
6. Inspect thrust bearing rollers and washers for wear, Steering Fluid and drive or press seals into adjuster plug
pitting or scoring. If any of these conditions exist, re until seated (fig. 41).
place the bearing and washers. 3. Install retaining ring with Internal Pliers J-4245.
Assem bly 4. Lubricate the thrust bearing assembly with Power
Steering Fluid. Place the large thrust bearing washer on
CAUTION: Place a block of wood under the adjuster the adjuster plug hub, then install the upper thrust
plug to protect the thrust bearing surface. bearing, small bearing washer and spacer (grooves of
spacer away from bearing washer).
1. If the needle bearing was removed, place new needle 5. Install a new bearing retainer on the adjuster plug by
bearing over Tool J-8524-1 and J-7079-2, with the bear carefully tapping on the flat surface of the retainer (fig.
ing m anufacturer’s identification tow ard the tool, and 42).
BEARING W ITH
ID E N TIFIC ATIO N
TO W ARD TO O L
Fig. 4 0 —1nsta lling Bearing Fig. 4 2-1 nsta 11i ng Retainer

STEERING 9-18
NOTE: The projections must not extend beyond the

spacer when the retainer is seated. The spacer must
be free to rotate.
Valve and Stub Sh aft Assembly
Disassem bly
1. Remove and discard the "O" ring in the shaft cap end
of the valve assembly.
2. To remove the lower shaft assembly from the valve
body, proceed as follows:
a. W hile holding the assembly (stub shaft down),
lightly tap the stub shaft against the bench until t he
shaft cap is free from the valve body (fig. 43).
b. Pull the shaft assembly out of the spool valve until Fig. 44-R em oving Spool Valve
the shaft cap clears the valve body approximately
1/4".
3. If there is evidence of leakage between the torsion bar
and the stub shaft, or scores, nicks, or burrs on the
CAUTION: Do not pull the shaft assembly out too
ground surface of the stub shaft that cannot be cleaned
far or the spool valve may become cocked in the
up with crocus cloth, the entire valve and shaft assem
valve body.
bly m ust be replaced.
4. Check the outside diam eter of the spool valve and the
c. Carefully disengage the shaft pin from the valve
inside diam eter of the valve body for nicks, burrs, or
spool and remove the shaft assembly (fig. 43).
bad wear spots. If the irregularities cannot be cleaned
3. Push the spool valve out of the flush end of the valve
up by the use of crocus cloth, the complete valve and
body until the dam pener "O" ring is exposed, then
shaft assembly will have to be replaced.
carefully pull the spool from the valve body, while
5. If the small notch in the skirt of the valve body is
rotating the valve (fig. 44). If the spool valve becomes
excessively worn, the complete valve and shaft assem
cocked, carefully realign the spool valve, then remove.
bly will have to be replaced.
4. Remove the dam pener "O" ring from the spool valve 6. Lubricate the spool valve with Power Steering Fluid
and discard. and check the fit of the spool valve in the valve body
5. If the teflon oil rings are to be replaced, cut the 3 teflon (with the spool valve dam pener "O" ring removed). If
oil rings and "O" rings from the valve body and discard. the valve does not rotate freely w ithout binding, the
Cleaning and Inspection complete valve and shaft assembly will have to be re
placed.
1. W ash all parts in clean solvent and blow out all oil holes
with compressed air. Assem bly (Fig. 45)
2. If the drive pin in the stub shaft or valve body is
cracked, excessively worn or broken, replace the com 1. If valve body "O" rings and teflon rings were removed,
plete valve and shaft assembly. install new "O" rings in the oil ring grooves and lubri
cate with Power Steering Fluid.
2. Lubricate the 3 new teflon oil rings with Power Steering
Fluid and install in grooves over "O" rings.
NOTE: The teflon rings may appear to be distorted,

but the heat of the oil during operation of the gear
will straighten them out.
3. Lubricate the spool valve dam pener "O" ring with

Power Steering Fluid and install over the spool valve.
4. Lubricate the spool valve and valve body with Power

Steering Fluid and slide the spool valve into the valve
body. R otate the spool valve while pushing it into the
valve body. Push the spool valve on through the valve
body until the shaft pin hole is visible from the opposite
end (spool valve flush with shaft cap end of valve body).
5. Lubricate the shaft assembly with Power Steering Fluid
and carefully install it into the spool valve until the
Fig. 43--Removing Stub Shaft Assem bly shaft pin can be placed into the hole in the spool valve.

STEERING 9-19
" O " RING 3. Check the sealing and bearing surfaces of the pitm an
SPO O L VALVE shaft for roughness, nicks, etc. If m inor irregularities in
TEFLON RINGS (3) surface cannot be cleaned by use of crocus cloth, replace
" O ” RINGS (3) the pitm an shaft.
INSTALLED UNDER 4. Replace pitm an shaft assembly if teeth are damaged or
TEFLON RINGS if the bearing surfaces are pitted or scored.
5. Check pitm an shaft lash adjusting screw. It must be free
to turn with no perceptible end play. If adjusting screw
V ALVE BODY is loose replace the pitm an shaft assembly.
STUB SHAFT Assem bly

Thread the side cover onto the pitm an shaft adjusting
screw until it bottom s and then turn in one-half turn. Install
" O ” RING
a new adjusting screw locknut, but do not tighten.
Fig. 45--Valve Body and S haft Assem bly - Explode
Rack-Piston
6. Align the notch in the shaft cap with the pin in the valve
body and press the spool valve and shaft assembly into Disassem bly
the valve body (fig. 46).
1. Remove tool J-7539 from the rack-piston.
CAUTION: Make sure that the shaft cap notch is 2. Remove the ball return guide clamp, ball guide and
mated with the valve body pin before installing balls.
valve body into the gear assembly. 3. If necessary to replace the teflon oil seal and "O" ring,
remove at this time.
7. Lubricate a new "O" ring with Pow er Steering Fluid
and install it in the shaft cap end of the valve body
assembly.
1. W ash all parts in clean solvent and dry with com
pressed air.
Pitman Shaft and Side Cover 2. Inspect the worm and rack-piston grooves and all the
Disassem bly balls for scoring. If either the worm or rack-piston
needs replacing, both m ust be replaced as a matched
Remove the locknut and unscrew the side cover from the assembly.
adjusting screw. Do not attem pt to disassemble pitm an shaft. 3. Inspect ball return guide halves, making sure that the
D iscard locknut. ends where the balls enter and leave the guides are not
damaged.
4. Inspect lower thrust bearing and washers for scores or
excessive wear. If any of these conditions are found,
1. W ash all parts in clean solvent and dry parts with com replace the thrust bearing and washers.
pressed air. 5. Inspect rack-piston teeth for scoring or excessive wear.
2. Check pitm an shaft bearing surface in the side cover for Inspect the external ground surfaces for wear, scoring
scoring. If badly worn or scored, replace the side cover. Or burrs.
N O T C H IN END C AP MU ST FULLY
E N G A G E PIN PR O JEC TIN G IN T O
VALVE BODY
BACK-UP
O -R IN G MUST
BE INSTALLED
RACK-PISTON
UNDER PISTON
NUT
R ING
Fig. 4 6 — 1nsta llin g S tub S ha ft Assem bly Fig. 4 7 --Installing Ring on Rack-Piston

STEERING 9-20
Assem bly CAUTION: Do not tap the threads too deep in the
pressure hose connector seat as the tap will bottom
1. If the teflon oil seal and "O" ring were removed, lubri the poppet valve against the housing and damage it.
cate a new "O" ring and seal with Power Steering Fluid It is necessary to tap only two or three threads deep.
and install in groove on rack-piston. The teflon ring
may be slightly loose after assembly, but will tighten up 2. Thread a 5/16-18 bolt, with a nut and flat washer at
when subjected to the hot oil in the system (fig. 47). tached, into the tapped hole so that the washer rides
2. Slide the worm all the way into the rack-piston. It is not against the face of the port boss and the nut rides
necessary to have the thrust bearing assembly on the against the washer.
worm at this time. 3. Hold the bolt from rotating while turning the nut off
3. T urn the worm until the worm groove is aligned with the bolt. This will force the washer against the bolt boss
the lower ball return guide hole (fig. 48). and will back out the bolt, drawing the connector from
4. Lubricate the balls with Pow er Steering Fluid, then feed the housing. Discard the connector.
17 balls into the rack-piston, while slowly rotating the 4. Clean the housing thoroughly to remove any tapping
worm counter- clockwise. chips.
5. Drive the new connector against the housing seat using
IMPORTANT: The black balls are .0005" smaller Tool J-6217, being careful not to dam age either the
than the silver balls. The black and silver balls must connector or housing seat (fig. 49).
be installed alternately into the rack- piston and re
turn guide. Pitman Shaft Needle Bearing and Seals
5. A lternately install 7 balls into the return guide and Removal
retain with chassis lubricant at each end of guide. In
stall the return guide assembly onto the rack-piston. 1. If pitm an shaft seals ONLY are to be replaced, remove
Install the return guide clam p and tighten the 2 clamp the seal retaining ring with Internal Pliers J-4245 and
screws to 10 ft. lbs. remove outer steel washer. Pry out the outer seal.
6. Insert Bearing R etainer Tool J-7539 into the rack-pis Remove the inner steel washer, then pry out the inner
ton, then while holding tool tightly against end of seal (fig. 50). Discard seals.
worm, thread worm out of the rack-piston.
CAUTION: When prying out seals, be extremely
Hose Connector Inverted Flares careful not to score the housing bore.
If the brass inverted flare connectors show need of re 2. If pitm an shaft needle bearing replacement is necessary,
placement, proceed as follows: remove with Tool J-6278. Since this bearing is shoul
1. Tap threads into the center hole of the connector with dered, it must be pressed out the pitm an shaft end of the
a 5/16-18 tap. housing.
Installation
WORM
FLANGE 1. If the pitm an shaft needle bearing was removed, place
bearing Installer Tool J-22407 onto H andle J-8092.
Place needle bearing (shouldered end first) on to Tool
J-22407. Press bearing into gear housing until Tool bot
toms on housing. The bearing is now correctly posi
tioned (fig. 51).
INSTALL BALLS
WHILE ROTATING W O R M
COUNTER C LOCKW ISE
GUIDE
HALVES
Fig 4 9 -ln s ta llin g New Connector in Housing Using Tool

Fig. 4 8 -ln s ta llin g Balls in Rack-Piston J-6217

STEERING 9-21
WASHER
INNER OUTER
•# t ^ i SEAL SEAL
J-6278-1
- <
J-6278-2
TOP OF TOOL
FLUSH WITH
H O USIN G
Fig. 50--Pitman S haft Bearing and Seals Fig. 5 2--I nsta 11i ng Pitman S haft Seals (Bench Overhaul)
1. Housing 5. Oil Seal (Double Lip) c. Remove the tool and adapter, then install the outer
2. Bearing 6. Steel W asher steel washer and seal retaining ring. The retaining
3. Oil Seal 7. Retaining Ring ring will not seat in the groove at this time.
4. Steel W asher d. Reinsert Tool J-6278 with A daper J-6278-2 and
continue driving the seals until the retaining ring
seats in its groove (Refer to Inset, Figure 52), then
CAUTION: Do not drive the bearing further into the
remove the tool and adapter.
housing after removing Tool J-22407, since damage
to the bearing would result.
Removal and Installation of Pitman
2. Lubricate the lips of the oil seals with Power Steering
Fluid. Shaft Seals w ith Steering Gear in
3. Install the pitm an shaft oil seals as follows:
a. Place A dapter J-6278-2 over Tool J-6278, then in Vehicle (fig. 53)
stall the outer seal (double lip), inner steel washer,
and inner seal with the lips of the seals facing away If upon inspection of the gear, it is found that oil leakage
from the adapter. exists at the pitm an shaft seals, the seals may often be re
b. Drive the seals into the housing until the top of placed w ithout removing the gear assembly from the vehicle
A dapter J-6278-2 is flush with the housing (fig. 52). as follows:
DO NOT
BOTTOM BEARING
IN HO U SIN G
J-8092
J -6 2 1 9
W HEN TOOL J-22407

BOTTOMS O N HOUSING.
BEARING IS FULLY
INSTALLED
Fig. 5 1-In s ta llin g Pitman Shaft Bearing Fig. 5 3--I n sta 11i n g Pitman Shaft Seals

STEERING 9-22
1. Remove pitm an nut and disconnect pitm an arm from

pitm an shaft using Puller J-6632. STUB VALVE
SHAFT BODY
CAUTION: Do not hammer on the end of Puller Tool
J-6632.
WORM
SHAFT
2. Thoroughly clean end of pitm an shaft and gear hous
ing, then tape splines on end of pitm an shaft to insure LOWER THRUST
BEARING
that seals will not be cut by splines during assembly.
“ O ” RING
NOTE: Only one layer of tape should be used; an
excessive amount of tape will not allow the seals to
pass over it, due to the close tolerance between the
seals and the pitman shaft.
LOWER THRUST
BEARING WASHERS
3. Remove pitm an shaft seal retaining ring with Snap

Ring Pliers J-4245. Fig. 5 4 -W o rm and Valve Body-E xploded View
4. Start engine and turn steering wheel fully to the left so
that oil pressure in the housing can force out pitman
shaft seals. Turn off engine.
GEAR A S S E M B L Y
NOTE: Use suitable container to catch oil forced out 1. Lubricate the worm, lower thrust bearing and the two
of gear. This method of removing the pitman shaft thrust washers with Power Steering Fluid, then install
seals is recommended, as it eliminates the possibil one thrust washer, the bearing, and the other thrust
ity of scoring the housing while attempting to pry washer over the end of the worm (fig. 54).
seals out. If pressure of oil does not remove seals,
turn off engine, remove the steering gear and
remove the seals as outlined previously in this sec 2. Lubricate the valve body teflon rings and a new stub
tion. shaft cap "O" ring with Power Steering Fluid. Install
the stub shaft cap "O" ring in the valve body so it is
seated against the stub shaft cap. Align the N A R R O W
5. Clean the end of housing thoroughly so that dirt will N O TC H in the valve body with the pin in the worm,
not enter housing with the installation of the new seals. then install the valve and stub shaft assembly in the gear
6 . Lubricate the seals thoroughly with Power Steering housing (fig. 55). Apply pressure to the VALVE BODY
Fluid to install seals with Installer J-6219. Install the when installing. If pressure is applied to the stub shaft
inner single lip seal first, then a back-up washer. Drive during installation, the stub shaft may be forced out of
seal in far enough to provide clearance for the outer the valve body (fig. 56).
seal, back-up washer and retaining ring. M ake sure that
the inner seal does not bottom on the counterbore. In
stall the outer double lip seal and the second back-up
washer in only far enough to provide clearance for the
retaining ring. Install retaining ring.
7. Fill pum p reservoir to proper level. Start engine and POSITION WORM PIN
allow engine to idle for at least three m inutes without IN VALVE BODY NOTCH
turning steering wheel. T urn wheel to left and check for
leaks.
8 . Remove tape and reconnect pitm an arm.
NOTE: The pitman arm to steering gear nut 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 neces
sary. Do not use a replacement part of lesser quality
or substitute design. Torque values must be used as
specified during reassembly to assure proper reten
tion of this part. Fig. 5 5 -V a lve to W orm A lig nm e nt

STEERING 9-23
Fig. 5 8— 1nsta I ling A d ju ste r Plug
NOTE: The valve body is properly seated when the c. W ith Ball Retainer J-7539 in place in the rack-pis
oil return hole in the housing is entirely uncovered ton, push the rack-piston (with teeth tow ard pitm an
(fig. 57). shaft opening), into the housing until Tool J-7539
contacts the center of worm (fig. 59).
d. T urn the stub shaft clockwise with a 3/4" twelve
3. Lubricate a new adjuster plug "O" ring with Power point socket or box end wrench to thread the rack-
Steering Fluid and install in groove on adjuster plug. piston onto the worm while holding Tool J-7539
Place Seal Protector J-6222 over the stub shaft, then against the end of the worm.
install the adjuster plug assembly in the housing until e. W hen the rack-piston is completely threaded on the
it seats against the valve body (fig. 58). Remove Seal worm, remove Ball Retainer J-7539 and Seal Com
Protector. Do not adjust the thru st bearing preload at pressor J-8947 (Cars) or J-7576 (Trucks).
this time. 5. Install the pitm an shaft and side cover as follows:
a. Install a new "O" ring in the pitm an shaft side cover
and retain with chassis lubricant.
4. Install the rack-piston as follows: b. T urn the stub shaft until the rack-piston teeth are
a. Lubricate the rack-piston teflon seal with Power centered in the pitm an shaft opening, then install
Steering Fluid. the pitm an shaft and side cover so that the center
b. Position Seal Com pressor J-8947 (Passenger Cars) tooth of the pitm an shaft engages the center groove
J-7576 (Trucks) against the shoulder in the housing. of the rack-piston.
Fig. 5 7 -V a lv e Body Position in Housing Fig. 5 9—I nsta lling Rack-Piston

STEERING 9-24
c. Install the side cover bolts and lock washers and

tighten to 30 ft. lbs. J-58 60
6. Install the rack-piston plug in the rack-piston and
torque to 75 ft. lbs.
7. Install a new housing end cover "O" ring and lubricate
it with Pow er Steering Fluid. Install the end cover and
retaining ring.
8. Adjust the thru st bearing preload as follows:
a. Using Spanner W rench J-7624, tighten adjuster
plug up snug (clockwise). Back adjuster plug off 1/8
tu rn and m easure valve drag.
b. A djust thrust bearing preload to obtain approxi
m ately 2 in. lbs. in excess of seal drag. Tighten
adjuster plug locknut securely while holding ad
ju ster plug in position with Tool J-7624.
9. A djust the over-center preload as follows:
a. M ake sure the over-center adjusting screw is backed
all the way out and then turned back in one-half
turn. Fig. 6 0 -T o rq u in g Over-Center Locknut
b. Install an inch-lb. torque wrench with a 3 /4 ", 12-
point socket on the stub shaft splines. d. Tighten the pitm an shaft over-center adjusting
c. R otate the stub shaft from one stop to the other. screw until the torque wrench reads 3-6 in. lbs.
C ount the num ber of turns and locate the center of higher than the reading noted in Step c. The total
travel, then check the combined seal drag and thrust reading should not exceed 14 in. lb.
bearing preload by rotating the torque wrench e. W hile holding the adjusting screw, tighten the lock-
through the center of travel. Note the highest read nut to 25 ft. lbs. using using A dapter J-5860 (fig. 60)
ing. and recheck the adjustment.
CONTROL VALVE CORVETTE

INDEX
Overhaul O p erations........................................................ 9-24 R epairs............................................................................ ...... 9-25

D isassem bly................................................................... 9-25 A ssem bly.............................................................................. 9-26
Inspection ...................................................................... 9-25 Valve B alancing............................................................ ...... 9-27
OVERHAUL OPERATIONS
Fig. 6 1 -D u s t Cap Removal Fig. 62--Removing A d ju stin g Nut

STEERING 9-25
Fig. 63-R e m o vin g Spool from Housing Fig. 65~Rem oving Plug-to-Sleeve Key
Disassem bly 9. Remove the adapter from the vise and invert, perm it
ting the spring and one of the two ball seats to fall free.
1. Place the valve in a vise as shown and remove dust
10. Remove the ball stud and the other ball seat and the
cover (fig. 61).
sleeve will fall free.
2. Remove adjusting nut (fig. 62).
3. Remove valve to adapter bolts and remove valve hous Inspection
ing and spool from adapter.
1. W ash all metal parts in nontoxic solvent and blow dry
4. Remove spool from the housing (fig. 63).
with compressed air.
5. Remove spring, reaction spool, washer reaction spring, 2. Inspect all parts for scratches, burrs, distortion, evi
spring retainer, and seal (fig. 64). "O" ring may now be dence of wear and replace all worn or damaged parts,
removed from the reaction spool. including mating parts when necessary.
6. Remove the annulus spacer valve shaft washer and plug 3. Replace all seals, gaskets, covers with approved service
to sleeve key (See Figure 65). parts.
7. Remove clam p by removing nut, bolt and spacer or, if
Repairs
crim ped type clamp is used, straighten clamp end and
pull clamp and seal off end of stud (fig. 66 ). NOTE: The Corvette valve incorporates a 55 lb. cen
tering spring. The Corvette valve incorporating this
8 . Carefully, so as not to nick the top surface, turn ad
spring is identified by an "X " stamped on the dust
juster plug out of sleeve (fig. 67).
cover.
Fig. 64-R em oving Valve Parts from Shaft Fig. 66--Seal w ith Clamp A ttachm ent

