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1979 Chevy - 73-87ChevyTrucks.com

1. esee 4C 1 Drive Pimiony iier ete he e e pr en 4C2 General Information sess 4C 1 Installation and Adjustment sss 4C 2 Differential Case insere eese een nnns 4C 1 Differential Case 00200 onere tenerent Re Removal eene ee ESA 4C 1 Preload and Adjustment Oil Seal 4C 2 Installatiounen 4C 2 Gear Tooth Contact Pattern Check Drive E 4C 2 Gear Tooth Nomenclature teer Ded 4C 2 DOS TEE Inspection i 4 2 Adjustments cerra einer Pr Differential Case nere eerte 4C2 Special Tools oett ritenere Reassembly etam 4C 2 GENERAL INFORMATION K10 20 Models use a Chevrolet or a Dana 44 Series style front axle which incorporates an 8 1 2 ring gear The K 30 axle is a Dana 60 series which incorporates a 9 3 4 ring gear The following procedures pertain to Dana model axles only Procedures for the Chevrolet 8 1 2 model are the same as covered previously in Section 4B of this manual FRONT AXLE DIFFERENTIAL Differential Case Dana Models Removal Fig 4C 1 1 If front axle assembly is removed from vehicle mount assembly in suitable holding fixture and remove axle shafts as outlined in Axle Shaft Removal Truck Service Manual 2 Remove cover attaching bolts and lock washers and the met
2. Fig 4C 8 Drive Pinion Shim Chart 6 Install drive pinion and inner bearing cone and roller assembly in differential carrier 7 Install shims and outer pinion cone and roller on pinion shaft using Tool J 5590 and companion flange to press bearing onto pinion Fig 4C 10 8 Install flange holding bar and install washer and nut on pinion shaft Torque nut to 255 ft Ibs 9 Remove holding bar and with an inch pound torque wrench measure rotating torque Rotating torque should be 10 to 20 in lbs with original bearings or 20 to 40 in Ib with new bearings Torque reading to start shaft turning must be disregarded 10 If torque requirements preload are not to specifications adjust shim pack as necessary Increase the outer shim pack to reduce rotation torque Decrease shim pack to increase rotating torque 11 Remove nut washer and flange from pinion shaft 12 Install oil slinger gasket and using Tool J 22804 install oil seal 13 Install flange washer and nut Torque nut to specifications Fig 4C 9 Installing Inner Pinion Core and Roller QVERHAUL MANUAL DIFFERENTIAL CASE Preload and Adjustment 1 Place differential assembly with pinion assembled into housing Install bearing caps in their proper position and tighten screws just enough to hold the bearing cups in place 2 Install dial indicator on carrier with indicator button contacting back of ring gear Fig 4C 7 3 Place two screwdr
3. 1 d 1 RECOMMENDED TORQUE SPECIFICATIONS Gear To Frame Bolts 1st Design High Pressure Line Fitting At Gear 2nd Design High Pressure Line Fitting At Gear 1st Design Oil Return Line Fitting At Gear 2nd Design Oil Return Line Fitting At Gear Adjusting Screw Locknut Adjuster Plug Locknut Pitman Shaft Nut Coupling Flange Bolt SPECIAL TOOLS J 4245 Snap Ring Pliers J 5504 Pitman Arm Puller J 6133 01 Pitman Shaft Seal Installer J 6217 Connector Seat Installer J 7754 0 5 Newton metre Torque Wrench 0 25 inch pounds NEWTON METRES FOOT POUNDS TIME 95 200 e Blei ques ba 40 dps MR LE d WEE EE o Mufa srt 0 2 00 EE BO DEEG 250 ee eege 180 tiM Ee 42 enis 30 J 8058 0 125 Newton metre Torque Wrench 0 50 foot pounds J 8524 2 Adjuster Plug Bearing Remover J 8810 Pitman Shaft Bearing Remover And Installer J 25323 Power Steering Analyzer Fig 3B3 5C Overhaul 605 Gear Chart E torque to turn stub shaft is Ibs more than reading 1 Prevent adjuster screw OVERHAUL MANUAL 3B 12 STEERING POWER STEERING GEAR 800 AND 605 MODELS GENERAL DESCRIPTION These Integral Power Steering Gears Repair procedures for these two have a control valve wh
4. UNIT REPAIR MANUAL OVERHAUL e 1979 UNIT REPAIR OVERHAUL MANUAL covering CHEVROLET MALIBU MONTE CARLO NOVA CAMARO and LIGHT DUTY TRUCKS SERIES 10 30 FOREWORD This manual includes procedures involved in disassembly and assembly of major components of 1979 Chevrolet Malibu Monte Carlo Nova Camaro and Light Duty Trucks Information on diagnosis maintenance and adjust ments minor service operations and removal and installation for these components is contained in either the 1979 Passenger Car or the Light Duty Truck Service Manuals The Section Index on the contents page enables the user to quickly locate any desired section At the beginning of each section containing more than one major subject is a Table of Contents which gives the page number on which each major subject begins An index is placed at the beginning of each major subject within the section Summaries of Special Tools when required are found at the end of major sections When reference is made in this manual to a brand name number or specific tool an equivalent product may be used in place of the recommended item The manual should be kept a handy place for ready reference If prop erly used it will enable the technician to better serve the owners of Chev rolet built vehicles information illustrations and specifications contained in this literature are based on the latest product information available at the t
5. 1D 41 R 4 Compressor Cylinder and Shaft Assembly cente netiis 1D 42 A 6 and R 4 Comp Leak Testing External and Internal se 10 42 exterior of the compressor should be cleaned off as much as possible prior to any on car repairs or removal of the compressor for workbench service The parts must be kept clean at all times and any parts to be reassembled should be cleaned with naphtha stoddard solvent kerosene or equivlent solvent and dried off with dry air When necessary to use a cloth on any part it should be of a non lint producing type Although certain service operations can be performed without completely removing the compressor from the vehicle the operations described herein are based on bench over haul with the compressor removed from the vehicle TT O O mme 1D 2 AIR CONDITIONING COMPRESSOR OVERHAUL They have been prepared in sequence in order of accessibility of the components Pad fender skirt and secure compressor near top of fender skirt with wire rope etc when performing on car service When an A 6 or R 4 compressor is removed from the vehicle for servicing the amount of oil remaining in the compressor should be drained and measured This oil should then be discarded and new 525 viscosity refrigerant oil added to the compressor See Figure 1D 1 and C C O T Refrigerant Oil Distribution in the Air Conditioning section Should an 6 compressor its compressor shaft seal
6. Ga Pob apa 30999 Fig 70 11S Model 203 Transfer Case Exploded View OVERHAUL MANUAL 7D 14 L I C C CN TRANSFER CASES Adapter Input Gear Bearing Retainer Input Gear Bearing Retainer Gasket Input Gear Seals Bearing Outer Ring Bearing to Shaft Retaining Ring Input Gear Bearing Adapter to Selector Housing Gasket Range Selector Housing Range Box P T O Cover Gasket P T O Cover Selector Housing to Chain Housing Gasket Main Drive Input Gear Range Selector Sliding Clutch Shift Lever Lock Nut Range Selector Shift Lever Shift Lever Retaining Ring Lockout Shift Lever Detent Plate Spring Plug Detent Plate Spring Plug Gasket Detent Plate Spring Detent Plate Lockout Shifter Shaft 20 Ring Seal Lockout Shaft Connector Link 0 Ring Seal Range Selector Shifter Shaft Range Selector Shift Fork Detent Plate Pivot Pin Thrust Washer Spacer short Range Selector Counter Gear Countergear Roller Bearings and Spacers 72 Bearings Req d Countergear Shaft Thrust Washer Input Shaft Roller Bearings 15 Req d Thrust Washer Pins 2 Req d Input Shaft 20 Ring Seal Low Speed Gear and Bushing Thrust Washer Input Shaft Bearing Retainer Input Shaft Bearing Input Shaft Bearing Retaining Ring Large Input Shaft Bearing Retaining Ring Chain Drive Housing