STEERING 9-26
Fig. 6 7 -T u rn in g A d ju ste r Plug out of Sleeve Fig. 6 9 —1nsta11 ing Connector Seat
In case a connector seat becomes damaged, proceed as 2. Clam p the adapter in vise, put the shaft through the seat
follows: in the adjuster plug and screw adjuster plug in sleeve
To remove connector seat, tap threads in center hole using (fig. 70).
a 5/16- 18 tap. Thread a bolt with nut and flat washer a t
3. T urn the plug in until it is tight, then back it off until
tached into tapped hole so that the washer rides against the
the slot lines up with notches in the sleeve.
face of the port boss and the nut rides against the washer.
Hold the bolt from rotating while turning the nut off the bolt. 4. Install new seal and clamp over stud so lips on seal mate
This will force the washer against the port boss face and will with clamp. (A nut and bolt attachm ent type clamp
back out the bolt thus drawing the connector seat from the replaces the crimped type for service fig. 66 ).
top cover housing (fig. 68 ). D iscard the connector seat. Clean 5. Center the ball stud, seal and clamp at opening in
the housing out thoroughly to remove any tapping chips. adapter housing, then install spacer, bolt and nut.
Drive new connector seat against housing seat, using Tool
6. Insert the key, making sure that the small tangs on the
J 6217, being careful not to dam age either the connector seat
ends of the key fit into the notches in the sleeve (fig. 72).
or the housing seat (fig. 69).
7. Install the valve shaft washer, annulus spacer, and the
Assem bly (Fig. 71) reaction seal (lip up), spring retainer, reaction spring
1. Replace the sleeve and ball seat in the adapter, then the and spool, washer and adjustm ent spring. (Install "O"
ball stud, and finally the other ball seat and the spring, ring seal on reaction spool before installing spool on
small coil down. shaft.) Install the washer with the cham fer "up".
Fig. 68 -R em oving Connector Seat Fig. 70 -R e p la cin g A djuster Plug and Shaft

STEERING 9-27
Fig. 7 1 -P o w e r Steering Control Valve and A d a p ter-E xp lod ed V iew
1. Dust Cover 11. Spring T hrust W asher 21. Valve S haft

2. A d ju stin g Nut 12. Valve Spring 22. Ball Seat Spring
3. Vee Block Seal 13. Spring Retainer 23. Ball Seat
4. Valve Spool 14. Annulus Seal 24. Ball Seat
5. Valve M ounting Bolts 15. Annulus Spacer 25. Sleeve Bearing
6. Lock W asher 16. Gasket 26. A da pter Housing
7. Valve Housing 17. Valve S haft W asher 27. Lubrication F itting
8. Valve A djustm en t Spring 18. "O '' Ring Seal 28. Ball Stud
9. "O '' Ring Seal 19. Plug to Sleeve Key 29. Seal
10. Valve Reaction Spool 20. Ball A d ju ste r Nut 30. Clamp
8. Install the seal on the valve spool (lip down), then

install spool in housing being careful not to jam spool
in housing.
9. Install housing and spool onto adapter. The side ports
should be on the same side as the ball stud. Bolt the
housing to the adapter.
10. Depress the valve spool and turn the locknut onto the
shaft about four turns with a clean wrench or socket.
NOTE: Always use a new nut.
Valve Balancing (Fig. 73)
The control valve must be adjusted, after being disassem

bled, as outlined in the following procedure. The same proce
dure may be followed to correct a com plaint of harder
steering effort required in one direction than the other. See
Figure 73.
1. Install valve
pump reservoir with oil. Do not connect the piston rod
Fig. 7 2 -P ro p e r Key Installation to the frame bracket. If the vehicle is already in operat-

STEERING 9-28
a. If the piston rod remains retracted, turn the adjust

ing nut clockwise until the rod begins to move out.
Then turn the nut counter-clockwise until the rod
just begins to move in. Now turn the nut clockwise
to exactly one-half the rotation needed to change the
direction of the piston rod movement.
b. If the rod extends upon starting the pump, move the
nut counter- clockwise until the rod begins to move
in. Now position the nut exactly one-half the rota
tion needed to change the direction of the piston rod
movement.
CAUTION: Do not turn the nut back and forth more

than is absolutely necessary to balance the valve.
3. W ith the valve balanced it should be possible to move

the rod in and out manually.
4. T urn off the engine and connect the cylinder rod to the
Fig. 73--Balancing Valve frame bracket.
Restart the engine. If the front wheels (still on the hoist)
do not turn in either direction from center, the valve has
ion, it will be necessary to delach the piston rod from been properly balanced. Correct the valve adjustm ent if
the frame bracket. necessary.
2. W ith the car on a hoist, start the engine. One of the 6. W hen the valve is properly adjusted, grease end of valve
following two conditions will exist. and install dust cap.
POWER C Y LIN D ER - CORVETTE
INDEX
Overhaul O peratio n s........................................................ 9-28 A ssem bly........................................................................ 9-28

D isassem bly................................................................... 9-28
OVERHAUL OPERATIONS
Disassem bly (Fig. 74) 6. Remove the "O" ring seal from the top lip of the power
cylinder ball stud opening.
1. To remove the piston rod seal, remove the snap ring; 7. If the ball seat is to be replaced, it m ust be pressed out
then pull out on rod, being careful not to spray oil. using Tool J-8937.
2. Remove the piston rod scraper and scraper element,
back up washer and piston rod seal from the rod.
Assem bly
3. A t the ball stud end of the cylinder, remove the ball
stud seal. 1. Reassemble the piston rod seal components by revers
4. Remove the snap ring retaining the end plug and lube ing the disassembly procedure. Apply power steering
fitting. fluid, or transmission fluid bearing the m ark DEX-
5. Push on the end of the ball stud and remove the end RO N , on the inner surfaces of the seal and scraper
plug, spring, spring seat and ball stud. before assembly.

STEERING 9-29
Fig. 74--Power Steering Power C ylinder C om ponents
1. Snap Ring 9. Piston Body

2. End Plug and Lube Fitting 10. Piston Rod Seal
3. " 0 " Ring 1 1. B ackup W asher
4. Spring 12. Scraper Element
5. Spring Seat 13. Piston Rod Scraper
6. Ball Stud 14. Snap Ring
7. Ball Seat 15. Piston Rod
8. Ball Stud Seal
2. Reverse the disassembly procedure when reassembling NOTE: Be sure to use new seals and"0"rings when
the ball stud. re-assembling cylinder.
3. In each case be sure th at the snap ring is securely seated
in the ring groove.

STEERING 9-30
SPECIAL TOOLS
Fig. 75--M anual and Power Steering Special T ools-P assenger Car
1. J-6 6 3 2 Pitman Arm Puller 17. J-42 45 No. 23 Internal Pliers

2. J-5 5 0 4 Pitman Arm Puller 18. J -2 2 6 7 0 Pump Shaft Seal Installer
3. J-2 3 0 7 3 S h ift Tube Installer 19. J-6 2 2 2 Shaft Seal Protector
4. J-2 3 0 7 2 S h ift Tube Remover 20. J -2 3 6 0 0 Belt Tension Gauge
5. J-5 1 7 6 Oil Pressure Gauge 21. J-89 47 Rack-Piston Seal Com pressor
6. J-5 8 2 2 W orm sha ft Bearing Race 22. J-5 7 5 5 W orm sha ft Bearing Race
Remover Installer
7. J-8 4 3 3 Pump Pulley Remover (Cast 23. J-2 6 1 9 Slide Hammer
Pulley) 24. J-8 0 9 2 Handle
8. J -2 1 8 5 4 Colum n Pivot Pin Remover 25. J-6 2 7 8 Pitman Shaft Bearing Remover
9. J-2 3 6 5 3 Lock Plate Compressor 26. J-62 78 -2 Pitman Shaft Seal Installer
10. J-5421 T herm om eter 27. J-7 0 7 9 -2 Handle
11. J -5 8 6 0 Torque W rench A dapter 28. J-8524-1 A d ju ste r Plug Bearing Installer
12. J -2 1 2 3 9 Pump Pulley Remover (Stamped 29. J-85 24 -2 A d ju ste r Plug Bearing Remover
Pulley) 30. J-6 2 1 9 Pitman S haft Seal Installer
13. J-29 27 Steering W heel Puller 31. J -2 2 4 0 7 Pitman S haft Bearing Installer
14. J-16 14 Pitman S haft Bushing Remover 32. J-8 9 3 7 Ball Seat Remover
15. J-75 39 Ball Retainer 33. J-6 2 1 7 C onnector Seat Installer
16. J-76 24 Spanner W rench 34. Torque W renches

STEERING 9-31
20 21 23 24 25 26 28
Fig. 76--M anual and Power Steering Special Tools--T ruck
1. J-6 6 3 2 Pitman Arm Puller 16. J -2 3 6 0 0 Belt Tension Gauge

2. J-5 5 0 4 Pitman Arm Puller 17. J-5 7 5 5 W orm sha ft Bearing Race
3. J-5 1 7 6 Pressure Gauge Installer
4. J-5 8 2 2 W o rm sh a ft Bearing Race Puller 18. J-2 6 1 9 Slide Hammer
5. J -5 8 6 0 Torque W rench A dapter 19. J-6 2 7 8 Pitman Shaft Bearing Remover
6. J -2 2 6 7 0 Pump S haft Seal Installer 20. J-627 8-2 Pitman Shaft Seal Installer
7. J-6 2 2 2 S haft Seal P rotector 21. J-70 79 -2 Drive Handle
8. J-9 2 2 6 Pitman S haft Bushing Replacer 22. J-8524-1 A d ju ste r Plug Bearing Installer
9. J-7 5 7 6 Rack-Piston Seal Com pressor 23. J-85 24 -2 A d ju ste r Plug Bearing Remover
10. J-2 1 2 3 9 Pump Pulley Remover 24. J-6 2 1 9 Pitman Shaft Seal Installer
1 1. J-2 9 2 7 Steering W heel Puller 25. J-6 2 1 7 C onnector Seat Installer
12. J-1 6 1 4 Pitman S haft Bushing Remover 26. J-5421 Therm om eter
13. J-7 5 3 9 Ball Retainer 27. J-2 2 4 0 7 Pitman S haft Bearing Installer
14. J-7 6 2 4 Spanner W rench 28. In. Lb. Torque W rench
15. J-4 2 4 5 No. 23 Internal Pliers

SPECIFICATIONS
PASSENGER CAR
Section Page
1 Heating and A s t r o - V e n t ila t io n .......................................................... 1

3 Front S u sp e n sio n ................................................................................... 2
4 R ear S u s p e n s io n ................................................................................... 6
5 B r a k e s.......................................................................................................... 7
6 E n g in e .......................................................................................................... 8
6M C a r b u r e t o r ................................................................................................ 12
6Y Engine E le c t r ic a l..................................................................................... 15
7 T r a n s m is s io n .......................................................................................... 20
9 S te e r in g ........................................................................................................ 23
10 W heels and T i r e s ................................................................................... 26
11 Sheet M e t a l.............................................................................................. 27
12 E lectrical-B ody and C h a s s is ............................................................ 28
13 Radiator and G r ille ............................................................................... 30
14 B u m p ers...................................................................................................... 30
15 A c c e sso r ie s and A ir C onditioning................................................... 31
10-30 SERIES TRUCK

Section Page
1 Heating and Air Conditioning.............................................................. 33

IB B o d y ................................................................................................................ 34
3 Front S u sp e n sio n ................................................................................... 35
4 Rear S u s p e n s io n ................................................................................... 37
5 B r a k e s......................................................................................................... 39
6 E n g in e .......................................................................................................... 40
6M C a r b u r e t o r ................................................................................................. 43
6Y Engine E le c tr ic a l..................................................................................... 45
7 T r a n s m is s io n ........................................................................................... 48
9 S te e r in g ........................................................................................................ 50
10 W heels and T i r e s ................................................................................... 52
11 Sheet M e t a l.............................................................................................. 52
12 E lectrical-B ody and C h a s s is ............................................................ 53
13 Radiator and G r ille ............................................................................... 54
14 B u m p ers...................................................................................................... 54
15 A c c e s s o r ie s .............................................................................................. 54

SPECIFICATIONS 1
PASSENGER CAR
HEATING AND ASTRO-VENTILATION

SECTION 1
HEATER
Amps RPM
V olts (Cold) (Cold)
Blower Motor................... 13.5 6.25 Max. 2550 Min.
2950 Max.
Fuses
Fuse B l o c k .................................................................... 25 Amp.

SPECIFICATIONS 2
FRONT SUSPENSION
SECTION 3
BOLT TORQUES
Chevrolet C hevelle and Nova Camaro Corvette
Monte Carlo
B all Joint Stud Nut
Upper Stud *50 ft. lbs. *50 ft. lbs. *50 ft. lbs. *50 ft. lbs. *50 ft. lb s.
Lower Stud *90 ft. lbs. *90 ft. lbs. *90 ft. lbs. *90 ft. lbs. *90 ft. lbs.
Joint to Upper Arm
(Service Replacem ent) 25 ft. lb s. 25 ft. lb s. 25 ft. lbs. 25 ft. lb s. 25 ft. lbs.
Steering Arm Nuts - 70 ft. lbs. 70 ft. lb s. - 70 ft. lbs.
Control Arm P ivot to
Fram e
Upper 85 ft. lb s. 55 ft. lb s. 55 ft. lb s. 85 ft. lb s. 55 ft. lbs.
Lower 90 ft. lbs. 90 ft. lb s. 90 ft. lb s. 90 ft. lb s. See Below
Upper Control Arm Shaft
N u ts/B olts 60 ft. lbs. 40 ft. lbs. 40 ft. lbs. 60 ft. lb s. 60 ft. lbs.
Shock A bsorber
Upper End 100 in. lb. 100 in. lbs. 100 in. lbs. 100 in. lbs. 100 in. lb s.
Lower End 20 ft. lbs. 20 ft. lbs. 20 ft. lbs. 20 ft. lb s. 150 in. lb s.
Stabilizer Bar
Link Nuts 15 ft. lb s. 150 in. lbs. 20 ft. lb s. 150 in. lbs. 20 ft. lbs.
Bracket Bolts 24 ft. lbs. 24 ft. lbs. 24 ft. lbs. 24 ft. lb s. 120 in. lb s.
Lower Control Arm
Shaft to C ross m em ber
Front 70 ft. lbs.
Rear - — — — 95 ft. lbs.
Anchor Pin Drum 130 ft. lb s. 130 ft. lbs. - -
-
Brakes
Mounting Bolts D isc 35 ft. lb s. 35 ft. lbs. 35 ft. lbs. 35 ft. lb s. 120 ft. lb s.
Brake Caliper
Wheel Stud Nuts 70 ft. lb s. 70 ft. lb s. 70 ft. lb s. 70 ft. lb s. 75 ft. lb s.
Wheel Bearing Adjustm ent 12 ft. lb s. 12 ft. lbs. 12 ft. lbs. 12 ft. lbs. 12 ft. lbs.
Preload Zero Zero Zero Zero Zero
End Movement .001 to .008 .001 to .008 .001 to .008 .001 to .008 .001 to .008
* P lu s additional torque to align cotter pin hole. NEVER back off to align cotter pin.
VEHICLE ALIGNMENT TOLERANCES

Field Usage
S ervice Checking S ervice R eset
C a m b e r ..................................................................................................................................... ± 3 /4 ° ± 1 /2 °
C a s t e r ........................................................................................................................................ ± 1° ± 1/2°
T oe-in ..................................................................................................................................... ± 1/8" ± 1/16"
Camber (Side to S i d e ) ...................................................................................................... 1° 1 /2 °
C aster (Side to S id e ) .......................................................................................................... 1° 1 /2 °
VEHICLE INSPECTION TOLERANCES

C a s t e r ............................................................................ ± 2° of custom er satisfaction and should not require resettin g.
C a m b e r ........................................................................ ± 1 1 /2 °
T o e ................................................................................± 3/8"
Service Reset
C ars within these toleran ces from the mean sp ec ifi Values that the veh icle should be se t within if it is
cation are safe and not hazardous with resp ect to a lign observed out of the se rv ic e checking tolerance, or if it
ment effects on operation and handling. Settings outside is being aligned due to replacem ent of com ponents, or
these lim its are not n e c e ssa r ily unsafe; however, c u s for any other reason.
tom er d issatisfaction , due to steerin g pull or tire wear
may occur or the veh icle may be in a damaged condition.
Vehicle Inspection Tolerances
Definitions For governm ent inspection station u sage although no
Service Checking relationship between alignm ent and safety has been
V alues within these lim its should provide a high lev el established.

SPECIFICATIONS 3
WHEEL ALIGNMENT SPECIFICATIONS

# (All Vehicles at Curb Weight)
##1 ##2 ##3
Specification For
Specification For
Diagnosis for W arranty Specifications For
Periodic Motor
Repair or Customer Resetting Alignment
Vehicle Inspection
Paid Service
CHEVROLET
(except 116" W .B. Wagon)
Caster *- 2 ° to 0 ° -3° to +1° @ -1 ° ± 1/ 2°
Camber * 0 ° to + 1 ° -1 ° to +2 ° @ + 1/ 2 ° ± 1/ 2 °
Toe-In (total) 1/16" to 5/16" 1/ 2 " toe-in to 1/4 " toe-out $ 1/8" to 1/4"
S.A.I. 10 ° ± 1/ 2 °
C H EV ELLE, MONTE CARLO

E L CAMINO and 116" W.B.
Wagon
Caster *-2 ° to 0 ° -3° t o + l° @ -1 ° ± 1/ 2 °
Camber * 0 ° to + 1 -1/ 2 ° -3/4° to +2-1/4° @ +3/4° ± 1/2°
Toe-in (total) 1/16" to 5/16" 1/ 2 " toe-in to 1/4" toe-out $ 1/8" to 1/4"
S.A.I. 8-1/4° ± 1/2°
NOVA
Caster *- 1/ 2 ° to + 1 -1/ 2 ° -1 -1/ 2 ° to +2 -1/ 2 ° @ + 1/ 2 ° ± 1/ 2 °
Camber *- 1/ 2 ° to + 1 ° -1-1/4° to +1-3/4° @ +1/4° ± 1/2°
S.A.I. 8-3/4° ± 1/2°
CAMARO (standard)
Caster *- 1 ° to + 1 ° -2 ° to +2 ° @ 0 ° ± 1/ 2 °
Camber *+1/4° to +1-3/4° -1/ 2 ° to +2 -1/ 2 ° @ +1 ° ± 1/ 2 °
Toe-in (total) 1/16" to 5/16" 1/ 2 " toe-in to 1/4" toe-out $ 1/8 " to 1/4"
S.A.I. 9-1/2° ± 1/2°
Z-28
Caster *-2 ° to 0 ° -3° to +1° @ -1 ° ± 1/ 2 °
Camber * 0 ° to + 1 -1/ 2 ° -3/4° to +2-1/4° @ +3/4° ± 1/2°
S.A.I. 9-3/4° ± 1/2°
CORVETTE
Caster-Manual strg. * 0 ° to +2 ° -1° to +3° @ + 1 ° ± 1/ 2 °
Caster-Power strg. *+1-1/4° to +3-1/4° + 1/4° to ±4-1/4° @ +2-1/4° ± 1/2°
Front Camber * 0 ° to + 1 -1/ 2 ° -3/4° to +2-1/4° @ +3/4° ± 1/2°
Front toe-in (total) 3/16" to 5/16" 5/8" toe-in to 1/ 8" toe-out $ 3/16" to 5/16"
S.A.I. 7° ± 1/2°
R ear Camber -7/8° ± 1/4°
Rear toe-in (per wheel) $ 1/16" ± 1/32"
## See explanatory copy in front suspension section page 2.

# Curb weight means weight of vehicles including production options and full capacity of engine oil, fuel and coolant.
* Caster and Camber must not vary more than 1° from side to side.
@ Caster and Camber must not vary more than 1/2° from side to side.
$ Toe setting must always be made after caster and camber.