7. Fig 7A 151A Installing Case Cup Plug and Seal SHIFT TV VALVE SCREWDRIVER 6 3 1 47 DIA ROD PLUG 9 5 MM 3 8 LONG SHIFT TV Fig 7A 154A Removing Shift T V Plug 40 41 43 44 45 46 AUTOMATIC TRANSMISSION 200 7 39 Om az 16 13 14 15 Gugga sos 9T T e 21 22 43 4 4 SN var mm 32 EO mmm 0c 22276 38 34 n NOTE 1979 MODELS BR AND CX ONLY USE A DETENT PIN ITEM 35 OTHER MODELS DO NOT USE DETENT PIN 39 1 MANUAL VALVE 17 RETAINING COILED PIN 33 THROTTLE VALVE 2 RETAINING COILED PIN 18 RETAINING COILED PIN 34 RETAINING COILED PIN 3 INTERMEDIATE BOOST SPRING 19 DIRECT CLUTCH EXHAUST SPRING 35 DETENT PIN 4 INTERMEDIATE BOOST VALVE 20 DIRECT CLUTCH EXHAUST VALVE 36 THROTTLE VALVE SPRING 5 2 3 SHIFT VALVE 21 REVERSE BOOST VALVE 37 THROTTLE VALVE PLUNGER 6 2 3 THROTTLE VALVE 22 REVERSE BOOST SPRING 38 THROTTLE VALVE PLUNGER BUSHING 7 23 THROTTLE VALVE SPRING 23 REVERSE BOOST BORE PLUG 39 RETAINING COILED PIN 8 23 THROTTLE VALVE BUSHING 24 RETAINING COILED PIN 40 1 2 ACCUMULATOR SPRING 9 RETAINING COILED PIN 25 RETAINING COILED PIN 41 1 2 ACCUMULATOR PISTON SEAL 10 RETAINING COILED PIN 26 1 2 ACCUMULATOR BORE PLUG 42 1 2 ACCUMULATOR PISTON 11 LO OVERRUN CLUTCH SPRING 27 1 2 ACCUMULATOR VALVE 43 CHECK BALL 94 12 LO OVERRUN CLUTCH VALVE 28 1 2 ACCUMULATOR VALVE SPRING 44 CHECK BA
8. any other component ever be removed for servicing because it was determined to be the cause of excessive signs of oil leakage in the A C system then the oil in the A 6 compressor must be drained measured and replaced according to C C O T Refrigerant Oil Distribution in the Air Conditioning section to determine oil loss The accumulator in this A 6 system then must also be removed oil drained measured etc according to same section NOTICE Do not kink or place excessive tension on refrigerant lines or hoses MINOR REPAIR PROCEDURES FOR THE A 6 COMPRESSOR THE FOLLOWING OPERATIONS TO THE 6 COMPRESSOR CLUTCH PLATE AND HUB PULLEY AND BEARING AND COIL AND HOUSING ARE COVERED AS MINOR BECAUSE THEY MAY BE PERFORMED WITHOUT FIRST PURGING THE SYSTEM OR REMOVING THE COMPRESSOR FROM THE VEHICLE The Compressor Shaft Seal assembly Pressure Relief Valve and Pressure Switch may also be serviced WITHOUT REMOVING THE COMPRESSOR from the vehicle but these operations are covered later in this section as Major Repair Procedures because the system MUST FIRST BE PURGED of Refrigerant 12 Illustrations used in describing these operations show the compressor removed from the vehicle only to more clearly illustrate the various operations When servicing the compressor remove only the necessary components that preliminary diagnosis indicates are in need of service Refer to the AIR CONDITIONING section and Figure 1D 2 and Figure 1D
9. 0 171 0 175 1 Orange 2 White 3 Yellow 4 Blue 5 Red 6 Brown 7 Green 8 Black 9 Purple Fig 7A 96A Rear Unit End Play Washer Thickness Chart OVERHAUL MANUAL 7 Inspect output shaft to turbine shaft front selective thrust washer for damage or scoring 8 Install output shaft to turbine shaft front selective thrust washer locating in output shaft and retain with petrolatum Fig 7A 97A FRONT UNIT PARTS Direct Clutch Housing Assembly Fig 7 98 1 Remove snap ring Fig 7 99 2 Remove the clutch backing plate from the direct clutch housing 3 Remove the clutch plates from the direct clutch housing and keep them separated from the forward clutch plates See Clutch Plate Usage Chart Fig 7A 82A 4 Inspect composition faced plates and steel clutch plates for wear or burning 5 Inspect clutch backing plate for scoring or other damage 6 Using J 23327 compress retainer and spring assembly Fig 7A 100A remove snap ring and inspect for damage distortion 7 Remove J 23327 8 Remove retainer and spring assembly from housing 9 release spring retainer for being collapsed 10 Inspect release springs for being collapsed 11 Remove release spring guide and inspect for damage 12 Remove direct clutch piston 13 Remove outer and inner seals from direct clutch piston and discard Figs 7A 101A and 7A 102A 14 Do not remove the clutch apply ring from the pisto