SPECIFICATIONS 4
TRIM HEIGHTS
The following procedure should be followed before NOTE: Follow the same pattern as stated above
making any trim height measurement. for the “ Z ” dimension when measuring the “ D "
1. “ Z ” Dimension dimension except: lift and push on the rear
a. Lift vehicle up approximately 1-1/2" at the front bumper.
bumper and gently remove hands allowing vehicle 3. “ J ” & “ K” Dimensions
to settle on its own. Repeat this lifting operation a. Jostle the front of the car up and down three
three tim es. Measure the “ Z ” height in the set tim es by lifting the vehicle up approximately
tled position after the third lift. 1-1/ 2" at the front bumper and im mediately push
b. Push vehicle down approximately 1-1/2" at the vehicle down approximately 3" from the raised
front bumper and gently remove hands allowing position, raising up 3" and repeating the cycle
vehicle to settle on its own. Repeat this pushing three tim es.
down operation three tim es. Measure the “ Z ” b. Jostle the rear of the car three times by applying
height in the settled position after the third push the same procedure to the rear bumper as used
down. on the front in (3 a.).
c. The true " Z " height is the average of (a) and (b) c. Repeat the jostling of front a second time.
for each side. d. Measure the “ J ” and “ K ” dimensions in the set
2. “ D ” Dimension tled position.
Z J K D
Tires Curb Curb Curb Curb
CHEVROLET MODELS
Coupes - Sedans and F-78 9.62 9.57
Convertibles with V -8 G-78 3.13 9.78 9.91 6.24
Engines (Exc. 116” W .B. Wag.) H-78 10.06 10.03
Coupes - Sedans with 9.58

F-78 9.65
L -6 Engines
Wagon 2-Seat (125" W .B.) L-78 5.74
2.90 10.28 10.23
Wagon 3-Seat (125" W .B.) L-78
Wagon 2-Seat (116" W .B.) G-78
2.66 11.09 11.32 6.13
Wagon 3-Seat (116" W .B.) G-78
CHEVELLE MODELS
E-78 9.98 9.96
Sedan 2.10 5.07
F-78 10.20 10.20
E-78 10.06 9.79
Coupe and Convertible 2.30 4.80
F-78 10.27 9.97
SS Coupe and Convertible F-70 2.03 9.73 9.46 4.48
Pick-Up F-78 10.82 10.97

2.63 5.88
SS Pick-Up F-70 10.54 10.68
G-78 1.33 10.04 9.98

MONTE CARLO 4.28
G-70 1.28 9.64 9.63
CH EVELLE MODELS
w/F-40 Suspension
E-78 9.95 10.18
Sedan 1.94 5.40
F-78 10.17 10.42
E-78 10.02 9.96

5.07
Coupe and Convertible 2.14
F-78 10.24 10.21
Pick-Up F-78 10.86 11.24
2.55 6.26
SS Pick-Up F-70 10.59 10.87

SPECIFICATIONS 5
Z J K D
Tires
Curb Curb Curb Curb
CAMARO MODELS
Base A ll 1.82 5.83 8.07 7.63
Z-28 A ll 2.69 6.97 9.16 8.84
NOVA MODELS
A ll Except "SS" A ll 9.70 9.69
2.18 5.55
"SS" A ll 9.38 9.39
CORVETTE MODELS
Coupe w/C-60 2.29 7.79 7.77 1.99
A ll
w o/C -60 2.65 8.16 8.03 2.18
Convertible w/C-60 2.33 7.82 7.68 1.85

A ll
wo/C -60 2.77 8.25 7.95 2.04
♦
F-41 Suspension
A ll 1.89 7.57 7.82 2.13
Coupe and Convertible
CENTER O F LOW ER B O TT O M
C O N TR O L A R M BOLT END OF FRAME
LOW EST P O IN T O N TOP OF

STEERING KNUCKLE AXLE
M e a s u re J' a n d 'K ' H e ig h t a t th e fo llo w in g d is ta n c e re a rw a rd o f th e fro n t w h e e l o r fro n tw a r d

o f th e r e a r w h e e l
CHEVROLET CHEVELLE CAMARO NOVA CORVETTE
F ro n t 3 6 .. 3 r 36» 3 3 .. 3 0 ..
Rear 24" 24” 16 " 20" 24"

SPECIFICATIONS 6
REAR SUSPENSION
SECTION 4
CHEVROLET, CAMARO, CH EV ELLE, Ring Gear (Except Chevrolet, C a m a r o ........................ 50

MONTE CARLO, AND NOVA Chevrolet, Cam aro ...........................................................85
Gear Backlash (.005"-.008" preferred) . .003" - .010" D ifferential Bearing Caps Except Chevrolet, Cam aro 55
Axle Shaft End Play Chevrolet, Cam aro ....................................................... 60
Chevrolet B-0 Type A x le s............................. 001" - .018" F ille r P l u g .........................................................................20
Pinion Bearing Preload (in. lbs.) . . . . 25 D ifferential Pinion L o c k .................................................20
N e w .............................................................. 25
CORVETTE
U sed.............................................................. 10
Lubricant Capacity Gear Backlash (.005" - .008" Preferred) .003" - .010"
C a rrie r Only - D rain and R efill Pinion Bearing Preload (In. Lbs.)
Light Duty Axles ............................... .. 3.75 Pints N e w ................................................................................20-25
Heavy Duty A x l e s ................................... 4.25 Pints U sed................................................................................5-10
Dry F ill (Both Axle Housing and Lubricant C a p a c ity ..........................................3-3/4 Pints
Tubes Completely Dry of Lube) Bolt Torque (Ft. Lbs.)
Light Duty Axles ................................... 4.4 Pints C a rrie r C o v e r ............................................. .................50
Heavy Duty A x l e s ................................... 4.9 Pints Ring Gear ..................................................................... 50
Bolt Torques (Ft. Lbs.) D ifferential Bearing C a p s ..........................................55
C a rrie r C o v e r .......................................... 20 F ille r P l u g ..................................................................... 20
Chevrolet, C a m a r o ...................................... 30 D ifferential Pinion Lock . .......................................... 20
TORQUE (FT. LBS.)
Chevrolet Chevelle
Except Monte Carlo
Chevy Nova Cam aro Corvette
116" W.B. and 116" W.B.
Station Wagon Station Wagon
Upper Control A rm
Front Bushing Nut 115 80
Rear Bushing Nut 80 80
Lower Control A rm
Front Bushing 115 80 50
R ear Bushing 115 80
Shock Absorber
Upper 12 12 18 18 50
Lower 65 65 45* 8 35
Leaf Spring
Front Eye Bolt Nut 80 75 75
R ear Shackle Bolt Nut 115 50 50
Leaf Spring Front Mounting
Bracket 30 30
Leaf Spring Retainer
(Anchor Plate) 40 40 40 70
Universal Joint Wagons 70

Companion Flange A ll Other 15 15 15 15 15
Wheel Stud Nuts 70 70 70 70 75
Axle Drive Shaft
to Spindle 75
To Yoke 15
Stabilizer-to -
Control A rm 55
Stabilizer
-To Fram e Bracket 60 40
-To Spring Retainer Plate 18 40
*60 Ft. Lb. with Special Performance Suspension

SPECIFICATIONS 7
TORQUE (FT. LBS.)

CORVETTE (CONT'D)
Stabilizer Shaft Drive Spindle Support

to Torque A r m ........................................................... 30
Strut Rod
to Spindle S u p p o r t .................................................... 75s1
Bracket to C a r r ie r .................................................... 35
Camber C a m .................................................................. 65
C a rrie r Front Support
Torque A rm P i v o t ....................................................... 50
to C ro s s m e m b e r........................................................... 65
Spring Link Bolt Install Nut to expose hole
to Torque A rm then insert cotter pin.
Rear Wheel Alignment #
*P lus additional torque necessary to line up cotter pin hole.

#See Wheel Alignment Chart in Front Suspension Specification Section.
RIDING HEIGHTS
See "Riding Heights" in Front Suspension Specification Section.
BRAKES
SECTION 5
TORQUE SPECIFICATIONS
Chevelle
Chevrolet and 116"
and 125" W.B. Wagons Camaro Nova Corvette
W.B. Wagons and Monte
Carlo
Main Cylinder to D ash ............................................. 24 ft. lbs. 24 ft. lbs. 24 ft. lbs. 24 ft. lbs. 24 ft. lbs.
Main Cylinder to B o o s te r ...................................... 24 ft. lbs. 24 ft. lbs. 24 ft. lbs. 24 ft. lbs. 24 ft. lbs.
Vacuum Cylinder to D a s h ...................................... 25 ft. lbs. 25 in. lbs. 25 ft. lbs. 25 ft. lbs. 22 ft. lbs.
Push Rod to C l e v i s ................................................. 14 in. lbs. — 14 ft. lbs. 14 ft. lbs.
P rim ary Brake Pipe N u t ...................................... 150 in. lbs. 150 in. lbs. 150 in. lbs. 150 in. lbs. 150 in. lbs.
Secondary Brake Pipe N u t...................................... 150 in. lbs. 150 in. lbs. 150 in. lbs. 150 in. lbs. 150 in. lbs.
Brake Line to Fram e S c r e w ............................... 100 in. lbs. 100 ft. lbs. 100 in. lbs. 100 in. lbs. 100 in. lbs.
Brake Shoe Anchor P i n .......................................... 120 ft. lbs. 120 ft. lbs. 120 ft. lbs. 120 ft. lbs. __
Wheel Cylinder to Backing P l a t e ........................ 50 in. lbs. 50 in. lbs. 50 in. lbs. 50 in. lbs. —
Parking Brake E q u a l i z e r ...................................... 60 in. lbs. 90 in. lbs. 90 in. lbs. 90 in. lbs. 70 ill. lbs.
Parking Brake Assem bly A tta ch m e nt................. 150 in. lbs. 100 in. lbs. 100 in. lbs. 100 in. lbs. 100 in. lbs.
Flex Hose to Wheel C y l in d e r ............................... 22 ft. lbs. — 22 ft. lbs. __
Tubing to Flex H o s e ................................................. 120 in. lbs. 120 in. lbs. 120 in. lbs. 120 in. lbs. 120 in. lbs.
Caliper Mounting B o l t ............................................. 35 ft. lbs. 35 ft. lbs. 35 ft. lbs. 35 ft. lbs. 70 ft. lbs.
C aliper Housing B o l t ............................................. — — — — 130 ft. lbs.
Flex Hose to C a l i p e r ............................................. 22 ft. lbs. 22 ft. lbs. 22 ft. lbs. 22 ft. lbs. 22 ft. lbs.
Support Plate to Steering Knuckle (Upper Bolt) 140 in. lbs. 140 ft. lbs. 140 in. lbs. 140 ft. lbs. —
Support Plate/Steering A rm to Knuckle Nuts . — 70 ft. lbs. — 70 ft. lbs. __
Shield to Steering Knuckle Nuts (Hold Bolt) . . 70 ft. lbs. — 70 ft. lbs. __
Shield to Steering Knuckle Bolt (Hold Nut) . . 95 ft. lbs. — 95 ft. lbs. __
Pedal Mounting Pivot Bolt (Nut)............................ 30 ft. lbs. — 30 ft. lbs. — _
Combination Valve M ou nting................................... 150 ft. lbs. 100 in. lbs. 150 in. lbs. 150 in. lbs. -

SPECIFICATIONS 8
ENGINE
SECTION 6
GENERAL DATA:
In Line V-8
TyPe
Displacement (cu. in.) 250 307 350 TOO" ~m r
145 200 245 270 330 255 300 365 425
Horsepower @ rpm @ @ @ @ @ @
4200 4600 4800 4800 5600 4400 4800 4800 5600
230 300 350 360 360 390 400 465 475
Torque @ rpm @ @ @ @ @ @ @ @ @
1600 2400 2800 3200 4000 2400 3200 3200 4000
Bore 3 7/8 4 1/8 4 1/4
Stroke 3.53 3.25 3.48 3.75 3.76
Compression Ratio 8.5:1 9.0:1 8.5:1 9.0:1
Firing Order 1-5-3-6-2-4 f 1-8-4-3-6-5-7-2
CYLINDER BORE:
Diameter 3.8745-3.8775 3.9995-4.0025 4.1246-4.1274 4.2495-4.2525
Out of Production .0005 Max. .001 Max.
Round Service .002 Max.
Thrust
.0005 Max.
Produc Side
Taper tion Relief .001 Max.
.0005 Max.
Side
Service .005 Max.
PISTON:
.0005 .0005 .0036 .0014 .0018 .0024 .0040
Production .0007-.0013
Clearance .0015 .0011 .0042 .0020 .0026 .0034 .0050
.0034 .0035 .0049 .0065
Service .0025 Max. .0027 Max. .0061 Max.
Max. Max. Max. Max.
PISTON RING:
Clear Produc Top .0012-.0027 . 001 2 - .0012-.0032 .0012-.0027
.0017-.0032
ance tion 2nd .0012-.0032 .0032 .0012-.0027 .0012-.0032
Groove Service Hi Limit Production + .001
.010
Top . 0 10-.020 .010-.020 . 010-.020
Produc .020
Gap tion .013
2nd . 010-.020 .013-.025 .010-.020
.023
Service Hi Limit Production + .01
Groove Production .005 Max. |.002-.007l~ .005 Max. .0005-.0065
Clearance Service Hi Limit Production + .001
Production .015-.055
Gap
Service Hi Limit Production + .01
PISTON PIN:
Diameter .9270-.9273 .9895-.9898
.00045 .00015
Production .00015-.00025 .00025-.00035
Clearance .00025
.00055
Service .001 Max.
Fit in Rod .0008-. 0016 Interference
CRANKSHAFT:
Auto. Man. #1-2 #1
#i #l-2-3-4 2.7487 2.7485
#l-2-3-4 #l-2-3-4
2.7475 2.7481
2.6484 2.7481
#l-2-3-4 2.7496 2.7494
2.4484-2.4493 2.7484 2.7490 #3-4 #2-3-4
All 2.6493 2.7490
#2-3-4 #5 2.7481 2.7481
2.2983
Diameter 2.7481 2.7473
2.7490 2.7490
2.2993 #5 #5
2.7490 2.7483 #5 #5
Main #5 2.6479 2.7478
#5 2.7473 2.7478
Journal 2.4479-2.4488
2.7473
2.6488 2.7488
2.7483 2.7488
2.7483
Produc
.0002 Max.
Taper tion
Service .001 Max.
Produc .0002 Max.
Out of
tion
Round .001 Max.
Service

SPECIFICATIONS 9
Type In Line V-8

Displacement (cu. in.) 250 307 350 400 402 454
Horsepower 145 200 245 270 330 255 300 'x 425
CRANKSHAFT:
Auto. Man. #1 #1
#r #1 .0008 .0007
#l-2-3-4
.0008-.0020 .0019 #l-2-3-4
.0013-.0025
.0013 .0020 .0019
All .0031 .0025 #2-3-4 #2-3-4
Main
.0003 #2-3-4 #2-3-4 .0011 .0013
Bearing Production
.0011-.0023 .0013
Clearance #5 #5
.0029 .0025 #5 .0023 .0025
.0024 .0029
#5 .0023 #5 #5
#5 .0023 .0017 .0019
.0040 .0045
.0017-.0033 .0033
.0033 .0033 .0035
Service #1 - .002 Max.; All Others - .0035 Max.
Crankshaft End Play .002-. 006 .006-.010
1.999 2.1985
Diameter 2.099-2.100 2.199 -2.200
2.000 2.1995
Crankpin Production .0003 Max.
i aper
Service .001 Max.
Out of Production .0002 Max.
Round Service .001 Max.
.0007
Rod Bearing .0013-. 0035 .0009-.0025
Production
. Clearance
.0027
Service .0035 Max.
Rod Side Clearance .009-.014 .008-. 014 .013-.023 .015-.021 .019-.025
CAMSHAFT:
Lobe Intake .2217 .2600 .3057 .2235 .2343 .2714
Lift ± .002" Exhaust .2217 .2733 .3234 .2411 .2343 .2824
Journal Diameter 1.8682-1.8692 1.9482- 1.9492
Camshaft Runout .0015 Max.
VALVE SYSTEM:
Lifter Hifdraulic Mechanical Hydraulic Mechanical
Rocker Arm Ratio 1.75:1 1.50:1 1.70:1
Intake .024* One Turn .024*
One Turn Down From
Valve Lash
Zero Lash Zero Lash .028*
Exhaust .030*
Face Angle (Int. & Exh.) 45°
Seat Angle (Int. & Exh.) 46°
Seat Runout (Int. & Exh.) .002 Max.
Seat Width Intake 1/32- 1/16

Exhaust 1/16-3/32
Int. .0010- .0027
Stem Froaucuon .0012-.0029 .0012 -.0027
Exh. .0015-.0032
Clearance Hi Limit Production ± .001 Intake - .002 Exhaust
Service
Free Length 1.90 2.03 2.12
55-64 69-81
Closed @ 76-84 @ 1.70 @
Valve 1.88
Pressure 1.66
Spring 228-252
lbs. @ in. 180-192
(Outer) 194-206 @ 1.25 @
Open @
1.27 1.38
Installed He ight 1 21/32 1 23/32 1 7/8
± 1/32"
Free Length N.A. 2.06
Valve Pressure Closed N.A. 26-34 @ 1.78
Spring lbs. @ in. Open N.A. 81-99 @ 1.28
(Inner) Installed He ight N.A. 1 25/32
± 1/32"
Free Length _ 1.94 N.A.
Damper
Approx. # of Coils - 4 N.A.
♦Engine at operating temperature and running

SPECIFICATIONS 10
ENGINE TUNE UP
E Type L -6 V8
N
G Displacement 250 307 350 400 402 454
I
N
E Horsepower 145 200 245 270 330 255 300 365 425
Compression © (P S I) 130 150 160 150 160 150
s P Make Standard AC-R46TS AC-R45TS AC-R44TS AC-R42TS

&
I L Number Cold AC-R45TS AC-R44TS AC-R43TS
K 0 Gap .035"
D Point Dwell 31°-34° 29°-31°

I
S Point Gap .016" (Used) - .019" (New)
T
R Arm Spring Tension 19-23 Ounces
I
B Condenser .18-.23 Microfarad
U
T
T I Synchro. 4 °B 4°B 2°B 4°B* 8 °B 4°B 8°B 8 °B 8 °B
O M
R I®
© N Auto. 4 °B 8 °B 6 °B 8 °B 12°B 8 °B 8°B 8 °B 12°B
G
Fan & P/S 50 lb. minimum - Adjust to 75 ± 5 lbs. (Used) or 125 ± 5 lbs. (New) using Strand Tension Gauge
Drive
A/C Compressor 65 lb. minimum - Adjust to 95 ± 5 lbs. (Used) or 140 ± 5 lbs. (New) using Strand Tension Gauge
Belts
A.I.R. P u m p © 50 lb. minimum - Adjust to 75 ± 5 lbs. (Used) or 125 ± 5 lbs. (New) using Strand Tension Gauge
A ir Cleaner See Note©
Valve Inlet .024 .024

Hydraulic - One Turn Hydraulic - One Turn
Lash
Down From Zero Lash Down From Zero Lash
© Exhaust .030 .028
Idle Synchro. 550 600 600 600 700 600 600 600 700
rpm
© Auto. 500 550 550 550 700 550 600 600 700
3 1/2 to 5 to
Fuel Pressure 7 to 8 1/2 @ 3600 rpm
4 1/2 6 1/2
Pump
Volume One Pint in 30-45 Seconds @ Cranking Speed
©
Crankcase Vent Replace at 24,000 Miles
* 8°B- Corvette only

© PSI at Cranking Speed, throttle wide open - Maximum variation, 20 PSI between cylinders.
© 6 Cylinder engine—Rotate cam lubricator 180° at 12,000 mile intervals—Replace at 24,000 mile intervals.
8 Cylinder engine—Change cam lubricator end for end at 12,000 mile intervals-Replace at 24,000 mile intervals.
© At idle speed with vacuum advance line disconnected and plugged. B = B.T.D.C.
© Do not pry against A.I.R. pump housing. (Corvette—Adjust to 75 ± 5 lbs.)
(J ) CAUTION: In addition to its function of filtering air drawn into the engine through the carburetor, the air cleaner also
acts as a flame arrestor in the event the engine backfires. Because backfiring may cause fire in the engine compartment,
the air cleaner should be installed at all times unless its removal is necessary for repair or maintenance services.
Paper Element Type—First 12,000 miles, inspect element for dust leaks, holes, or other damage and replace if necessary.
If satisfactory, rotate element 180° from original installation position. Replace element at 24,000 miles. Element must
not be washed, oiled, tapped, or cleaned with an air hose. If so equipped, replace P.C.V. breather filter every 24,000
miles (do not attempt to clean). If so equipped, clean wire mesh frame arrester every 12,000 miles.
© Mechanical—Set with engine at operating temperature and running.
© See “ TUNE-UP” section.
® Replace filter element located in carburetor inlet every 12 months or 12,000 miles, whichever occurs first.

SPECIFICATIONS 11
ENGINE TORQUES
------------------------
In Line Sm all V -8 Mark IV-V -8
Size Usage
250 307 350 402 454
1/4-20 Camshaft Thrust Plate 80 lb. in.

Crankcase Front Cover 80 lb. in.
Flywheel Housing Cover 80 lb. in.
O il Filter Bypass Valve 80 lb. in.
O il Pan (To Crankcase) 80 lb. in.
O il Pan (To Front Cover) 50 lb. in. 80 lb. in.
O il Pump Cover 70 lb. in. 80 lb. in.
Rocker A rm Cover 45 lb. in. 1 50 lb. in.
11/32-24 Connecting Rod Cap 35 lb. ft.
5/16-18 Camshaft Sprocket 20 lb. ft.

O il Pan (To Crankcase) 75 lb. in. 65 lb. in. | 135 lb. in.
O il Pump 115 lb. in.
Push Rod Cover 50 lb. in.
W ater Pump 15 lb. in.
3/8-16 Clutch Pressure Plate 35 lb. ft.

D istributor Clam p 20 lb. ft.
Flywheel Housing 30 lb. ft.
Manifold (Exhaust) 20 lb. ft.®
Manifold (Exhaust to Inlet) 25 lb. ft.
Manifold (Inlet) 30 lb. ft.
Manifold Clam p (L 6 Outer) 20 lb. ft.
Manifold Clam p (All Others) 30 lb. ft.
Thermostat Housing 30 lb. ft.
W ater Outlet 20 lb. ft.
W ater Pump 30 lb. ft.
3/8-24 Connecting Rod Cap 45 lb. ft. 50 lb. ft.
*7/16-14 Cylinder Head 65 lb. ft. 80 lb. ft.

M ain Bearing Cap 65 lb. ft. 75 lb. ft.©
O il Pump 65 lb. ft.
Rocker A rm Stud 50 lb. ft.
7/16-20 Flywheel 60 lb. ft. 65 lb. ft.

Torsional Damper 60 lb. ft.
1/2-13 Cylinder Head 95 lb. ft.

M ain Bearing Cap 105 lb. ft.
1/2-14 Temperature Send Unit 20 lb. ft.
1/ 2-20 T orsional Damper 85 lb. ft.

O il Filter Hand Tight | 25 lb. ft.
O il Pan D rain Plug 20 lb. ft.
14mm 5/8 Spark Plug 15 lb. ft.
(D Inside bolts on 307-350 engines 30 lb. ft.

© Outer bolts on engines with 4 bolt caps 65 lb. ft.

SPECIFICATIONS 12
CARBURETOR
SECTION 6 M
IDENTIFICATION
Also refer to Rochester and Holley Carburetor Identification Illustrations in the 1971 Overhaul Shop Manual.
VEHICLES ENGINES CARBURETORS

C arlo
B arrel
D isplace
(Bbl.)
Chevrolet
RPO
Corvette
Chevelle
ment and HP Manual Automatic

Cam aro
Option and
Type
Monte
Type
Nova
X X X X 250 L -6 Base 145 1 7041017 7041014

x X X 307 V -8 Base 200 2 7041101 7041110
X X 350 V -8 Base 245 2 7041113 7041114
X X 350 V -8 L-65 245 2 7041113 7041114
X 350 V -8 L-65 245 2 7041127 7041102
X 350 V -8 Z-28 330 4H 3989021 3989022
X X X X X 350 V -8 L-48 270 4QJ 7041203 7041202
X 350 V -8 Base 270 4QJ 7041213 7041212
X 350 V -8 LT-1 330 4H 3989021 N/A
X 400 V -8 L F -6 255 2 7041117 7041118
X X X X 402 M-4 LS-3 300 4QJ 7041201 7041200
X X X 454 M-4 LS-5 365 4QJ 7041201 7041200
X 454 M-4 LS-5 365 4QJ 7041205 7041204
X X X 454 M-4 LS -6 425 4H 3986195 3986196
ADJUSTMENTS
Rochester Carburetors
M NUMBER
O Fast
(A) Automatic Float Float Metering Pump Choke A ir Valve Vacuum
D Idle Unloader
Trans. Level Drop Rod Rod (Bench) Rod Dashpot Break
E
L (M) Manual Trar LS.
MV 7041014 (A) 1/4 - .080 _ .100 .160 - .200 .350
MV 7041017 (M) 1/4 - .080 - .100 .180 - .230 .350
MV 7041023 (M) 1/16 - - - .110 .120 - .200 .350
2GV 7041024 (A) 1/16 - - - .110 .080 - .140 .350
2GV 7041101 (M) 13/16 1 3/4 - 1 3/64 - .075 - .110 .215
2GV 7041110 (A) 13/16 1 3/4 - 1 3/64 - .040 - .080 .215
2GV 7041102 (A) 25/32 1 3/8 - 1 5/32 - .100 - .170 .325
2GV 7041114 (A) 25/32 1 3/8 - 1 5/32 - .100 - .170 .325
2GV 7041113 (M) 23/32 1 3/8 - 1 5/32 - .100 - .180 .325
2GV 7041127 (M) 23/32 1 3/8 - 1 5/32 - .100 - .180 .325
2GV 7041117 (M) 23/32 1 3/8 - 1 5/32 - .100 - .170 .325
2GV 7041118 (A) 23/32 1 3/8 _ 1 5/32 - .100 - .170 .325
2GV 7041181 (M) 5/8 1 3/4 - 1 3/8 - .080 - .120 .180
2GV 7041182 (A) 5/8 1 3/4 _ 1 3/8 - .080 - .120 .180
4MV 7041200 (A) 1/4 _ _ - .100 .020 .260 -
4MV 7041202 (A) 1/4 _ _ - - .100 .020 .260 -

4MV 7041204 (A) 1/4 _ _ - - .100 .020 .260 -
4MV 7041212 (A) 1/4 _ _ _ _ .100 .020 .260 -
4MV 7041201 (M) 1/4 _ _ - - .100 .020 .275 -
4MV 7041203 (M) 1/4 _ - - - .100 .020 .275 -

4MV 7041205 (M) 1/4 _ _ _ - .100 .020 .275 -
4MV 7041213 (M) 1/4 - - - - .100 .020 .275 -

SPECIFICATIONS 13
Holley Carburetors
Holley No. R-4800A R-4801A R-4802A R-4803A

Chevrolet No. 3989022 3989021 3986196 3986195
TRANSMISSION Auto. Std. Auto. Std.
FLOAT LEV EL
(Bowl Inverted)
P rim ary Float Centered in Bowl.
Secondary Float Centered in Bowl.
WET FUEL LE V EL
(On Engine)
P rim ary Fuel Level with Bottom of Sight Plug Hole.
Secondary Fuel Level with Bottom of Sight Plug Hole.
A CCELERA T O R PUMP .015 min.

.015 min. .015 min. .015 min.
(Wide Open Throttle)
FAST ID LE
Mechanical (Hi-Step) .025 .025 .025 .025
Running (R .P.M .) (Hi-Step) 2200 2200 2200 2200
CHOKE ROD ADJUSTMENT

(Bottom of Throttle Body to 1.320 1.320 1.320 1.320
Center of Hole in Operating ±.015 ±.015 ±.015 ±.015
Lever)
CHOKE VACUUM BREAK .350 .350 .350 .350
CHOKE UNLOADER .350 .350 .350 .350
SECONDARY STOP 1/2 Turn Open
MAIN M ETERING JE T
P rim ary #70 #70 #70 #70
Secondary #76 #76 #76 #76
THROTTLE BORE
P rim ary 1 11/16" 1 11/16" 1 11/16” 1 11/16”
Secondary 1 11/16” 1 11/16” 1 11/16” 1 11/16”

SPECIFICATIONS 14
OTHER ADJUSTMENTS
Refer to “Additional External Settings and Adjustments’Vor “C.E.C. Valve Adjustment”, as

applicable, in Section 6M (Service), undeir carburetors before using the following charts.
EQUIPMENT COLUMN #1 COLUMN #2 COLUMN #3 COLUMN #4
Initial Idle Speed Final Idle Speed % "C O " CEC Valve Engine Speed
Transm ission Engine
(RPM) (RPM) @ Idle **(RPM )
Manual L -6 250 C.I.D . 625 550 1.0 850

(In Neutral)
V -8 307 C .I.D .
V -8 350 C .I.D .
(L-65) 700 600 0.5 900
V -8 400 C .I.D .
(LF- 6)
V -8 350 C .I.D .
675 600 1.0 900
(L-48)
MK IV 402
C .I.D . (LS-3)
675 600 1.0 850
MK IV 454
C .I.D . (LS-5)
Automatic L -6 250 C.I.D. 530 500 1.0 650

(In Drive)
V -8 307 C .I.D .
V -8 350 C.I.D.
(L-65)
V -8 400 C .I.D . 580 550 0.5 650
(LF- 6)
V -8 350 C .LD .
(L-48)
MK IV 402
C .I.D . (LS-3)
630 600 1.0 650
MK IV 454
C.LD. (LS-5)
Manual V -8 350 C .I.D . * *

(In Neutral) (Z-28)
V -8 350 C .LD . * 700 * 900
(LT-1)
MK IV 454 * *
C .I.D . (LS- 6)
Automatic V -8 350 C.LD. * *

(In Drive) (Z-28)
V -8 350 C .I.D . * 700 * 750
(LT-1)
MK IV 454 * *
C .I.D . (LS- 6)
* These engines incorporate A .I.R . and do not have "M ixture Screw L im ite r" caps. Idle adjustment is 1/4 turn
rich from lean ro ll on mixture screws (See Tune-Up Sticker).
** CAUTION: If the C .E .C . Valve (solenoid) on the carburetor is used to set engine idle or is adjusted out of
lim its specified in the Service Manual, decrease in engine braking may result."

SPECIFICATIONS 15
ENGINE ELECTRICAL
SECTION 6Y
BATTERIES
Model No. No. of Cranking Capacity @20

& Application Plates Power @ Hour Rate
Catalog No. Per Cell 0°F (Watts) (Amp. Hr.)
1980141 A ll with 250 L -6 54 2300 45

(y-86)
1980145 A ll with 307, 350 and 400 V- 8 's 66 2900 61
(R- 88)
1980149 Chevrolet, Chevelle, Monte Carlo 90 3750 76
(R- 88W) and with 454 V- 8. A ll with
RPOT- 6O
1980147 Corvette with 350 V -8 72 3250 62
(R- 88ST)
1980150 Corvette with 454 V -8 90 3750 76
(R- 88WT)
GENERATORS
Field Current Cold Output* Rated Hot

Model Delco Remy
Application Amps (80°F) Amps @ Amps @ Output**
No. Spec. No. Spec. Volts
@ 12 Volts 2000 R PM 5000 R PM Amps
1100544 Corvette w/AC 4522 4 - 4.5 *** *** 55 61

1100543 Corvette with 4521 4 - 4.5 *** *** 37 42
R PO LS5, LS 6
1100566 A ll with 307, 3395 2.2 - 2.6 14 25 35 37
350, 400 and
454 V- 8's.
A ll with base
L- 6. Not
used R PO B02,
B07, Z28 or LS 6
1100836 A ll L -6 with 3395 2.2 - 2.6 14 25 35 37
N-40
1100837 A ll with RPO 3395 2.2 - 2.6 14 25 35 37
Z28, and LS 6
1100843 Chevelle, 4500 2.2 - 2.6 14 33 58 61
Cam aro and
Nova w/C60
1100917 Chevrolet with 3398 2.8 - 3.2 14 35 59 63
C60, Chevrolet
and Chevelle
w/RPOK85
1100567 R PO BO2 & B07 3396 2.2 - 2.6 14 28 40 42
1100950 Corvette Base 4521 4 -4.5 37 42
and R PO LT1
*Generator temperature approximately 80°F.

**Ambient Temperature 80°F.
***Voltm eter not needed for cold output check. Load battery with carbon pile to obtain maximum output.

SPECIFICATIONS 16
VOLTAGE REGULATOR
Field Relay Voltage Regulator
Model
Application Voltage
No. A ir Gap Point Opening Closing Voltage A ir Gap Point Opening Setting
1119515 Base .015 .030 1.5 - 3.2 .067 .014 13.8-14.8

@ 85° F.
1119519 W ith Delcotron .030 .030 1.5 - 3.2 .067 .014 13.8-14.8
#1100917 @ 85° F.
STARTING MOTOR
Model Ring Gear Free Speed

A pplication Spec. No.
No. Dia. -In. Volts RPM
Amperes
1108365** Chevrolet, 3573
Chevelle, Cam aro,
Nova 250 L -6 (Low) 12-3/4 9 50-80* 5500-10500
with 3-Spd., P.G .,
or M-38
1108367 Monte Carlo, 3753
Chevelle, C am aro
& Nova 307 V -8 (Low) 12-3/4 9 50-80* 5500-10500
w/3 spd. 4-spd.,
P .G ., or M-38
1108418 A ll 350 V -8 3563
w/3 spd. or 4 spd.
(U ltra High) 14 9 65-95* 7500-10500
Chevrolet and
Monte C arlo
400 V -8
w/3 spd. or 4 spd.
Cam aro 402 V -8
w/3 spd. or 4 spd.
Chevrolet,
Chevelle, Cam aro
and Monte C arlo
454 V -8
w/3 spd. or 4 spd.
1108430 A ll 350 V -8 3563
w/M-38 or M-40
(U ltra High) 14 9 65-95* 7500-10500
Chevrolet and
Monte C arlo
400 V -8 w/M-38
or M-40
Cam aro 402 V -8
*
w/M-38 or M-40
Chevrolet,
Chevelle, Cam aro
and Monte Carlo
454 V- 8,
w/M-38 or M-40
1108400 Corvette 454 3563
V- 8, w/4 Spd (U ltra High) 14 9 65-95* 7500-10500
1108429 Corvette 454 3563
V- 8, w/M-40 (U ltra High) 14 9 65-95* 7500-10500
♦♦Incorporates molded arm ature design
♦Includes Solenoid

SPECIFICATIONS 17
DISTRIBUTORS
Engine Ignition Centrifugal Vacuum Ignition O rig inal

Description Point
D istributor Advance Advance Tim ing Equipment
and Dwell Trans.
(Product (Crank D egrees@ (In Crank BTDC at Spark
Setting
Available P art No.) Engine R PM Degrees) Engine Idle* Plug
C-4797 C-3990
250 Cu. In. L -6 1110489 0 @ 930 R PM 0 @ 8" Hg 31° - 34° 4° @ 500 R PM Manual AC-46TS
(145 HP) Nova, 2° @ 1270 R PM 23° @ 16” Hg
Chevelle and 14° @ 2300 R PM
Chevrolet 24° @ 4100 R PM 4° @ 550 RPM Automatic
C-4815 C-3954
307 Cu. In. V -8 1112039 0 @ 680 R PM 0 @ 8” Hg 29° - 31° 8 ° @ 550 R PM Automatic AC-R45TS
(200 HP) Nova, 2° @ 1320 R PM 20° @ 17” Hg
Cam aro
C-4753 C-3954
307 Cu. In. V -8 1112005 0 @ 800 R PM 0 @ 8” Hg 29° - 31° 4° @ 600 R PM Manual AC-R45TS
(200 HP) Nova, 2° @ 1200 R PM 20° @ 17” Hg
Cam aro 24° @ 4300 R PM
C-4816 C-3954
350 Cu. In. V -8 1112042 0 @ 880 R PM 0 @ 8” Hg 29° - 31° 2° @ 600 R PM Manual AC-R45TS
(250 HP) Base and 2° @ 1120 RPM 20° @ 17” Hg
R PO L-65 Chevrolet, 10° @ 1600 R PM
Chevelle, Nova, 15° @ 2200 R PM
Cam aro and Monte 28° @ 4300 R PM
Carlo
C-4573 C-3954
350 Cu. In. V -8 1112005 0 @ 800 R PM 0 @ 8” Hg 29° - 31° 6 ° @ 550 RPM Automatic AC-R45TS
(250 HP) Base and .2° @ 1200 R PM 20° @ 17” Hg
R PO L-65 Chevrolet, 12° @ 2200 R PM
Chevelle, Nova, 24° @ 4300 R PM
Cam aro and Monte
Carlo
C-4817 C-3036
350 Cu. In. V -8 1112044 0 @ 840 RPM- 0 @ 8” Hg 29° - 31° 4° @ 600 R PM Manual AC-R44TS
RPO L-48 Chevelle 2° @ 1160 R PM 15° @15.5”Hg
and Monte Carlo 10° @ 1800 R PM
15° @ 2400 R PM
22° @ 4200 R PM
C-4818 C-3036
350 Cu. In. V -8 1112045 0 @ 865 R PM 0 @ 8” Hg 29° - 31° 8 ° @ 550 RPM Automatic AC-R45TS
R PO L-48 Chevelle, 2° @ 1335 R PM 15° @15.5”Hg
Camaro, Nova and 11° @ 2400 R PM
Monte C arlo 18° @ 4200 R PM
*Refer to Vehicle Emission Control Information Sticker

SPECIFICATIONS 18
DISTRIBUTORS (CONT’D)

Point
Description D istributor Advance Advance Tim ing Equipment
Dwell Trans.
and (Product (Crank Degrees@ (In Crank BTDC at Spark
Setting
Available P art No.) Engine RPM) Degrees) Engine Idle* Plug
C-4827 C-3036
350 Cu. In. V -8 1112049 0 @ 1070 RPM 0 @ 8” Hg 29° - 31° 8 ° @ 700 R PM Manual AC-R44TS
RPO Z28. 2° @ 1330 R PM 15° @15.5"Hg
Camaro 16° @ 2250 R PM
24° @ 5000 R PM
C-4844 C-3036
350 Cu. In. V -8 1112074 0 @ 1034 R PM 0 @ 8” Hg 29° - 31° 12° @ 700 R PM Automatic AC-R44TS
R PO Z28 2° @ 1366 RPM 15° @15.5"Hg
12° @ 2200 RPM
20° @ 5000 R PM
C-4829 C-3993
400 Cu. In. V -8 1112056 0 @ 930 RPM 0 @ 10” Hg 29° - 31° 8 ° @ 550 R PM Automatic AC-R44TS
RPO L F -6 2° @ 1270 R PM 18° @ 17” Hg
Chevrolet 14° @ 2300 R PM
24° @ 4500 R PM
C-4830 C-3954
402 Cu. In. V -8 1112057 0 @ 930 RPM 0 @ 8” Hg 29° - 31° 8 ° @ 600 R PM A ll AC-R44TS
RPO LS-3 2° @ 1260 RPM 20° @ 17” Hg
Chevrolet, Chevelle, 16° @ 2400 R PM
Monte C arlo and 30° @ 4400 R PM
Camaro
C-4823 C-3954
454 Cu. In. V- 8, 1112052 0 @ 857 R PM 0 @ 8” Hg 29° - 31° 8 ° @ 600 R PM A ll AC-R43TS
RPO LS-5. 2° @ 1143 R PM 20° @ 17” Hg
Chevrolet, Chevelle 14° @ 2000 R PM
and Monte C arlo 22° @ 3900 R PM
C-4831 C-3955
454 Cu. In. V- 8, 1112054 0 @ 1090 RPM 0 @ 7” Hg 29° - 31° 12° @ 700 R PM Automatic AC-R43TS
R PO LS- 6. 2° @ 1310 RPM 12° @ 12” Hg
Monte Carlo 28° @ 5000 R PM
C-4845 C-3955
454 Cu. In. V- 8, 1112075 0 @ 1300 RPM 0 @ 7” Hg 29° - 31° 8 ° @ 700 R PM Manual AC-R43TS
RPO LS-6. 5° @ 1500 RPM 12° @ 12” Hg
Chevelle and 12° @ 2400 RPM
Monte Carlo 16° @ 5000 R PM
♦Refer to Vehicle Emission Control Information Sticker

SPECIFICATIONS 19
DISTRIBUTORS (CONT’D)

Point
Description D istributor Advance Advance Tim ing Equipment
Dwell Trans.
and (Product (Crank Degrees@ (In Crank BTDC at Spark
Setting
Available P art No.) Engine RPM) Degrees) Engine Idle* Plug
C-4818 C-3036
350 Cu. In. V- 8, 1112050 0 @ 865 RPM 0 @ 8” Hg 29° - 31° 4° @ 600 R PM Manual AC-R44TS
Base Corvette 2° @ 1335 R PM 12° @15.5"Hg
(RPO L-48) 11° @ 2400 R PM
18° @ 4200 R PM 8 ° @ 550 R PM Automatic
C-4842 C-3036
350 Cu. In. V- 8, 1112038 0 @ 1060 R PM 0 @ 8" Hg -- 8 ° @ 700 R PM Manual AC-R44TS
RPO LT-1 (T ransis 2° @ 1340 R PM 15° @15.5"Hg
Corvette tor Ign.) 17° @ 2400 R PM
24° @ 4800 R PM 12° @ 700 R PM Automatic
C-4823 C-3954
454 Cu. In. V- 8, 1112051 0 @ 857 R PM 0 @ 8" Hg 29° - 31° 8 ° @ 600 R PM A ll AC-R43TS
R PO LS-5 2° @ 1143 R PM 20° @ 17" Hg
Corvette 14° @ 2000 R PM
22° @ 3900 R PM
C-4846 C-3955
454 Cu. In. V- 8, 1112076 0 @1100 R PM 0 @ 7" Hg - - 8 ° @ 700 R PM Manual AC-R43TS
RPO LS- 6, (T ran sis 3° @ 1300 R PM 12° @ 12" Hg
Corvette tor Ign.) 10.8°@1590 R PM
25° @ 2350 R PM
32° @ 5000 RPM
C-4843 C-3955
454 Cu. In. V- 8, 1112053 0 @ 1090 R PM 0 @ 7" Hg - - 12° @ 700 R PM Automatic AC-R43TS
RPO LS -6 (T ransis 2° @ 1310 R PM 12° @ 12" Hg
Corvette tor Ign.) 22° @ 2400 R PM
28° @ 5450 R PM
♦Refer to Vehicle E m ission Control Inform ation Sticker
IGNITION COIL
P rim a ry Resistance Secondary Resistance

Ignition Resistor
@ 75° F. @ 75° F.
Application
OHMS OHMS Type OHMS
L -6 1.41 - 1.65 3,000 - 20,000 Fixed (In 1.8

W iring Harness)
V -8 (Non- 1.77 - 2.05 3,000 - 20,000 Fixed (In 1.35

Transistor) W iring Harness)
V -8 .41 - .51 3,000 - 20,000 Fixed (In .43 & .68

(Transistor) W iring Harness)

SPECIFICATIONS 20
TRANSMISSION AND CLUTCH
SECTION 7
THREE SPEED SAGINAW
Clutch Gear Retainer to Case B o l t s ...................................................................................................................... 22 ft. lbs.

Side Cover to Case B o l t s .......................................................................................................................................... 22 ft. lbs.
Extension to Case B o l t s .............................................................................................................................................. 45 ft. lbs.
Shift Lever to Shifter Shaft Bolts ......................................................................................................................... 20 ft. lbs.
Lubrication F ille r P l u g .............................................................................................................................................. 15 ft. lbs.
T ransm ission Case to Clutch Housing B o l t s ........................................................................................................ 55 ft. lbs.
Crossm em ber to Fram e Nuts ................................................................................................................................ 25 ft. lbs.
Crossm em ber to Mount and Mount to Extension B o l t s ................................................................................... 40 ft. lbs.
THREE SPEED MUNCIE
Clutch Gear Retainer to Case B o l t s .......................................................................................................................... 22 ft. lbs.