10. 1 Left hand thread H Suitable Socket Installer J 6133 01 E Separate pitman shaft from side cover if required Depress side cover install Seals 4 REMOVE AND INSTALL LOWER BEARING AND ADJUSTER REMOVE Loosen lock nut 1 Use punch against edge of one slot Remove parts as shown Inspect lower thrust 2 REMOVE AND INSTALL STUB SHAFT SEALS WITHOUT DISASSEMBLING GEAR REMOVE INSTALL Remove retaining ring 1 Install stub shaft seal and dust seal Take care Liberally coat top of seal not to scratch shaft with anhydrous calcium Wrap 0 1mm to 0 2mm grease 005 to 008 shim Install dust seal just deep INSTALL Install parts as shown 2 Adjust thrust bearing preload see adjustment procedure before tightening tock nut stock around shaft and insert between shaft and sealing lip until it bottoms Pry seal out RETAINING RING STUB SHAFT SHIM STOCK Ki 4 Screwdriver HOUSING ASSEMBLY OVERHAUL MANUAL enough to clear retaining ring groove then install retaining ring OUST SEAL bearing assembly HOUSING ASSEMBLY __ 2 LOWER THRUST BEARING ASSEMBLY Inspect for smooth operation LOCK NUT a ADJUSTER PLUG RING SEAL ADJUSTER PLUG qe Hexagon Driver 17mm Fig 3B3 2C Overhaul 605 Gear Chart STEERING 3 9 5 REMOVE AND INSTALL RACK PISTON AND VALVE ASSEMBLY REMOVE 1 Rem
11. MODULATOR ASSEMBLY OIL RING Fig 7A 134C Modulator Assembly and Valve 4 Inspect oil seal for damage If replacement is required proceed as follows a Pry oil seal from extension b Apply non hardening sealer to outside of new oil seal and install oil seal into case extension using tool J 24057 see Fig 7A 171C 5 Inspect ball bearing assemblies If they are damaged or if they require cleaning proceed as follows a Remove rear seal b Remove snap ring c Remove ball bearings and bearing spacer using a brass rod on the outside race of bearing An arbor press can be used if tool to press bearing out is located on outer race of bearing DO NOT locate against inner race or balls d Install ball bearing assembly and spacer bearing first Install ball bearing assembly and snap ring f Install new rear oil seal INSPECTION OF MODULATOR AND VALVE 1 Inspect modulator assembly for any signs of bending or distortion Fig 7A 134C 2 Inspect O ring seal seat for damage 3 Apply suction to vacuum tube and check for diaphragm leaks 4 Check modulator bellows as outlined in Section 7 of Service Manual modulator plunger is under pressure 16 lbs If bellows is damaged plunger will have very little pressure 5 Inspect modulator valve for nicks or damage 6 Check freeness of valve operation in case bore INSPECTION OF MANUAL AND PARKING LINKAGE 1 Inspect parking actuator
12. Valve Body Transfer Spacer Plate and Gasket Fig 7A 18B Check Bal Four 4 Locations 5 Remove four 4 check balls from correct passages in case face fig 7A 18B 6 Remove oil pump pressure screen from oil pump pressure hole in case fig 7A 19B i hu OIL PUMP PRESSURE SCREEN Fig 7A 19B Removing Oil Pump Pressure Screen AUTOMATIC TRANSMISSION 350 7A 7 GOVERNOR SCREEN Fig 7A 20B Removing Governor Feed Screen 7 Remove governor feed screen from governor feed hole drive oil in case fig 7A 20B On JA and JH models there are two governor feed screens 8 Remove manual shaft to case retainer with screwdriver fig 7A 21B MANUAL SHAFT TO CASE RETAINER SCREWDRIVER Fig 7A 21B Removing Manual Shaft to Case Retainer OVERHAUL MANUAL 350 7A 8 AUTOMATIC TRANSMISSION RANGE SELECTOR INNER LEVER TO MANUAL SHAFT NUT TORQUE TO 30 LB FT Fig 7A 22B Loosening Nut Holding Range Selector Inner Lever to Manual Shaft 9 Loosen nut holding range selector inner lever to manual shaft fig 7A 22B 10 Remove range selector inner lever from manual shaft Remove manual shaft from case Remove inner lever and parking actuator rod from case Disassembly inner lever from parking pawl actuator rod fig 7A 23B 11 Remove manual shaft to case lip seal fig 7A 24B 12 Remove parking lock lock bracket fig 7A 25B Special Bolts RANGE SELECTOR INNER LE
13. 3 Drive out pin holding reverse shifter head and drive out the shaft NOTICE Exercise care during shaft removal since detent balls are under spring tension in the rear rail boss holes Assembly Fig 7B 6L 1 In reassembling the transmission cover care must be used in installing the shifter shafts They should be installed in the order shown in Fig 7B 7L namely reverse 3rd 4th and lst 2nd Fig 7B 6L illustrates the difference in the shafts OVERHAUL MANUAL 7B 36 MANUAL TRANSMISSION Main Drive Gear Drive Gear Bearing Retainer Snap Ring Outer 3rd and 4th Synchronizer Ring 3rd and 4th Synchronizer Collar 3rd and 4th Shift Fork 3rd