Side Cover to Case B o l t s .......................................................................................................................................... .... 22 ft. lbs.
Extension to Case B o l t s .............................................................................................................................................. .... 45 ft. lbs.
Shift Lever to Shifter Shaft B o lt s ................................................................................................................................. 20 ft. lbs.
Lubrication F ille r P l u g .............................................................................................................................................. .... 15 ft. lbs.
Transm ission Case to Clutch Housing B o l t s ............................................................................................................ 55 ft. lbs.
Crossm em ber to Fram e N u t s ........................................................................................................................................ 25 ft. lbs.
Crossm em ber to Mount and Mount to Extension B o l t s ................................................................................... .... 40 ft. lbs.
Transm ission D rain P l u g .......................................................................................................................................... .... 30 ft. lbs.
FOUR SPEED SAGINAW

Side Cover to Case B o l t s ........................................................................................................................................... 22 ft. lbs.
Shift Lever to Shifter Shaft Bolts ......................................................................................................................... 20 ft. lbs.
Transm ission Case to Clutch Housing Bolts ........................................................................................................ 55 ft. lbs.
Crossmember to Fram e N u t s .................................................................................................................................... 25 ft. lbs.
Crossmember to Mount and Mount to Extension B o l t s ................................................................................... 40 ft. lbs.
FOUR SPEED MUNCIE
Clutch Gear Bearing Retainer to Case B o l t s .................................................................................................... .....25 ft. lbs.

Cover to Case B o lt s ..................................................................................................................................................... .....20 ft. lbs.
Extension and Retainer to Case Bolts-(Upper) ................................................................................................. .... 20 ft. lbs.
-(Lower) ................................................................................................. .... 30 ft. lbs.
Lubrication F ille r P l u g .............................................................................................................................................. .... 30 ft. lbs.
Shift Lever to Shifter Shaft Nut ................................................................................................................................. 20 ft. lbs.

SPECIFICATIONS 21
POWERGLIDE AND TORQUEDRIVE
T ransm ission Case to E n g in e ................................................................................................................................... 35 ft. lbs.

T ransm ission O il Pan to C a s e ................................................................................................................................ 8 ft. lbs.
T ransm ission Extension to C a s e ............................................................................................................................. 25 ft. lbs.
Speedometer Driven Gear Fitting R e ta in e r ........................................................................................................... 4 ft. lbs.
Servo Cover to T ransm ission Case B o l t s ........................................................................................................... 20 ft. lbs.
Front Pump to T ransm ission Case Bolts ........................................................................................................... 15 ft. lbs.
Front Pump Cover to Body Attaching B o l t s ........................................................................................................ 20 ft. lbs.
Pinion Shaft Lock Plate Attaching S c r e w s ........................................................................................................2-1/2 ft. lbs.
Governor Body to Hub Attaching B o l t s .................................................................................................................. 7 ft. lbs.
Governor Hub Drive S c r e w ....................................................................................................................................... 8 ft. lbs.
Governor Support to T ransm ission Case B o lts .................................................................................................... 10 ft. lbs.
Valve Body to T ransm ission Case B o l t s ............................................................................................................... 15 ft. lbs.
Valve Body Suction Screen Attaching Screws ................................................................................................. 2-1/2 ft. lbs.
Upper Valve Body Plate Bolts ................................................................................................................................ 5 ft. lbs.
Lower to Upper Valve Body Attaching B o lt s ........................................................................................................ 15 ft. lbs.
Inner Control Lever A llen Head S c re w ...............................................................................................................2-1/2 ft. lbs.
Parking Lock Pawl Reaction Bracket Attaching B o lt s ....................................................................................... 10 ft. lbs.
O il Cooler Plugs at T ransm ission C a s e ................................................................................................. ... 5 ft. lbs.
P ressure Test Point P l u g s ....................................................................................................................................... 5 ft. lbs.
Low Band Adjustment L o c k n u t ................................................................................................................................ 15 ft. lbs.
Converter to Engine B o lt s ........................................................................................................................................... 35 ft. lbs.
Under Pan to T ransm ission C a s e ......................................................................................................................... 7-1/2 ft. lbs.
O il Cooler Pipe Connectors to T ransm ission Case or R a d i a t o r .................................................................. 10 ft. lbs.
O il Cooler Pipe to Connectors.................................................................................................................................... 10 ft. lbs.
Vacuum Modulator to T ransm ission C a s e ........................................................................................................... 15 ft. lbs.
O il Pan D rain P l u g ..................................................................................................................................................... 20 ft. lbs.
Converter D rain Plug ( T a x ie s ) ................................................................................................................................ 20 ft. lbs.
Parking Brake Lock & Range Selector Inner Lever A llen Head S c r e w .................................................2-1/2 ft. lbs.
TURBO HYDRA-MATIC—350
Pump Cover to Pump B o d y ............................................................................................................................ 17 ft. lbs.

Pump Assembly to C a s e ................................................................................................................................... 18-1/2 ft. lbs.
Valve Body and Support P la t e ......................................................................................................................... 130 in. lbs.
Parking Lock B r a c k e t ....................................................................................................................................... 29 ft. lbs.
O il Suction S c r e e n .............................................................................................................................................. 40 in. lbs.
O il Pan to C a s e ................................................................................................................................................. 130 in. lbs.
Extension to C a s e .............................................................................................................................................. 25 ft. lbs.
Modulator Retainer to C a s e ............................................................................................................................ 130 in. lbs.
Inner Selector Lever to S h a f t ......................................................................................................................... 25 ft. lbs.
Detent Valve Actuating B r a c k e t .................................................................................................................. . 52 in. lbs.
Converter to Flywheel Bolts ......................................................................................................................... 35 ft. lbs.
Under Pan to T ransm ission C a s e .................................................................................................................. 110 in. lbs.
O il Pan D rain Plug .......................................................................................................................................... 20 ft. lbs.
Transm ission Case to E n g in e ......................................................................................................................... 35 ft. lbs.

SPECIFICATIONS 22
TURBO HIYDRA-MATIC—400
Pump Cover B o l t s ......................................................................................................................................................... 18 lb. ft.

Parking Pawl Bracket B o lt s ....................................................................................................................................... 18 lb. ft.
Center Support B o l t ..................................................................................................................................................... 23 lb. ft.
Pump to Case Attaching B o lts .................................................................................................................................... 18 lb. ft.
Extension Housing to Case Attaching B o lts ............................................................................................................ 23 lb. ft.
Rear Servo Cover B o l t s .............. ................................................................................................................................ 18 lb. ft.
Detent Solenoid Bolts .................................................................................................................................................. 7 lb. ft.
Control Valve Body Bolts ....................................................................................................................................... 8 lb. ft.
Bottom Pan Attaching S c re w s .................................................................................................................................... 12 lb. ft.
Modulator Retainer B o l t .............................................................................................................................................. 18 lb. ft.
Governor Cover B o l t s .................................................................................................................................................. 18 lb. ft.
Manual Lever to M anual Shaft N u t .......................................................................................................................... 8 lb. ft.
Manual Shaft to Inside Detent L e v e r ...................................................................................................................... 18 lb. ft.
Linkage Swivel Clam p N u t ........................................................................................................................................... 43 lb. ft.
Converter Dust Shield S c re w s.................................................................................................................................... 93 lb. ft.
T ransm ission to Engine Mounting B o l t s ............................................................................................................... 28 lb. ft.
Converter to Flywheel Bolts .................................................................................................................................... 33 lb. ft.
R ear Mount to T ransm ission B o l t s .......................................................................................................................... 40 lb. ft.
Rear Mount to Crossm em ber B o l t .......................................................................................................................... 40 lb. ft.
Crossm em ber Mounting B o l t s .................................................................................................................................... 25 lb. ft.
O il Cooler Line .............................................................................................................................................................113 lb. In.
Line Pressure Take-Off P l u g .................................................................................................................................... 13 lb. ft.
Strainer Retainer B o l t .................................................................................................................................................. 10 lb. ft.

SPECIFICATIONS 23
STEERING
SECTION 9
STANDARD STEERING
Chevrolet & Chevelle, 116” W.B. Wagon,

Item Nova Corvette
125” W.B. Wagon Monte Carlo & Camaro
Type
Except “ SS”
A ll A ll Road Fast
“ SS” Models
Steering
Ratio Gear 24:1 24:1 24:1 24:1 16:1 16:1
Gear
O verall 30.7:1 28.7:1 27.3:1 21.4:1 20. 2:1 17.6:1
Type P a ra lle l Relay Rod
Linkage Location Rear Front Rear
Tie Rods 2
STANDARD STEERING—CAM ARO

L -6 Z-28 V -8 (Exc. Z-28
Gear O verall Gear Overall Gear Overall
Gear Ratio 24:1 28.3:1 24:1 22.3:1 28:1 33.1:1
POWER STEERING —PUMP
Vehicle Constant Ratio Steering Variable R atio Steering

Chevrolet 1350-1450
1200-1300 (L- 6)
Chevelle-Camaro
1350-1450 (V-8)
Station Wagon 900-1000
Monte Carlo 1350-1450
1200-1300 (L- 6)
Nova
1350-1450 (V-8)
Corvette 870-1000

SPECIFICATIONS 24
POWER STEERING-GEAR
Constant Ratio V ariable Ratio
Vehicle Regular Fast Regular Fast
Gear O verall* Gear O verall* Gear O verall Gear O verall
16:1 19.3:1
Chevrolet - - - - to to - -
12.4:1 15.5:1
16:1 18.6:1
Chevelle & to
- - - - to - -
Monte Carlo 14.5:1
12.4:1
125” W.B.
17.5:1 21. 2:1 - - - - - -
Sta. Wgn.
116" W.B.
17.5:1 21. 6:1 - - - - - -
Sta. Wgn.
16:1 18.9:1 16:1 14.25:1
Nova - - - - to to to to
12.4:1 14.7:1 12.4:1 11:1
Corvette - - 16:1 17.6:1 - - - -
*On Center
ADJUSTMENT SPECIFICATIONS—STANDARD STEERING
Adjustment Torque to Turn W orm Shaft
% W orm Bearing Preload 5-8 Lb. In.

Sector Lash Adjustment 4 - 1 0 Lb. In. in excess of above
Total Steering Gear Preload 16 Lb. In. Maximum
ADJUSTMENT SPECIFICATIONS-POW ER STEERING
Chevrolet, Chevelle, Station Wagon, Monte Carlo, Cam aro and Nova
Ball Drag 3 In. Lb. Max.
Thrust Bearing Preload 1 / 2 - 2 In. Lb. in excess of valve assy, drag
Over Center Preload 3 - 6 In. Lb. in excess of above
Total Steering Gear Preload 14 In. Lb. Max.
Corvette
W orm Bearing Preload 4 to 7 In. Lb.
Sector Lash Adjustment 4 to 10 In. Lb. excess of above
Total Steering Gear Preload 14 In. Lb. Max.

SPECIFICATIONS 25
TORQUE CHART
Chevrolet & 125" Chevelle, 116" W.B.

Nova Corvette Camaro
W.B. Station Wagon Wagon & Monte Carlo
Steering Gear Mounting Bolts 70 ft. lb. 70 ft. lb. 68 ft. lb. 70 ft. lb. 70 ft. lb.
Pitm an Shaft Nut 180 ft. lb. 140 ft. lb. 180 ft. lb.
Pitm an A rm to Relay Rod
50 ft. lb.*
Stud Nut
Idler A rm to Relay Rod
50 ft. lb.*
Stud Nut
Idler A rm to Fram e Nuts 45 ft. lb. | 35 ft. lb.
Tie Rod End Stud Nuts 35 ft. lb.**
Tie Rod Clam p Nuts 22 ft. lb. | 150 in. lb. | 22 ft. lb.
Steering Coupling to Shaft
20 ft. lb.
Flange Nuts
Steering Coupling Clam p Bolts 30 ft. lb.
Steering Wheel Nut 30 ft. lb.
Steering Wheel to Hub
Screws (Corvette and 25 in. lb. 25 in. lb. - 25 in. lb. 25 in. lb.
Cushioned R im Wheels)
Floor Pan Cover Screws 35 in. lb.
Floor Pan Cover Clamp
35 in. lb.
Screws
Floor Pan Bracket Nuts — — — 120 in. lb. -
Dash Panel Bracket to
15 ft. lb. 15 ft. lb. 15 ft. lb. - 15 ft. lb.
Column Screws
Dash Panel Bracket to
20 ft. lb. 20 ft. lb. 20 ft. lb. 15 ft. lb. 20 ft. lb.
Dash Nuts
Ignition Switch Screws 35 in. lb.
Turn Signal Switch Screws 35 in. lb.
Column Lock Plate Cover
20 in. lb.
Screws
Turn Signal Housing Screws 45 in. lb.
Lock Bolt Spring Screw
35 in. lb. 35 in. lb. - 35 in. lb.
(Tilt a Tilt-Telescope)
Bearing Housing Support
60 in. lb. 60 in. lb. - 60 in. lb.
Screws (Tilt & Tilt^Tele)
Trans. Control Lock Tube
Hsg. Ext. Screws - - - 40 in. lb. -
(Tilt-Telescope)
Power Steering Pump
58 ft. lb.
Pulley Nut
Power Steering Pump
20 ft. lb.
Mounting Bolts
Power Steering Pump
25 ft. lb.
Mounting Stud Nut
Power Steering Pump Return
26 in. lb. 26 in. lb. 26 in. lb. 15 in. lb. 26 in. lb.
Hose Clam p Screw
Power Steering Pum p &
25 ft. lb.
Gear Hose Fittings
Power Cylinder to Relay
- - — 45 ft. lb .* -
Rod Nut
Power Cylinder to Frame
- - - 23 ft. lb .* -
Bracket
Power Cylinder Fram e
- - - 17 ft. lb. -
Bracket to Fram e Nuts
Control Valve to Pitm an
- - - 45 ft. lb .* -
A rm
Control Valve Clam p Bolt - - - 25 ft. lb. —
* Plus additional torque required to align castellation with cotter pin hole in stud (not to exceed 60 ft. lb. maximum)
** Plus additional torque required to align castellation with cotter pin hole in stud (not to exceed 50 ft. lb. maximum)
★ Plus additional torque required to align castellation with cotter pin hole.

SPECIFICATIONS 26
WHEELS AND TIRES

SECTION 10
CHEVROLET TIRE USAGE CHARTS

Engine and Body Style Standard Optional
A ll L -6 A ll F78 x 15 or G78 x 15; H78 x 15;

and Base V -8 Biscayne and Bel A ir G78 x 15 White Stripe
350 V -8 (4 bbl.) A ll
400 V -8 (2 bbl.) Biscayne and Bel A ir
H78 x 15;
Base V -8 G78 x 15
White Stripe
350 V -8 (4 bbl.) Im pala
400 V -8 (2 bbl.) Caprice
402 V -8
A ll H78 x 15
454 V -8
Chevelle
L -6 Sedans, Coupes, Convertible E78 x 14 F78 x 14; White Stripe
E78 x 14
Except SS Models E78 x 14; or F78 x 14; White Stripe
F78 x 14
V -8
F60 x 15
SS Models
White Letters
E78 x 14
E l Camino Except
A ll or E78 x 14; or F78 x 14; White Stripe
SS Models
F78 x 14
F60 x 14
SS Models
White Letters
Camaro
F70 x 14
A ll E78 x 14 White Stripe or
White Letters
F70 x 14
SS Models
White Letters
F60 x 15
Z-28
White Letters
Monte Carlo
A ll A ll Exc. SS 454 G78 x 15
G70 x 15 White Stripe
SS454 G70 x 15
Nova
A ll except SS Models E78 x 14 E70 x 14 White Stripe
A ll
E70 x 14
SS Models -
White Stripe

SPECIFICATIONS 27
Chevrolet Station Wagons
A ll Station Wagon L78 x 15 or L78 or 15D

(125" W.B.) L78 x 15 D —
A ll Station Wagon G78 x 14 or G78 x 14D

(116" WB.) G78 x 14D —
Standard and Optional Tires are Load Range B unless otherwise specified.
Tire inflation pressure may increase as much as 6 pounds per square inch (psi) when hot. For continuous high
speed operation (over 75 mph) increase tire inflation pressure 4 pounds per square inch over the recommended
pressures up to a maximum of 32 pounds per square inch cold for load range B tires. Sustained speeds above
75 mph are not recommended when the 4 pounds per square inch adjustment would require pressures great than the
m axim um stated above.
Cold tire inflation pressure: after vehicle has been inoperative for 3 hours or more, or driven less than 1 m ile.
Hot tire inflation pressure: after vehicle has been driven 10 m iles at speeds of more than 60 m iles per hour.
Station wagon loads should be distributed as far forward as possible. Vehicles with luggage racks do not have a
vehicle load lim it greater than specified. When towing tra ile rs, the allowable passenger and cargo load must be
reduced by an amount equal to the tra ile r tongue load on the tra ile r hitch.
CORVETTE TIRE USAGE

Tire Usage and Recommended Tire Inflation Pressures Pounds per Square Inch
Standard Inflation Pressure For

A ll Loads Including Full Rated
Full
And Continuous High Speed
Rated
Operation (Over 75 MPH)
Models Load Tire Ply Tire Usage
Front Rear
1 to 2 Passengers
A ll Models + 150 Lbs. Luggage 4 ply rating- F70-15 Nylon 24 24
(450 Lbs. Load) 2 ply*
♦Optional tires are not available.

1. Tire inflation pressures may increase as much as six (6) pounds per square inch (PSI) when hot.
2. Cold tire inflation pressure: after vehicle has been inoperative for three (3) hours or more, or driven less than
one (1) m ile. Hot tire inflation pressure: after vehicle has been driven ten (10) m iles or more at 60-70 MPH.
3. Vehicles with luggage racks do not have a load lim it greater than specified above.
CHASSIS SHEET METAL

SECTION 11
Chevrolet Chevelle Monte Carlo Nova Camaro Corvette
Hood Safety Catch Bolt 55 in.

Hood Catch Assembly 20 ft.
Hood Catch Tension Spring 20 ft.
Hood Catch Plate 20 ft. 20 ft. 20 ft. 20 ft. 20 ft.
Hood Lock Bolt 30 ft. 30 ft. 30 ft. 30 ft. 25 ft.
Hood Lock Bolt Plate 20 ft. 20 ft. 20 ft. 20 ft. 120 in.
Hood Hinge 25 ft. 25 ft. 25 ft. 25 ft. 25 ft. 20 ft.
Hood Bumper 85 in. 85 in. 85 in. 85 in. 85 in. 85 in.
Hood Im pact Bolt 25 ft. 25 ft. 25 ft. 25 ft.