and 4th Speed Synchronizer Ring 3rd Speed Gear 2nd Speed Gear 1st and 2nd Synchronizer Assembly OVERHAUL MANUAL 11 12 13 15 16 17 18 19 20 21 22 23 Fig 7B 1L 4 Speed 117mm Transmission Assembly Cross Section Reverse Driven Gear Poppet Spring Poppet Ball Shift Rail 1st and 2nd Shift Fork 1st Speed Gear Thrust Washer Bearing Snap Ring Speedometer Drive Gear Output Yoke Flange Nut Rear Bearing Retainer Oil Seal Rear Bearing Retainer 24 25 26 27 28 Mainshaft Rear Bearing Rear Bearing Snap Ring Snap Ring Countershaft Countershaft Rear Bearing Bearing Snap Ring Reverse idler Gear Reverse Idler Shaft Case Magnet Snap Ring Snap Ring Spacer Countergear 40 41 42 43 44 45 46
14. VOID CONVERTER TO COOLER CONVERTER FEED FROM COOLER LINE TO LUBE DIRECT CLUTCH LINE _ LINE BOOST PUMP INTAKE CHECK BALL 714mm 28l DRIVE 3RD REVERSE PUMP BODY PUMP INTAKE SEAL DRAIN BACK HOLE REVERSE Fig 7A 130A Pump Body Assembly PUMP BODY Fig 7A 131A Installing Seal Into Pump Body PUMP DRIVEN GEAR IDENTIFICATION MARK DOWN PUMP BODY Fig 7A 132A Installing Pump Driven Gear 11 Install driven pump gear with identification mark down against gear pocket of pump body Figs 7A 132A and 7A 133A 12 Install drive gear with identification marks on drive tangs up Fig 7A 129A 13 Pump body face to gear face clearance should be 0 020 0 055mm 0007 0021 Fig 7A 134A 14 Place the check ball into the check ball pocket in the pump body and retain it with petrolatum See Fig 7 130A for ball location Pump Cover Inspection 1 Inspect for open oil passages Figs 7A 135A and 7 136 2 Inspect seven 7 cup plugs If a plug is missing drive a new cup plug to 79mm 1 32 below top of hole using a 7 14mm 9 32 diameter rod on the smaller plugs and 7 92mm 5 16 diameter rod on the larger plugs Stake top of hole two places directly opposite each other to retain plug 3 Inspect pump cover face for nicks and overall flatness OPTIONAL IDENTIFICATION MARKS Fig 7A 133A Pump Driven Gear Identification AUTOMATIC
15. 1 24675 and compress spring and piston and secure with retaining E ring 3 Install the 1 2 accumulator valve train into the lower left hand bore as follows a Model CZ CK and CP Install the 1 2 accumulator spring and 1 2 accumulator valve stem end out into bore Place the bore plug into valve bore and install grooved retaining pin from the cast surface side of the valve body with the grooves entering the pin hole last Tap pin with a hammer until flush with cast surface of valve body b Models CB CD CJ and CL Install 1 2 accumulator valve stem end out into bore Place bore plug into valve bore and install grooved retaining pin from cast surface side of the valve body with the groove entering the pin holes last Tap pin with a hammer until flush with cast surface of valve body c Models CF CG CH CM and CT Install the 1 2 accumulator valve stem end out and 1 2 accumulator secondary spring Install the bore plug and compress spring until grooved retaining pin can be inserted from the cast surface side of the valve body Install retaining pin with the grooved end entering the pin hole last and tap in place until flush with cast surface of the valve body 4 In next bore up install detent spring and spacer Compress spring and secure with small screwdriver Fig 7A 68C 5 Install detent regulator valve wide land first 6 Install detent valve narrow land first 7 Install bore plug hole out depress spring
16. 19 Wet poppet valve with denatured alcohol and assemble in rear plate hub small end first Wet poppet retainer with denatured alcohol and assemble with shoulder inside poppet Assemble retainer filters and silencer over ridge on rod and return spring over ball end of operating valve rod Wet grommet in valve plunger with denatured alcohol and guide air valve rod into valve plunger Tap end of operating valve rod with plastic hammer to lock ball in grommet Press filters and silencers into hub and install retainer on hub 20 Assemble silencer in dust boot wet dust boot opening with denatured alcohol and assemble over operating valve rod and over flange of rear housing REAR BEARING AND VACUUM SEAL Fig 5 7B Rear