SPECIFICATIONS 28
BODY AND CHASSIS ELECTRICAL

SECTION 12
CANDLE
BULB
LAM P USAGE POW ER
NUMBER
(OR WATTS)
Headlamp Unit
Chevrolet, & Corvette
37 1/2 Watts
4002
55 Watts
37 1/2 Watts 4001
Nova, Camaro, Monte Carlo, Chevelle
60 Watts
6014
50 Watts
3-32 1157NA
3-32 1157
32 1156
Instrum ent Illum ination Lamps
2 194
2 1895
3 168
Console Instrum ent Cluster (N o v a )............................................................................ 2.5 1816
2 194
2 194
2 194
Hi-Beam Indicator
2 194
2 1895
Directional Indicator
2 194
2 1895
Cigar Lighter Lamp
1 1445
Warning Lamps
Corvette - Door A j a r .................................................................................................... 2 1895
Headlamps U p ............................................................................................. 2 1895
Seat B e l t s .................................................................................................... 2 194
Chevrolet - Low F u e l .................................................................................................... 2 194
2 194
Seat B e l t .................................................................................................... 2 194
Nova - Low Fuel ............................................................................ .............................. 2 194
Heater or A /C Control Panel
Chevelle, Monte C arlo, Cam aro ................................................................................ 1 1445
Chevrolet & N o v a ........................................................................................................... 2 1895
Corvette ............................................................................................................................ 2.5 1816
Glove Box Lamps
Camaro, Chevrolet, without A /C , Nova & C o r v e tte ............................................. 2 1895
Camaro, Chevelle, Monte Carlo & Chevrolet with A /C ................................... 2 1893
Dome and Courtesy Lamps
Cartridge Type ( A l l ) ........................................................................................................ 12 211
Bayonet Type ..................................................................................................................... 6 631
Seat Separator - Courtesy Lamp ................................................................................... 6 212
Side M arker - Front (Except Chevelle, Chevrolet) ................................................ 2 194
Chevelle, C h e v r o le t ....................................................... ' .............................................. 2 194A
Side M arker - Rear ........................................................................................................... 2 194
Side M arker - Corvette Only .................................. ....................................................... 3 168
License Plate Lamp (Except C o r v e t t e ) ................. ....................................................... 4 67
Corvette ..................................................................... ....................................................... 4 97
Radio D ial Lamp
AM Only Radios ( N o v a ) ................................................................................................ 2 293
Tape Players and FM Radios, Corvette, Nova .................................................... 2 1893
A ll Except Corvette, N o v a ............................... ....................................................... 3 1816

SPECIFICATIONS 29
CANDLE
BULB
LAM P USAGE (Cont’d.) POW ER
NUMBER
(OR WATTS)
Tape Player Lens Illum ination Lamp (Except C h e v r o le t ) .......................................... 1 216

C h e v r o le t................................................................................................................................ 2 564
Stereo Indicator Lamp (Except Chevrolet) ..................................................................... .3 2182D
C h e v ro le t................................................................................................................................ .07 66
Automatic Transm ission Control Indicator Lamp
Chevrolet, Chevelle & Monte Carlo (without seat separator) ............................ 2 194
Camaro, Nova, Chevelle & Monte Carlo (with seat se p a ra to r)............................ 1 1445
C o r v e tt e .................................................................................................................................. 2 1895
Brake A larm Lamp
A ll Except C o r v e tt e ........................................................................................................... 2 194
Corvette ................................................................................................................................ 2 1895
Luggage Compartment L a m p ................................................................................................. 15 1003
Chevrolet O n l y ...................................................................................................................... 6 89
Map Lamp (M ir r o r ) .................................................................................................................. 4 563
Underhood Lamp ...................................................................................................................... 15 93
Washer Fluid Level I n d i c a t o r ............................................................................................. 3 168
FUSES A N D CIRCUIT BREAKER
A circuit breaker in the light control switch protects separate 15 amp in-line fuse. Where current load is too
the headlamp circuit, thus elim inating one fuse. A sep heavy, the circuit breaker rapidly opens and closes, p ro
arate 30 amp circuit breaker mounted on the firew all tecting the circuit until the cause is found and eliminated.
protects the power window, seat and top circuits. The Fuses located in the Fuse Panel under the instrument
under hood and spot lamp circuit is also protected by a panel are:
Radio, Transm ission Control Spark System, Rear Defogger, Power Window,
3 Speed A /T Downshift, Glove Box L a m p ..................................................................... 10 Amp.
W ip e r /W a s h e r................................................................................................................................ 25 Amp.
Stop Lamps, Hazard F la s h e r .................................................................................................... 20 Amp.
Heater and A ir C o n d itio n in g .................................................................................................... 25 Amp.
D irectional Signals, Back-Up Lamp, Cruise Master, Blocking Relay ( A C ) .............. 20 Amp.
Instrum ent and Dome Lamps, Anti-Diesel and Blocking Relays ( C a m a r o ) .............. 2 Amp.
Instrum ent Lamps - C h e v ro le t................................................................................................. 3 Amp.
Instrum ent Lamps (incl. A /T Quadrant Illum ination) Nova, Chevelle, Monte Carlo 4 Amp.
Instrument Lamps - C o r v e t t e ................................................................................................. 5 Amp.
Gauges and Tell-Tale Warning Lamps ................................................................................ 10 Amp.
Clock, Cigar Lighter, Courtesy Lamps, Anti-Diesel Control, Deck Lid, Lock,
Anti-Theft A larm , Glove Box and Dome Lamps ....................................................... 25 Amp.
Tail, License, M arker, Luggage and Parking L a m p s ....................................................... 20 Amp.
In-Line Fuses:
A ir Conditioning High Blower Speed Fuse located in wire running from horn relay to A /C Relay
Comfortron and Four S e a s o n ...................................................................................................................... SAE 30 Amp.
Fusible Links:
P ig tail lead at battery positive cable (except C o r v e tt e ) ............................................................... 14 gauge brown wire
Molded splice at Solenoid "B a t" term inal (Corvette o n ly ) ....................................................... .... 14 gauge brown wire
Molded splice Located at the horn r e l a y ........................................................................................... 16 gauge black wire
Molded splice in Voltage Regulator #3 term inal w i r e .............................................................. .... 20 gauge orange wire
Molded splice in A m m eter c irc u it (Both sides of m e t e r ) ....................................................... .... 20 gauge orange wire

SPECIFICATIONS 30
WINDSHIELD WIPERS
Depressed Park Two Speed Washer Pump
Operation Test Voltage (Bench or Battery). . 12 VDC Number of "sq u irts" at full p r e s s u r e ................. 10
Gear R a t i o ........................................................... 51:1
Current Draw (Amps) No Load (no linkage) Pressure ( p s i ) .............................................................. 11-15
Low S p e e d ........................................................ 6 Max.
H i Speed ........................................................4.5 Max. Coil Resistance (ohm s).................................................9 ± 1
S t a l l ......................................................................... 18 Max.
Shunt F ield Resistance (ohms)........................ 5-6
Crank A rm Speed (rpm's)-No Load
L o w ......................................................................... 35-50
Hi ......................................................................... 70-95
RADIATOR AND GRILLE

)
SEC TIO N 13
G rille 12 In. 18 In. 85 In. 30 In. 18 In. 30 In.
G rille Brackets 18 Ft. 18 In. 20 Ft. 20 Ft. 20 Ft. 20 Ft.
Fan Shroud 50 In. 50 In. 50 In. 150 In. 50 In. 20 Ft. (Upr. Grille)
150 In. (Lwr. Grille)
Torque measurements above are in either "Inch L bs." or "Foot L bs."
BUMPERS
SECTION 14
Front Bumper 30 Ft. 25 Ft. 25 Ft. 30 Ft. 20 Ft. 30 Ft.
30 Ft. (Otr.)
Front Bumper Bracket & Brace 55 Ft. 70 Ft. 70 Ft. 70 Ft. 24 Ft. 55 Ft. (Otr.)
25 Ft. (Upr.)
R ear Bumper to Outer Bracket 30 Ft. 40 Ft. (Lwr.) 55 Ft. 30 Ft. 17 Ft. 30 Ft.
R ear Bumper to Outer Brace 30 Ft. 30 Ft. 17 Ft.
Rear Bumper to Center Bracket 24 Ft. 38 Ft. 17 Ft.
55 Ft.
Rear Bumper to Body Fram e (Wag. Only) 55 Ft. 38 Ft.
70 Ft.
Rear Bumper Outer Bracket & Brace 55 Ft. (Wag..) 55 Ft. 38 Ft. 25 Ft. 24 Ft. 70 Ft.
R ear Bumper Center Bracket - 38 Ft. -
Torque measurements above are in either "Inch L bs." or "Foot Lbs."

SPECIFICATIONS 31
ACCESSORIES
SECTION 15
CRUISE MASTER
Solenoid Resistance ..................................................................... ...........................................................5 ohms ± 1 / 4 ohm

Solenoid W ire R e s is t a n c e ........................................................... ............................................................................ 40 ohms
Maximum allowable Vacuum Leakage Rate for Servo Unit ............................... 5 inches of Vacuum Per Minute
Not greater than 1 inch of Vacuum per 10 seconds
Operational Test Speed.................................................................. ............................................................................... 60 MPH
AIR CONDITIONING
Compressor
M ake......................................................................... Frigidaire
T y p e .............................................................. 6 Cylinder Axial
Displacement
Four-Season (Except Corvette)
and C om fortron.......................................... 12.6 Cu. In.
Corvette Four-Season................................... 10.8 Cu. In.
Rotation ............................................................... Clockwise
Compressor Clutch Coil

Ohms (at 80°F) . ........................................................... 3.70
Amps (at 80°F) .......................................... 3.22 @ 12 volts
Torque Specifications
Com pressor Suction and Discharge
Connector B o l t ................................................. 25 ft. lbs.
Rear Head to Shell Stud N u t s ............................ 23 ft. lbs.
Shaft Mounting N u t ............................................. 15 ft. lbs.
Belt T e n s io n ...................................... See Tune-Up Chart
System Capacities
Refrigerant 12
Four-Season (Except Corvette) and
Comfortron S y s te m s ............................ 3 lbs., 12 oz.
Corvette F o u r - S e a s o n ............................... 3 lbs., 4 oz.
525 Viscosity Compressor O il
A ll S y s te m s ....................................................11 Fluid oz.
Amps RPM
Blower Motor Volts (Cold) (Cold)
Four-Season and
Comfortron . . . . . . . 12 16.5 Max. 3700 Min.
Fuse In
Fuses Block Line
Four-Season............................................. 25 amp 30 amp
C o m fo r tr o n ............................................. 25 amp 30 amp

................. 111......
SPECIFICATIONS 33
10-30 SERIES TRUCK

HEATING AND AIR CONDITIONING
SE C T IO N 1
HEATER Compressor Clutch Coil

Ohms (at 80° F) .................................................... . . 3.70
Amps RPM
Amps (at 80° F) ...................................... 3.22 r> 12 volts
Volts (Cold) (Cold)
Blower Motor System Capacities
Deluxe A i r ................. 13.5 6.25 Max 2550 Min. Refrigerant 12
2950 Max. Four-Season and GM C h e v ro le t..............3 lbs. 4 oz.
Fuses Roof-M ounted................................................ 4 lbs. 8 oz.
525 Viscosity Compressor O il
Deluxe H eater........................................................... 10 Amp.
Four-Season and GM C h e v ro le t................. 1( ) fluid oz.
Roof-M ounted....................................................1C 5 fluid oz.
AIR CONDITIONING
Compressor Torque Specifications
Make ..................................................................... F rig ida ire Compressor Suction and Discharge
Type ........................................................... 6 Cylinder Axial Connector B o l t ................................................ 25 ft. lbs.
D is p la c e m e n t.................................................... 12.6 Cu. In. Rear Head to Shell Stud N u t s ........................ 23 ft. lbs.
R o ta tio n .................................................................. Clockwise Shaft Mounting N u t ............................................. 15 ft. lbs.
Belt T e n s io n ...................................... See Tune Up Chart
Amps RPM
Volts (Cold) (Cold) Fuses
Blower Motor Four Season S y s te m s ......................................... 25 Amp.
GM Chevrolet and Roof-Mounted Systems . . 10 Amp.
Four-Season.....................12 16.5 Max. 3700 Min.
GM Chevrolet and Roof-
Mounted ........................ 12 13.7 Max. 3400 Min.

SPECIFICATIONS 34
IB BODY
SPECIFICATIONS
MIRRORS AND SUNSHADE

Inside Rear View M irro r
M irro r to B r a c k e t ...................................................................................................
Bracket to Header P a n e l........................................................................................ ....................................................... 15 in. lb.
Sunshade Support to Header P a n e l .......................................................................... ....................................................... 20 in. lb.
Outside Rear View M irro r to Door Panel
Series 10-20-30 Except (03-04-34 M o d e ls )....................................................... ....................................................... 40 in. lb.
Series 20-30 (03 M odels)........................................................................................
DOORS
Window Regulator to Door Panel .............................................................................. ....................................................... 40 in. lb.
Door Lock to Door P a n e l ........................................................................................... ....................................................... 75 in. lb.
Lock Striker to Body P i l l a r ..................................................................................... .......................................................... 25 ft. lb.
Rear Door Lock S t r ik e r ..............................................................................................
Outside Door H a n d le ...................................................................................................
Rear Door A rm C h e c k ...................... .........................................................................
Hinge to Door and Body
A ll Except Rear D o o r s ...........................................................................................
Rear D o o rs .................................................................................................................
Rear Door B u m p e r s ...................................................................................................
Rear Door Latch C o n t r o l...........................................................................................
Rear Door L a tc h . . . . < ..............................................................................................
LIFTGATE
Hinge B o l t s ....................................................................................................................
Liftgate S u p p o r t......................... .. ...............................................................................
H a n d le ............................................................................................................................
S t r ik e r ............................................................................................................................
ENDGATE (EXCEPT SUBURBAN)

H a n d le ............................................................................................................................
Tailgate-to-Pickup Box Support................................................................................ .......................................................... 17 ft. lb.
T ru n n io n ..........................................................................................................................
ENDGATE (SUBURBAN)
Latch Remote C o n t r o l.................................................................................................

Endgate to Body Support..............................................................................................
Striker (Body Mounted)................................................................................................. .......................................................... 90 in. lb.
Hinges ............................................................................................................................
B u m p e r s .........................................................................................................................
SEATS
............................................................. 25 ft. lb.
Front Seat
Bench Type
Adjuster-to-Seat................................................................................................... ............................................................. 150 in. lb.
Adjuster-to-Floor....................................................... ......................................... ............................................................. 150 in. lb.
Bucket Type
Adjuster-to-Seat...................................................................................................
Adjuster-to-Floor....................................................... ......................................... ............................................................. 18 ft. lb.
Center and Rear Seat (Bench Type)
Leg-to-Seat.................................................................. ......................................... ............................................................. 17 ft. lb.
Leg-to-Floor......................................................................................................... ............................................................. 50 ft. lb.
Rear Mounting Bracket
to S e a t................................................................................................................. ............................................................. 18 ft. lb.
to F lo o r ..................................................................... ......................................... ............................................................. 30 ft. lb.
Body Mounts A ll Except Rear # 2 ............................................................................. ............................................................. 20 ft. lb.
Rear # 2 ....................................................................................................................... ............................................................. 50 ft. lb.
Seat B e l t ................................................................................ ......................................... ............................................................. 40 ft. lb.

SPECIFICATIONS 35
FRONT SUSPENSION
SECTION 3
/
ALIG NM ENT SPECIFICATIONS
MODELS FOR CHECKING FOR RESETTING
C-10
Camber #*
Caster #*
Toe-In (Total) $ 1/16" to 5/16” $ 1/8" to 1/4"
C-20-30 m #*
Camber m #*
Caster
Toe-In (Total) $ 1/16” to 5/16" $ 1/8" to 1/4"
P-10
Camber #@ #*
Caster #*
Toe-In (Total) $ 1/16" to 5/16" $ 1/8" to 1/4"
P-20-30
Camber m #*
Caster m #*
Toe-In (Total) $ 1/16" to 5/16" $ 1/8" to 1/4"
K-10-20 * * —
Camber * * * —
Caster
Toe-rn (Total) $ 1/16" to 5/16" $ 1/8" to 1/4"
# See Chart. Figure 4 Section 3.

$ Toe setting must always be made after camber and caster. Any change in cam
ber and caster w ill effect toe.
* Camber and caster must not vary more than 1/2 from side to side.
** Camber: Designed to be + 1-1/2° at curb weight with no provision for resetting.
***Caster: Designed to be + 4 r at curb weight with no provision for resetting.
@ Cam ber and caster must not vary more than 1° from side to side.

SPECIFICATIONS 36
FRONT SUSPENSION BOLT TORQUE (Ft. Lbs.)
CP-10 CP-20-30 K-All
Lower Control A rm Shaft U-Bolt 45 110 -
Upper Control A rm Shaft Nuts 70 120 -

New 160 New 190
Lower Control A rm Bushing -
Replace 95 Replace 115
New 280 New 280
Lower Control A rm Bushing -
Replace 130 Replace 130
Upper Ball Joint Nut *50 **90 **100
Lower Ball Joint Nut **90 **90 *** 70
C rossm em ber to Side R ail 65 65 -

Crossm em ber to Bottom R ail 100 100 -
Stabilizer Bar to Control A rm 25 25 -
Stabilizer Bar to Frame 25 25 -

Shock Absorber Upper End 140 140 65
Shock Absorber Lower End 75 75 65
Brake Splash Shield to Knuckle 140 In. Lbs. 140 In. Lbs. -
Inner#-35
Wheel Bearing Adjustment #15 #40
Outer -50
Wheel Bearing Preload Zero Zero Zero
Wheel Bearing End Movement .001-.008 .001-.010 .001-.010
Caliper Mounting .Bolt 35 35 35
Spring-Front Eye Bolt - - 90
Spring-Rear Eye Bolt - - 50
Spring-To Rear Shackle Bolt - - 50
Spring-To Axle U-Bolt - - 120
Spring-Front Hanger to Frame - - 30
Suspension Bumper 15 15 15
* Plus additional torque to align cotter pin. Not to exceed 90 ft. lbs. maximum.
** Plus additional torque to align cotter pin. Not to exceed 130 ft. lbs. maximum.
***P lu s additional torque to align cotter pin.
# Back nut off to align cotter pin at nearest slot.

SPECIFICATIONS 37
REAR SUSPENSION
SECTION 4
TORQUE SPECIFICATIONS (FT. LBS.)

WHEEL BEARING ADJUSTMENT SPECIFICATIONS
R ear Axle Bearing Adjusting Adjusting Nut Outer Locknut Resulting Type of
Capacity Nut Torque* Back-off* Torque Bearing Adjustment Bearing
5,200# and 7,200# Slight B arrel

50-60 Ft. Lbs. 1/8 * 175 Ft. Lbs.
Preloaded Roller
Slight Barrel
11 , 000 # 75-100 Ft. Lbs. 1/8 * 250 Ft. Lbs.
Preloaded R oller
5,500# .001 to .010 Tapered
50 Ft. Lbs. ** 65 Ft. Lbs.
End Play R oller
** Back-off nut and retighten to 35 Ft. Lbs. then, back-off nut 1/4 turn.
* With wheel rotating.
UNIVERSAL JOINT ATTACHMENT

Strap Attachments ............................ .........................15 Ft. Lbs.

"U " Bolt A tta c h m e n t......................... ......................... 20 Ft. Lbs.
DIFFERENTIAL SPECIFICATJONS
11,000 Lb. Capacity

Lb. Capacity
Lb. Capacity
Lb. Capacity
5500# (Dana)
Lb. Capacity
5500# (Dana)
Lb. Capacity
3300-3600
5200-7200
3300-3600
5200-7200
11,000
Gear Backlash
F ille r Plugs 18 10 18 10
Preferred .005” - .004” - .005” - .005” - Differential Pinion
.008”
20 — — —
.009” .008” .008” Lock
.003” - .004” - .003” - .003” - Drive Pinion Nut — 255 220 220
Min. and Max.
.010 ” .009” .012 ” .012 ”
Differential C a rrie r
— — 45 85
Pinion Bearing to Axle Housing
Preload (In. Lbs.)
Differential Bearing
— — 15 15
New 20-25 20-40 Adjusting Lock
Used 5-10 10-20 Pinion Bearing Cage

— — 95 165
To C a rrie r
Trust Pad Lock

— — 135 135
Nut
C a rrie r Cover 23 35 18 —
Brake - Backing
35 35 105 155
Ring Gear 50 110 110 105 Plate
D ifferential Bearing Axle Shaft To

55 85 100 205
Caps Hub Bolts — 60 90 15

SPECIFICATIONS 38
TORQUE SPECIFICATIONS (FT. LBS.) (CO NT’D)
o
r-H o
< o CO
<N 1
ft o 1 o o
O
rH
< < < <
U O W ft O
Tie Rod Attaching Bolts

- Stud to Axle * **
- Tie Rod to Stud 135 135 - - -
- Frame 135 135 - - -
Axle to Control A rm
145 145 - - -
U Bolts
Spring to Axle U
- 120 120 150 120
Bolts Nuts
Control A rm Front
145 145 - - -
Attaching Bolts
Coil Spring Attaching

55 55 - - -
Bolt Lower
Coil Spring Attaching

50 50 - - -
Bolt Upper
Spring Front Bushing

- 90 90 90 90
Bolt
Spring Rear Shackle

- 90 90 90 90
Bolts
Shock Absorber
75 75 65 65 -
Attaching Bolts
Propshaft Bearing
Support Hanger
20 # - 35 35
Rear Stabilizer - - - 25 -
* C-P10 Models - 135 Ft. Lbs.

** Models CE-CS 25903-04-34 - 250 Ft. Lbs.
A ll others - 135 Ft. Lbs.
# C20 Except 133” W.B. Models - 20 Ft. Lbs.
C20 133" W .B. Models - 35 Ft. Lbs.

SECTION 5
Main Cylinder to Dash or B o o s te r ................................................................................................................. 25 Ft. Lbs.

Brake Line to Main C y lin d e r............................................................................................................................ 150 In. Lbs.
Brake Line to Combination V a lv e .................................................................................................................... 150 In. Lbs.
Brake Line From Combination V a lv e ............................................................................................................ 150 In. Lbs.
Brake Line to F r a m e .......................................................................................................................................... 150 In. Lbs.
Combination Valve Mounting N uts.................................................................................................................... 18 Ft. Lbs.
Combination Valve Main Cylinder B r a c e /D a s h ........................................................................................... 150 In. Lbs.
Flex Hose to C a lip e r .......................................................................................................................................... 25 Ft. Lbs.
Flex Hose to T u b in g .......................................................................................................................................... 100 In. Lbs.
Rear Pipe to Wheel C y lin d e r............................................................................................................................ 100 In. Lbs.
Rear Pipe to C o n n e c to r..................................................................................................................................... 100 In. Lbs.
Flex Hose to C o n n e c to r..................................................................................................................................... 115 In. Lbs.
Flex Hose to P ip e ................................................................................................................................................ 115 In. Lbs.
Push Rod to P e d a l................................................................................................................................................ 28 Ft. Lbs.
Push Rod to Clevis N u t ..................................................................................................................................... 25 Ft. Lbs.
Pedal Bracket to D a s h ....................................................................................................................................... 25 Ft. Lbs.
Pedal Support to B r a c k e t .................................................................................................................................. 150 In. Lbs.
Parking Brake Assembly to D a s h .................................................................................................................... 100 In. Lbs.
Parking Brake Assembly to Instrument P a n e l ........................................................................................... 100 In. Lbs.
Parking Brake Cable to Assembly C l i p ......................................................................................................... 20 Ft. Lbs.
Cable Clips to F r a m e ........................................................................................................................................ 15 Ft. Lbs.
Equalizer N u t s ..................................................................................................................................................... 90 In. Lbs.
Rear Brake Anchor P i n ..................................................................................................................................... 140 Ft. Lbs.
C aliper Mounting B o l t ....................................................................................................................................... 35 Ft. Lbs.
Support Plate to K n u c k le .................................................................................................................................. 140 In. Lbs.
___________________
SPECIFICATIONS 40
ENGINE
SECTION 6
TUNE-UP CHART
E
Type In Line V8
N
G
Displacement 250 292 307 350 402
I
N
Horsepower 145 165 200 215 250 300
E
COMPRESSION (D 130 psi 150 psi
Standard AC-R46TS AC-R44T AC-R45TS AC-R45TS AC-R44TS AC-R44TS

SPARK Make &
PLUG Number
Cold AC-R45TS AC-R43T AC-R44TS AC-R44TS AC-R43TS AC-R43TS
Gap .035"
D
Point Dwell
1
CO
CO
I
S
T Point Gap .016" (Used) .019" (New)
R
I Arm Spring Tension 19-23 ounces
B
U Condenser .18-.23 microfarad
T
O Timing Syn. 4°B 4°B 4°B 4°B 4°B 8°B
R
© Auto. 4°B 4°B 8°B 8°B
<D 4°B 8°B
DRIVE Fan and P/S 50 lb. Min. 75 ± 5 lbs. (Used) 125 ± 5 lbs. (New) Using Strand Tension Gauge
BELT
A/C Compressor 65 lb. Min. 95 ± 5 lbs. (Used) 140 ± 5 lbs. (New) Using Strand Tension Gauge
AIR CLEANER See Note (4)
VALVE LASH Hydraulic - 1 turn down from zero lash
IDLE Syn. 550 550 600 550 600 600

RPM
© Auto. 500 500 550 500 550 600
FUEL Pressure in lbs. 3-1/2 to 4-1 /S 5 to 6-1/2 7 to 8-1/2

PUMP
© Volume 1 pint in 30-45 seconds @ cranking speed
CRANKCASE VENTILATION Replace at 24,000 miles
(T) PSI at Cranking Speed, throttle wide open - Maximum variation, 20 PSI between cylinders.
(2) 6 Cylinder engine - Rotate cam lubricator 180° at 12,000 mile intervals - Replace at 24,000 mile intervals.
8 Cylinder engine - Change cam lubricator end for end at 12,000 mile intervals - Replace at 24,000 mile intervals.
(3) At idle speed with vacuum advance line disconnected and plugged. On Step Van vehicles, use number two cylinder
and timing tab on bottom of cover. B - B.T.D.C.
(4) CAUTION: In addition to its function of filtering air drawn into the engine through the carburetor, the air cleaner
also acts as a flame arrestor in the event the engine backfires. Because backfiring may cause fire in the engine
compartment, the air cleaner should be installed at all times unless its removal is necessary for repair or main
tenance services.
Paper Element Type - First 12,000 miles, inspect element for dust leaks, holes, or other damage and replace if
necessary. If satisfactory, rotate element 180° from original installation position. Replace element at 24,000
miles. Element must not be washed, oiled, tapped, or cleaned with an air hose. If so equipped, replace P.C.V.
breather filter every 24,000 miles (do not attempt to clean). If so equipped, clean wire mesh frame arrestor every
12,000 miles
Oil Bath Type - The oil level in the oil bath air cleaner reservoir should be checked every 12,000 miles and suf
ficient S.A.E. 50 oil added when temperature is above freezing or S.A.E. 20 oil added when temperature is below
freezing. Adding oil and servicing the cleaner will vary greatly, depending upon operating conditions.
Oil Wetted Paper Element With Polyurethane Wrap - This dual element air cleaner has extremely long life and
will not require replacement for 50,000 to 100,000 miles under normal operating conditions. Cleaning and oiling
of the polyurethane wrap should be done at 24,000 miles under normal highway or city-type operation. Service
under off-the-road or extremely dusty operations should be performed at 12,000 miles or less depending upon
severity of operating conditions
(5) See "TUNE-UP" section.

(§) Replace filter element located in carburetor inlet every 12 months or 12,000 miles, whichever occurs first.

SPECIFICATIONS 41

SPECIFICATIONS 42
ENGINE TORQUES
In Line Sm all V -8 Mark IV V -8

Size Usage
250 292 307 350 402
1/4-20 Camshaft Thrust Plate 80 lb. in.

Crankcase Front Cover 80 lb. in.
Flywheel Housing; Pans 80 lb. in.
O il F ille r Bypass Valve 80 lb. in.
O il Pan (To Crankcase) 80 lb. in.
O il Pan (To Front Cover) 50 lb. in. 80 lb. in.
O il Pump Cover 70 lb. in. 80 lb. in.
Rocker A rm Cover 45 lb. in. 50 lb. in.
11/32-24 Connecting Rod Cap 35 lb. ft.
5/16-18 Camshaft Sprocket 20 lb. ft.

Clutch Pressure Plate 20 lb. ft.
O il Pan (To Crankcase) 75 lb. in. 65 lb. in. 1 135 lb. in.
O il Pum p 115 lb. in.
Push Rod Cover 50 lb. in.
Water Pump 15 lb. in.
3/8-16 Clutch Pressure Plate 35 lb. ft.
D istributor Clamp 20 lb. ft.
Flywheel Housing 30 lb. ft.
Manifold (Exhaust) 20 lb. ft.®
Manifold (Exhaust to Inlet) 25 lb. ft.
Manifold (inlet) 30 lb. ft.
Manifold Clam p (L 6 Outer) 20 lb. ft.
Manifold Clam p (All Others) 30 lb. ft.
Thermostat Housing 30 lb. ft.
Water Outlet 30 lb. ft.
Water Pump 30 lb. ft.
3/8-24 Connecting Rod Cap 40 lb. ft. 45 lb. ft. 50 lb. ft.
7/16-14 Cylinder Head 65 lb. ft. 80 lb. ft.
M ain Bearing Cap 65 lb. ft. 70 lb. ft.
O il Pump 65 lb. ft.
Rocker A rm Stud. 50 lb. ft.
7/16-20 Flywheel 60 lb. ft. 60 lb. ft. 65 lb. ft.
Torsional Damper 60 lb. ft.
1/2-13 Cylinder Head 95 lb. ft.
M ain Bearing Cap 110 lb. ft.
1/2-14 Temperature Sending Unit 20 lb. ft.
1/ 2-20 Torsional Damper 85 lb. ft.
O il F ilte r Hand Tight 1 25 lb. ft.
O il Pan D rain Plug 20 lb. ft.
Flywheel 110 lb. ft.
14mm 5/8 Spark Plug 15 lb. ft.
® Inside bolts on 307-350 engines 30 lb. ft.

SPECIFICATIONS 43
CARBURETOR
SEC TIO N 6M
IDENTIFICATION
Also refer to Rochester Carburetor Identification
Illustration in the 1971 Overhaul Shop Manual.
VEHICLES ENGINES CARBURETORS
T5fPE
Displacement
RPO HP BBL. SYNCH. AUTOMATIC
and type
C K P G
10 10 10 10 250 L -6 Base 145 1 7041021 7041021

20-30 20 20-30 20-30 250 L -6 Base 145 1 7041025 7041025
10 10 292 L -6 L-25 170 1 7041022 7041022
20-30 20 20-30 292 L -6 L-25 170 1 7041026 7041026
10 10 307 V -8 Base 200 2 7041105* 7041125*
10 307 V -8 Base 200 2 7041111# 7041126#
20-30 20 20-30 307 V -8 Base 215 2 7041139 7041138
20-30 350 V -8 Base 250 4QJ 7041208 7041208
10 10 350 V -8 LS-9 250 4QJ 7041211 7041211
20-30 20 20-30 350 V -8 LS-9 250 4QJ 7041208 7041208
10 402 M-4 L-47 300 4QJ 7041209 7041209
20-30 402 M-4 L-47 300 4QJ 7041206 7041206
* Start of Production
# Interim Release

... ------ -v , ,,. - , .» M p i» y if r - RMH ‘■---f. . 1___ . ...
SPECIFICATIONS 44
ADJUSTMENTS
Rochester Carburetors
M
0 NUMBER
DASHPOT
D (A) Automatic Trans.
E (M) Manual Trans.
(bench)
BREAK
L
ROD
LE V EL
DROP
ROD
UNLOADER
AIR VALVE
ROD
METERING
FAST IDLE
VACUUM
FLOAT
FLOAT
CHOKE
PUMP
MV 7041021 (A)(M) 1/4 — .080 — .100 .180 — .230 .350
MV 7021022 (A)(M) 1/4 — .070 — .100 .300 — .350 .350
MV 7041025 (A)(M) 1/4 — .070 — .100 .180 — .260 .350
MV 7041026 (A)(M) 1/4 — .070 — .100 .275 — .350 .350
2GV 7041105 (M) 21/32 1-3/4 — 1-3/64 — .040 — .080 .215
2GV 7041125 (A) 21/32 1-3/4 — 1-3/64 — .040 — .080 .215
2GV 7041111 (M) 21/32 1-3/4 — 1-3/64 — .040 — .080 .215
2GV 7041126 (A) 21/32 1-3/4 — 1-3/64 — .040 — .080 .215
2GV 7041138 (A) 23/32 1-1/4 — 1-5/32 — .100 — .170 .325
2GV 7041139 (M) 23/32 1-1/4 — 1-5/32 — .100 — .180 .325
4MV 7041206 (M) 1/4 — — — — .100 .020 .260 —
4MV 7041208 (A)(M) 1/4 — — — — .100 .020 .260 —
4MV 7041209 (A)(M) 11/32 — — — — .100 .020 .260 —
4MV 7041211 (A)(M) 1/4 — — — — .100 .020 .260 —
'-w —r~
SPECIFICATIONS 45
OTHER ADJUSTMENTS
Refer to “Additional External Settings and Adjustments’Yor
“C.E.C. Valve Adjustment”, as applicable, in Section 6M
(Service), under carburetors before using the following charts.
EQUIPMENT COLUMN #1 COLUMN #2 COLUMN #3
Initial Final CEC Valve

Idle Speed Idle Speed Engine Speed
Transm ission Engine (R.P.M .) (R.P.M .) (R .P.M .)**
Manual L -6 250
C.I.D .
580 550 1000
L -6 292
C.I.D . (L-25)
V -8 307
700 600 1000
C.I.D .
V -8 350
675 600 900
C .I.D . (LS-9)
MK IV 402
675 600 850
C .I.D . (L-47)
Automatic L -6 250
C .I.D .
530 500 750
L -6 292
C .I.D . (L-25)
V -8 307
C.I.D .
580 550 650
V -8 350
C.I.D . (LS-9)
MK IV 402
630 600 650
C.I.D . (L-47)
** CAUTION: If the C .E .C . valve (solenoid) on the carburetor is used to set engine idle or is adjusted out of lim its
specified in the Service Manual, decrease in engine braking may result.
ENGINE ELECTRICAL
SECTION 6Y
BATTERY
NO. OF CRANKING CAPACITY @ 20

M ODEL NO. APPLICATION PLATES POW ER @ HOUR RATE
P ER CE LL 0 CF (WATTS) (AMP. HR.)
1980140 (Y- 88) 250 L -6 & 307 V -8 54 2350 53
1980141 (Y- 86) 250 L -6 & 307 V-8 , GS & GE 10-20-30 54 2300 45
1980145 (R- 88) 350 V -8 & 402 V -8 66 2900 61
1980149 (R 88W) T-60 Option 90 3750 76

SPECIFICATIONS 46
% .
GENERATORS
COLD OUTPUT*
FIELD
MODEL D ELCO REM Y RATED HOT
APPLICATION CURRENT AMPS AMPS
NO. SPEC. NO. SPEC OUTPUT** AMPS
AMPS (80 °F) @ 2000 @ 5000
VOLTS
RPM RPM
1100566 Base All 3395 2.2 - 2.6 14 25 35 37

C-G-P-K
Models
1100838 C-K Models 3395 2.2 - 2.6 14 25 35 37

With L -6
Engine and
N-40
1100567 RPOK 79; 3396 2.2 - 2.6 14 28 40 42

P20-30
Models
1100842 PS 20-30 3396 2.2 - 2.6 14 28 40 42

CS-KS 10,
20 & 30
Models
* Generator temperature approximately 800F.

** Ambient temperature 80°F.
VOLTAGE REGULATOR
FIELD RELA Y VOLTAGE REGULATOR

MODEL
APPLICATION
NO. POINT CLOSING POINT VOLTAGE
A IR GAP A IR GAP
OPENING VOLTAGE OPENING SETTING
1119515 A LL .015 .030 2.3 -3.7 .067 .014 13.8-14.8

@ 85°F.
STARTING M O TO R
BRUSH SPRING FREE SPEED

MODEL NO. SEC. NO. TENSION
oz. VOLTS AMPERES RPM
1108365
1108367 3573 35 9 50-80* 5500-10500
1108368
1108338
2438 35 9 55-80* 3500-6000
1108360
1108385 3563 — 9 65-95* 7500-10500
1108425 3533 — 9 40-105* 3500-6500
* Includes Solenoid

SPECIFICATIONS 47
DISTRIBUTORS
Centrifugal
Engine Ignition Vacuum Ignition O riginal
Advance Point
Description D istributor Advance Tim ing Equipment
(Crank Dwell Trans.
and (Product (In Crank BTDC at Spark
Degrees @ Setting
A vailability Part No.) Degrees) Engine Idle* Plug
Engine RPM)
250 Cu. In. L -6 1110489 C-4977 C-3990 31°-34° 4° @ 550 RPM Manual AC-R46TS
(145 HP) 0° @ 930 RPM 0° @ 8" Hg 4° @ 500 RPM Automatic
2° @ 1270 RPM 23° @ 16" Hg
14° @ 2300 RPM
24° @ 4100 RPM
292 Cu. In. L -6 1110486 C-4809 C-3991 31°- 34° 4° @ 550 RPM Manual AC-R44T
(165) HP) RPO L-25 0 0 @ 860 RPM 0° @ 8" Hg 4° @ 500 RPM Automatic
2° @ 1140 RPM 18° @ 16" Hg
17° @ 2150 RPM
28° @ 4000 RPM
307 Cu. In. V -8 (200 1112040 C-4815 C-3954 31° - 34° 8 ° @ 550 R PM Automatic AC-R45TS
HP) 10 Series 0° @ 680 RPM 0° @ 8" Hg
2° @ 1320 RPM 20° @ 17" Hg
20 ° @ 4200 RPM
307 Cu. In. V -8 1112041 C-4753 C-3954 31°- 34° 4° @ 600 RPM Manual AC-R45TS
(200 HP) 10 Series 0 0 @ 800 RPM 0° @ 8" Hg
2° @ 1200 RPM 20° @ 17" Hg
12° @ 2200 RPM
24° @ 4300 RPM
307 Cu. In. V -8 (215 1112043 C-4824 C-3036 31°- 34° 4° @ 600 RPM Manual AC-R45TS
HP) 20-30 Series 0° @ 800 RPM 0° @ 8" Hg 8 ° @ 550 RPM Automatic
2° @ 1200 RPM 15° @ 15.5" Hg
11° @ 2100 RPM
20 ° @ 4200 RPM
350 Cu. In. V -8 (250- 1112047 C-4818 C-3036 31°- 34° 8 ° @ 550 RPM Automatic AC-R44TS
255 HP), RPO LS-9 0° © 865 RPM 0° @ 8" Hg
2° @ 1335 RPM 15° @ 15.5" Hg
11° @ 2400 RPM
18° @ 4200 RPM
350 Cu. In. V -8 (250- 1112046 C-4753 C-3036 31°- 34° 4° @ 600 RPM Manual AC-R44TS
255 HP), RPO LS-9 0° @ 800 RPM 0° @ 8" Hg
2° @ 1200 RPM 15° @ 15.5" Hg
12° @ 2200 RPM
24° @ 4300 RPM
402 Cu. In. V -8 (300 1112064 C-4830 C-3954 31°- 34° 8 ° @ 600 RPM All AC-R44TS
HP) RPO L-47 0° @ 930 RPM 0° @ 8" Hg
2° @ 1260 RPM 20° @ 17" Hg
16° @ 2400 RPM
30 0 @ 4400 RPM
* Refer to Vehicle E m ission Control Information Sticker
IG N ITIO N COIL
P RIM A R Y RESISTANCE IGNITION RESISTOR
SECONDARY RESISTANCE
@ 75°F.
APPLICATION
- OHMS - - OHMS - TYPE OHMS
L -6 Engines 1.41 - 1.65 3,000 - 20,000 In W iring 1.8

Harness
V -8 Engines 1.77 - 2.01 3,000 - 20,000 In W iring 1.8

Harness

SPECIFICATIONS 48
TRANSMISSION AND CLUTCH

SECTION 7
THREE SPEED SAGINAW

Side Cover to Case B o l t s ........................................................................................................................................... 22 ft. lbs.
Shift Lever to Shifter Shaft Bolts .......................................................................................................................... 20 ft. lbs.
Lubrication F ille r P l u g ............................................................................................................................................... 15 ft. lbs.
Transm ission Case to Clutch Housing B o l t s ........................................................................................................ 55 ft. lbs.
Crossm em ber to Fram e Nuts ................................................................................................................................ 25 ft. lbs.
Crossm em ber to Mount and Mount to Extension B o l t s ................................................................................... 40 ft. lbs.
THREE SPEED MUNCIE
Clutch Gear Retainer to Case B o l t s ...................................................................................................................... .... 22 ft. lbs.

Side Cover to Case B o l t s ............................................................................................................................................... 22 ft. lbs.
Extension to Case B o l t s ................................................................................................................................................... 45 ft. lbs.
Shift Lever to Shifter Shaft B o lt s ............................................................................................................................. .... 20 ft. lbs.
Transm ission Case to Clutch Housing B o l t s ........................................................................................................ .... 55 ft. lbs.
Crossm em ber to Fram e N u t s .................................................................................................................................... .... 25 ft. lbs.
Crossm em ber to Mount and Mount to Extension B o l t s ................................................................................... .... 40 ft. lbs.
Transm ission D rain P l u g ........................................................................................................................................... .... 30 ft. lbs.
FOUR SPEED MUNCIE
R ear Bearing R e ta in e r .............................................................................................................................................. ........18 ft. lbs.

Cover Bolts ........................................................................................................................................................................25 ft. lbs.
F ille r P l u g ................................................................................................................................................................... ........35 ft. lbs.
D rain P l u g ................................................................................................................................................................... ........35 ft. lbs.
Clutch Gear Bearing Retainer B o l t s ...........................................................................................................................18 ft. lbs.
Universal Joint Front Flange Nut ...................................................................................................................... ........95 ft. lbs.
Power Take Off Cover B o l t s .........................................................................................................................................18 ft. lbs.
Parking B r a k e ......................................................................................................................................................... ...........22 ft. lbs.
Countergear Front Cover S c r e w s ..................................................................................................................................25 in. lbs.
R ear Mainshaft Lock Nut (4 Wheel Drive M od els).......................................................................................... ........95 ft. lbs.

SPECIFICATIONS 49
NEW PROCESS TRANSFER CASE MODEL 205
Idler Shaft Lock N u t .................................................................................................................................................. 200 ft. lbs.

Idler Shaft Cover B o l t s ........................................................................................................................................... 18 ft. lbs.
Front Output Shaft Front Bearing Retainer B o l t s .......................................................................................... 30 ft. lbs.
Front Output Shaft Yoke Lock N u t ...................................................................................................................... 200 ft. lbs.
R ear Output Shaft Bearing Retainer B o l t s ......................................................................................................... 30 ft. lbs.
R ear Output Shaft Housing B o l t s ......................................................................................................................... 30 ft. lbs.
R ear Output Shaft Yoke Lock N u t ......................................................................................................................... 200 ft. lbs.
P. T. O. Cover B o l t s .............................................................................................................................................. 15 ft. lbs.
Front Output Shaft Rear Bearing Retainer B o lts .............................................................................................. 30 ft. lbs.
D rain and F ille r Plugs ........................................................................................................................................... 30 ft. lbs.
Transfer Case to Fram e B o l t s ............................................................................................................................. 130 ft. lbs.
Transfer Case to Adapter B o lts ............................................................................................................................. 35 ft. lbs.
Adapter Mount B o lt s .................................................................................................................................................. 75 ft. lbs.
Transfer Case Bracket to Fram e Nuts ( U p p e r ) .............................................................................................. 30 ft. lbs.
Transfer Case Bracket to Fram e Nuts (L o w e r ).............................................................................................. 65 ft. lbs.
Adapter to Transm ission Bolts - (Manual Transmission) ..................................................................... 22 ft. lbs.
- (Automatic T r a n s m is s io n )..................................................................... 35 ft. lbs.
DANA TRANSFER CASE MODEL 20
Shift R a il Set Screw s.................................................................................................................................................. 15 ft. lbs.

Front Output Shaft R ear Cover B o lt s .................................................................................................................. 30 ft. lbs.
Front Output Shaft Front Bearing R e ta in e r.................................................... ................................................... 30 ft. lbs.
Front Output Shaft Yoke Lock N u t ...................................................................................................................... 200 ft. lbs.
Intermediate Shaft Lock Plate B o l t ...................................................................................................................... 15 ft. lbs.
R ear Output Shaft Housing B o l t s ......................................................................................................................... 30 ft. lbs.
Rear Output Shaft Yoke Lock N u t.......................................................................................................................... 200 ft. lbs.
Case Bottom Cover B o l t s ....................................................................................................................................... 15 ft. lbs.
Transfer Case to Adapter Bolts............................................................................................................................. 45 ft. lbs.
Transfer Case to Fram e B o l t s ............................................................................................................................ 45 ft. lbs.
Adapter Mount B o l t s .................................................................................................................................................. 75 ft. lbs.
Adapter to Transm ission B o l t s ............................................................................................................................. 45 ft. lbs.

SPECIFICATIONS 50
STEERING
SECTION 9
- C-P10 C20-30 K10-20 P20-30
—
Tie Rod Ball Joint
Nut 30 ft. lbs. 50 ft. lbs. 45 ft. lbs. 50 ft. lbs.
Tie Rod Clamp

Bolt 132 in. lbs. 132 in. lbs. 35 ft. lbs. 132 in. lbs.
Idler Arm Mounting

Bolts - 30 ft. lbs. 30 ft. lbs. - 30 ft. lbs.
Idler Arm to Relay

- 60 ft. lbs. 60 ft. lbs. - 60 ft. lbs.
Rod Nut
Pitman Arm to
- 60 ft. lbs. 60 ft. lbs. - 60 ft. lbs.
Relay Rod Nut
Steering Connecting
Rod Nut - - - 50 ft. lbs. -
Pitman Arm to Sector

- 125 ft. lbs. 125 ft. lbs. 90 ft. lbs. 125 ft. lbs.
Shaft Nut
Steering Gear
Mounting Bolts
Steering Wheel Nut - 40 ft. lbs. 40 ft. lbs. 40 ft. lbs. 40 ft. lbs.
Lower Mast Jacket P10-1.26 i .02

Bearing Adj. -- .50 * .02 .50 i .02 1.26 i .02
CIO- .50 * .02
Power Steering
125 lb. New --- 75 lb. Used
Belt Tension
Pump Pressure 850 — 1,000 psi
Lower Mast Jacket 120 in. lbs.

Bearing Clamp or P10
Intermediate Coupling - 32 ft. lbs. 32 ft. lbs. 120 in. lbs.
32 ft. lbs.
Clamp Bolt CIO
Lower Coupling to
Wormshaft Clamp C10-30 ft. lbs.
- 30 ft. lbs. 30 ft. lbs. 75 ft. lbs.
Bolt P10-75 ft. lbs.
Column to Dash Panel

Clamp Screws - 120 in. lbs. 120 in. lbs. 120 in. lbs. 120 in. lbs.
30 in. lbs.
Toe Panel Cover CIO
Screws - 30 in. lbs. 30 in. lbs. 24 in. lbs.
24 in. lbs.
P10
90 in. lbs.
Firewall Bracket CIO
Clamp Bolt - 120 in. lbs. 90 in. lbs. 90 in. lbs. 98 in. lbs.
P10
Lower Bearing
-- 70 in. lbs. 70 in. lbs. 70 in. lbs. 70 in. lbs.
Adjusting Ring Bolts

SPECIFICATIONS 51
SECTION 9 (C O N T’D)
MANUAL STEERING GEAR
- C-P10 C20-30 K10-20 P20-30
- 4 to 6 4 to 6 4 to 6 9 to 12
Worm Bearing Preload
in. lbs. in. lbs. in. lbs. in. lbs.
Worm Bearing Lock Nut - 85 ft. lb. 85 ft. lb. 85 ft. lb. 85 ft. lb.
- 4 to 10 .j. 4 to 10 ^ 4 to 10x 9 to 13 ,
Sector Lash Adjustment
in. lbs. in. lbs. in. lbs. in. lbs.
Sector Lash Lock Nut - 30 ft. lb. 30 ft. lb. 30 ft. lb. 30 ft. lb.
Total Steering Gear - 14 in. lbs. 14 in. lbs. 14 in. lbs. 25 in. lbs.
Preload Max. Max. Max. Max.
t in excess of worm bearing preload.

*In excess of valve assembly drag.
POWER STEERING GEAR
- C-P10 C20-30 K10-20 P20-30
Steering Gear 3 in. lbs. 3 in. lbs. 3 in. lbs. 3 in. lbs.
- Max. Max.
Ball Drag Max. Max.
Thrust Bearing 1/2 to 2 1/2 to 2 1/2 to 2 1/2 to 2
-
Preload in. lbs.* in. lbs.* in. lbs.* in. lbs.*
Adjuster Plug
Lock nut
Over-Center 3-6** 3-6** 3-6** 3-6**
-
Preload in. lbs. in. lbs. in. lbs. in. lbs.
Over-Center
Adjusting Screw
Locknut
Total Steering 14 in. lbs. 14 in. lbs. 14 in. lbs. 14 in. lbs.
-
Gear Preload Max. Max. Max. Max.
*In excess of ball drag.

**In excess of ball drag and thrust bearing preload.

SPECIFICATIONS 52
WHEELS AND TIRES

SECTION 10
WHEELS
Wheel Nut Torques - 10-30 Series
SERIES DESCRIPTION TORQUE

K10 7/16" Bolts (6) 55-75 ft. lbs.
C, P10 1/2" Bolts (5) 65-90 ft. lbs.
C, P20, 30 9/16" Bolts (8) 90-120 ft. lbs.
Heavy Duty Wheels
C30 200-250 ft. lbs.
1/2" Bolts (10)
TIRES
See "Load Capacity Charts" in Section 0 and "T ire Load

and Inflation Pressure" tables in Section 10 of this manual.
SHEET METAL
SECTION 11
Hood Safety P l a t e ........................................................................................ 20 ft. lbs.

Hood Lock B o lt.............................................................................................. 30 ft. lbs.
Hood Lock Bolt P la te .................................................................................. 150 in. lbs.
Hood H i n g e ................................................................................................... 25 ft. lbs.
Hood B u m p e r ................................................................................................. 85 in. lbs.

SPECIFICATIONS 53
BODY AND CHASSIS ELECTRICAL

SECTION 1 2
LAMP USAGE
Application Trade No. Rating* Trade

Use Rating*
No.
Instrument Cluster
Conventional Cab 194 2CP O il Pressure Gauge 1895 2CP
F /F Cowl 1895 2CP Tachometer 194 2CP
Temperature Indicator Heater Control 1895 2CP
Conventional Cab 194 2CP Dome Lamp 211 12CP
Brake Warning Indicator License Lamp 67 4CP
Conventional Cab 194 2CP Back-Up Lamps 1156 32CP
F /F Cowl 1895 2CP P arking and
Generator Indicator Directional Signal 1157 4-32CP
Conventional Cab 194 2CP T ail, Stop and Rear
D irectional Indicator D irectional Signal 1157 4-32CP
P-Models 194 2CP Headlamp 6014 60W-High Beam
Conventional Cab 168 3CP
50W-Low Beam
F /F Cowl 1445 1CP
Side Marker Lamps 194 2CP
O il Pressure Indicator
Conventional Cab 194 2CP Roof Clearance and
High Beam Indicator Identification Lamps
Conventional Cab 194 2CP A ll Exc. P & Suburban 194 2CP
F /F Cowl 1445 1CP Suburbans 1155 4CP
P-Models 67 4CP
* CP - Candle Power
W - Watts
WINDSHIELD WIPERS FUSE AND CIRCUIT BREAKER USAGE

TWO-SPEED W IP E R Applicablity Location Amps Type
Crank A rm Speed (RPM 's) (No Load)
Instrument
L o .................................................................................34 Min.
Cluster Feed 3 3AG/AGC
H i .................................................................................65 Min.
Current Draw, AMPS Panel Lights 3 3AG/AGC
No Load (Lo Speed - No Linkage)................................. 3.6
Stall (Lo Speed) .......................................................... 12 Wiper Motor 20 SFE/SAE
A ir Conditioning 25 3AG/AGC
WASHER____________________________________________________
Number of "sq u irts” at full p r e s s u r e ............................ 10 Heater Motor 15 3AG/AGC
Pressure ( P S I) ................................................................ 11-15
Coil Resistance (ohms)..................................................... 6±1 Backup Lamps Fuse block 10 3AG/AGC
in driver's
Tail, Stop, Dome compartment
License Lamps
M arker Lights 20 SAE/SFE
Spotlamp, Park
Lamps
Radio - TCS 3 3AG/AGC
Hazard Flash 15 3AG/AGC
Headlamps Light Switch 15 C ircuit breaker
In-Line Part
of Gen. & fwd. 3AG/AGC
Ammeter 4
lamp harness
(2 reqd.)

SPECIFICATIONS 54
RADIATOR AND GRILLE

SECTION 13
G r i l l e .............................................................150 in. lbs. outer
10 ft. lbs. inner
G rille B r a c k e t....................................................... 20 ft. lbs.
Fan S h r o u d ............................................................. 45 in. lbs.
BUMPERS
SECTION 14
Front B u m p e r ......................................... 35 ft. lbs.
Front Bumper Bracket and Brace . . . 40 ft. lbs.
Rear Bumper to Outer B r a c k e t ........... 35 ft. lbs.
Rear Bumper Outer Bracket and Brace 45 ft. lbs.
ACCESSORIES
SECTION 1 5
CRUISE-M ASTER
Solenoid R esistance....................................................................................................................................................... 5 ohms ±1/ 4 ohm
Solenoid W ire R e sista n c e ............................................................................................................................................................. 40 ohms
Maximum allowable Vacuum Leakage rate for Servo u n i t ..........................................................5 inches of Vacuum Per Minute
Not Greater than 1 inch of Vacuum per 10 seconds
Operational Test S p e e d .................................................................................................................................................................. 60 MPH

W EIG H TS A N D M EASURES
LINEAR MEASURE COMMON WEIGHT
16 ounces......................................... = 1 pound
1/12 foot (ft.)................................ = 1 inch (in.)
100 pounds................ = 1 hundred weight (cwt.)
12 in ch e s............................................ = 1 foot
2000 pounds......................................... = 1 ton
3 fe e t....................................... = 1 yard (ly d .)
AREA MEASURE COMMON U.S.A. EQUIVALENTS

LENGTH
1/144 square foot (sq. f t .).. = 1 square inch (sq. in.)
144 square inches...................... = 1 square foot 1 in ch .............................. = 2 5.4 001 m illim eters
9 square fe e t.............. = 1 square yard (sq. yd.) 1 m illim eter............................ = 0 .0 3 9 3 7 inches
1 fo o t.................................. =0.3 0 4 8 0 1 meters
LIQUID MEASURE 1 m eter..................................... = 3 .2 8 0 8 3 feet
1 y a rd .................................. = 9 .9 1 4 4 0 2 meters
1/16 pint (pt.). ........ = 1 ounce (oz.)
1 m e te r.................................. =1.093611 yards
1 pint .......... ............ = 1 6 ounces
1 m ile ............................. =1.60 93 47 kilom eters
2 pints......... 1 quart (qt.) = 32 ounces
1 kilom eter............................. =0.62 13 70 miles
4 qu arts....... ___ = 1 gallon (gal.)
31 1/2 gallons ___ = 1 barrel (bbl.)

LIQUID CAPACITY
DRY MEASURE
1 qu art..................................... = 0 .9 4 6 3 3 liters
1/2 quart (qt.)............................... = 1 pint (pt.) 1 lite r...................................... =1.05671 quarts
2 pin ts........................................ = 1 quart (qt.) 1 gallo n.................................... = 3.78533 liters
8 q u arts...................................... = lp e c k ( p k . ) 1 li t e r ................................... = 0.2 6 418 gallons
4 pecks..................................... = 1 bushel (bu.)
105 qu arts........................................ = 1 barrel DRY CAPACITY
1 quart........................................ =1.1012 liters

CUBIC MEASURE
1 lite r....................................... = 0.90 81 quarts
1,728 cubic inches........................ = 1 cubic foot 1 peck.......................................... = 8 .8 1 0 liters
27 cubic fe e t............................... = 1 cubic yard 1 lite r....................................... =0.11351 pecks

D E C IM A L E Q U IV A L E N T S
1*4 ............ .................... 015625 3%4 ................................................................ ......... 515625

V l2 ............ .................... 03125 ,7/ 32 ................................................................ ..........53125
u * ............ .....................046875 3%4 ...................... ..........546875
'/ « * ............ .....................0625 ’/16 ................................ ......... 5625
............ .....................078125 37/*4 ...................... ..........578125
3/32 ............ .....................09375 »% 2 ....................... ..........59375
7Aa ............... ............... .109375 3% 4 ...................... ..........609375
v % ............ .................... 125 S/8 ...................... ......... 625
A ............ .................... 140625 ...................... ....... .640625
V l2 ............ .................... 15625 J , /32 ................................................................ ......... 65625
"A* ................. .................... 171875 43A4 ...................... ......... 671875
/l6 ............ .................... 1875
3 "M ....................... ..........6875
............ .................... 203125 <%4 ...................... ......... 703125
%2 ............ .................... 21875 23/32 ...................... ......... 71875
>544 ............ .................... 234375 < 7/*4 ................................................................ ......... 734375
Va ................ .................... 25 3/4 ...................... ......... 75
'% 4 .................................. .................. .265625 <% 4 ...................... ......... 765625
%2 ............ .................... 28125 23/32 ...................... ......... 78125
'% 4 ............ .................... 296875 S ’/ i4 ....................... ......... 796875
3/ l4 ............ .................... 3125 ,3/l6 ...................... ......... 8125
2 !* 4 .................................. .................... 328125 5%4 ...................... ......... 828125
'!& ............ .................... 34375 2 7/32 ...................... ..........84375
J %4 ............ .................... 359375 5SA* ....................... ..........859375
Vb ............ .................. .375 7/ s ...................... ..........875
iSA i ............ .................... 390625 57Aa ............................. ..........890625
% ............ ........ ............40625 29/32 ....................... ....... .90625
27/*4 ............ .................... 421875 5% 4 ...................... ..........921875
7/ l6 ............ .................... 4375 '5/l6 ...................... ..........9375
2% 4 ............ .....................453125 6 ,/64 ............................................................... .953125
,5/32 ............ .................... 46875 3 ,/32 ...................... ........ 96875
3#4 ............ .................... 484375 6%4 ................................... .984375
’/ 2 ............ .................... 5 1 ...................................

GAGES
U. S. STANDARD GAGE* AMERICAN WIRE or B & S GAGE
GAGE NO. Approx. Thickness—Inches Thickness —Inches
0000000 0.490
000000 .460 0.5800
00000 .429 .5165
0000 .398 .4600
000 .368 .4096
00 .337 .3648
0 .306 .3248
1 .2757 .2893
2 .2604 .2576
3 .2451 .2294
4 .2298 .2043
5 .2145 .1819.
6 .1991 .1620
7 .1838 .1443
8 .1685 .1285
9 .1532 .1144
10 .1379 .1019
11 .1225 .0907
12 .1072 .0808
13 .0919 .0720
14 .0766 .0641
15 .0689 .0571
16 .0613 .0508
17 .0551 .0453
18 .0490 .0403
19 .0429 .0359
20 .0368 .0320
21 .0337 .0285
22 .0306 .0253
23 .0276 .0226
24 .0245 .0201
25 .0214 .0179
26 .0184 .0159
27 .0169 .0142
28 .0153 .0126
29 .0138 .0113
30 .0123 .0100
31 .0107 .00893
32 .0100 .00795
33 .0092 ................. .00708
34 .0084 .00630
35 .0077 .00561
36 .0069 .00500
37 .0065 .00445
38 .0061 .00397
39 .0057 .00353
40 .0054 .00314
41 .0052
42 .0050
43 .0048
44 .0046

DRILL SIZES
Drill Wire Drill Wire Drill Wire Drill
Diam. Gage Diam. Gage Diam. Gage Diam.
Inches Sizes Inches Sizes Inches Sizes Inches
Z 0.413 1 0.2280 28 0.1405 55 0.0520

Y 0.404 2 0.2210 29 0.1360 56 0.0465
X 0.397 3 0.2130 30 0.1285 57 0.0430
w 0.386 4 0.2090 31 0.1200 58 0.0420
V 0.377 5 0.2055 32 0.1160 59 0.0410
u 0.368 6 0.2040 33 0.1130 60 0.0400
T 0.358 7 0.2010 34 0.1110 61 0.0390
s 0.348 8 0.1990 35 0.1100 62 0.0380
R 0.339 9 0.1960 36 0.1065 63 0.0370
Q 0.332 10 0.1935 37 0.1040 64 0.0360

P 0.323 11 0.1910 38 0.1015 65 0.0350
0 0.316 12 0.1890 39 0.0995 66 0.0330
N 0.302 13 0.1850 40 0.0980 67 0.0320
M 0.295 14 0.1820 41 0.0960 68 0.0310
L 0.290 15 0.1800 42 0.0935 69 0.0292
K 0.281 16 0.1770 43 0.0890 70 0.0280
J 0.277 17 0.1730 44 0.0860 71 0.0260
1 0.272 18 0.1695 45 0.0820 72 0.0250
H 0.266 19 0.1660 46 0.0810 73 0.0240
G 0.261 20 0.1610 47 0.0785 74 0.0225
F 0.257 21 0.1590 48 0.0760 75 0.0210
E 0.250 22 0.1570 49 0.0730 76 0.0200
D 0.246 23 0.1540 50 0.0700 77 0.0180
C 0.242 24 0.1520 51 0.0670 78 0.0160
B 0.238 25 0.1495 52 0.0635 79 0.0145
A 0.234 26 0.1470 53 0.0595 80 0.0135
27 0.1440 54 0.0550

ST 333 71 1971 Chevrolet Chassis Overhaul Manual Passenger Cars and 10 To 30 Truck PDF

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ST 333 71 1971 Chevrolet Chassis Overhaul Manual Passenger Cars and 10 To 30 Truck PDF

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SECTIO N IN D EX

CHASSIS OVERHAUL MANUAL

CHEVROLET, CHEVELLE 4-WHEEL DRIVE

CAMARO, CORVETTE REAR AXLE

CH EVRO LET M O TO R D IV ISIO N

© 1970 General Motors Corporation Printed in U.S.A.

Inspection CAUTION: Never pound or drive the hub and drive

CHEVROLET OVERHAUL MANUAL

Fig. 1-S ix C ylinder Com pressor-C ross Sectional V iew

do so may result in serious internal compressor dam­ 3. Remove shaft key.

CHEVROLET OVERHAUL MANUAL

Fig. 4-D rive Plate Key Installed in Keyway

Coil Housing Assembly

CHEVROLET OVERHAUL MANUAL

NOTE: Install flat surface of the retainer ring facing

3. Replace the pulley and bearing assembly and the hub

Fig. 7-R em oving Pulley Fig. 9 -ln s ta llin g Coil Housing

CHEVROLET OVERHAUL MANUAL

CHEVROLET OVERHAUL MANUAL

Fig. 1 0 -S ix C ylinder C om pressor-Exploded V iew

CHEVROLET OVERHAUL MANUAL

Fig. 1 1-R em oving Seal Seat and O- Ring

Compressor Rear Head and Internal

CAUTION: Excessive force during this operation

CHEVROLET OVERHAUL MANUAL

Fig. 14--Removing Rear Discharge Valve Plate

CHEVROLET OVERHAUL MANUAL

Fig. 16— R em oving O il In le t T ube and " O ” Ring

by some other suitable means, to observe sound level

CHEVROLET OVERHAUL MANUAL

Gauging Procedure NOTE: Do not assemble any of the piston rings at

CHEVROLET OVERHAUL MANUAL

front thru st bearing pack tight against wobble plate hub

NOTE: Use undamaged feeler gauges generously

race to correspond to this feeler gauge reading and place

Fig. 24--Checking Clearance Between Rear T hrust Bearing and

CHEVROLET OVERHAUL MANUAL

CHEVROLET OVERHAUL MANUAL

3. Install the discharge crossover tube front ”0 ” ring and

NOTE: The front discharge plate has a larger diame­

NOTE: Dowel pin and hole location can be marked

8. A pply clean refrigeration oil to a new ”0 ” ring and ”0 ”

NOTE: Raise the front head slightly to facilitate

Leak Testing The Compressor

CHEVROLET OVERHAUL MANUAL

CHEVROLET OVERHAUL MANUAL

Fig. 28--Air C onditioning Special Tools

CHEVROLET OVERHAUL MANUAL

FRONT A X LE D IFFER EN TIA L Assem bly

3. Remove differential side bearing caps, making sure they Installation

CHEVROLET OVERHAUL MANUAL

Fig. 1~Front Axle D ifferential Assem bly

CHEVROLET OVERHAUL MANUAL

CHEVROLET OVERHAUL MANUAL

CHEVROLET OVERHAUL MANUAL

Fig. 2--Four-Wheel Drive D ifferential Special Tools

1. J-52 3 1-01 Spreader - Axle Carrier. 9. J-86 14 Holder and Remover -

CHEVROLET OVERHAUL MANUAL

CHEVELLE, MONTE CARLO, 1 16" W .B. STATION

Differential C a s e ................................................................ ....4-1 Inspection.................................................. ......................4-4

5. Place left and right bearing cups with bearing caps so

CHEVROLET OVERHAUL MANUAL

Fig. 1A-R ear Axle Cross-Section

do so may result in serious internal compressor dam 3. Remove shaft key.

NOTE: The front discharge plate has a larger diame

i. Position Tool J-6266-28 in carrier as shown in Fig

If the pattern shows a high face contact "D ", it indi