Bearing and Rear Shell OVERHAUL MANUAL REAR BEARING lt AND VACUUM SEAL Fig 5 BB Installing Rear Bearing and Vacuum Seal 21 Install new check valve and grommet 22 Apply silicone lubricant to piston end of hydraulic push rod and insert in cavity in front plate Twist rod to eliminate air bubbles at reaction disc Assemble seal over push rod and press into recess in front housing Piston Rod Gauging 1 Place the power head assembly in a padded vise front housing up Do not clamp tight 2 Remove the front housing seal to assure that no vacuum is in the power head while gaging 3 Insert the master cylinder piston rod flat end first into the piston rod retainer 4 Press down on the master c
17. 3 Remove and inspect rear carrier to roller clutch thrust washer for signs of scoring or excessive wear 4 Inspect 4 tanged rear carrier to rear internal gear thrust washer for being scored or distorted tangs Fig 7A 65A 5 rear carrier for damage 6 Inspect roller clutch cam ramps for damage 7 Inspect bushing for damage or scoring 8 Inspect planet pinions for damage rough bearings or tilt 9 Check pinion end play Pinion end play should be 0 24 0 69mm 0 009 0 027 Fig 7A 66A Reassembly 1 Install roller clutch to rear carrier thrust washer Fig 7A 67A 2 Install rollers that may have come out of roller clutch cage by compressing the energizing spring with forefinger and inserting roller from outer edge Fig 7A 68A 3 Install roller clutch assembly into roller clutch cam Fig 7A 69A 4 Install roller clutch race spline side out and rotate clutch race counterclockwise into position Fig 7A 70A 5 Install 4 tanged rear carrier to rear internal gear thrust washer Align tangs into slots of rear carrier and retain with petrolatum Fig 7A 71A 6 Install roller clutch and rear carrier assembly into rear internal gear Fig 7A 72A 7 Install J 25013 1 open end first into rear end of case Bolt J 25013 5 on end of case Fig 7A 73A 8 Turn case to vertical position pump end up 9 Install rear unit parts into case and into J 25013 1 sleeve Fig 7A 74A indexing rear int
18. 426 ba PULLEY ASSEMBLY RETAINER N Figure 1D 12 Removing A 6 Pulley Retainer Ring Pulley and Bearing asssembly should be cleaned with naphtha stoddard solvent kerosene or equivalent solvent before reinstallation Replace 1 If original Pulley and Bearing assembly is to be reinstalled wipe frictional surface of pulley clean If frictional surface of pulley shows any indication of damage due to overheating the Pulley and Bearing assembly should be replaced 2 Check bearing for brineling excessive looseness noise and lubricant leakage If any of these conditions exist bearing should be replaced See A 6 Compressor Pulley Bearing Replacement procedure PULLER J 8433 PULLEY AND BEARING ASSEMBLY PULLER PILOT J 9395 5066 Figure 1D 13 Removing 6 Pulley and Bearing Assembly 3 Press or tap Pulley and Bearing assembly on neck of compressor until it seats using Pulley and Bearing Installer J 9481 with Universal Handle J 8092 Figure 1D 14 The Installer will apply force to inner race of bearing and prevent damage to bearing AIR CONDITIONING COMPRESSOR OVERHAUL 1D 7 UNIVERSAL HANDLE J 8092 PULLEY AND BEARING INSTALLER J 9481 Figure 1D 14 Installing A 6 Pulley and Bearing Assembly 4 Check pulley for binding or roughness Pulley should rotate freely 5 Install retainer ring using Snap Ring Pliers J 6435 26 6 Install absorbent sleeve retainer in neck of compressor Usin
19. 5 Place power piston Tool J 21524 with square shank in vise Hold support plate and power piston with tube of power piston up fig 5 6C 6 Pull diaphragm edges away from support plate so hands can grip steel support plate Position assembly on power piston Tool J 21524 so three lugs on tool fit into three notches in power piston fig 5 7C 7 Press down on support plate and rotate counter clockwise until support plate separates from power piston fig 5 8C 8 Remove diaphragm from support plate and lay both parts aside 9 Position power piston tube down in a tool fabricated from a piece of wood 2 x 4 x 8 long with a 1 3 8 hole in center clamped in a vise Do not clamp tube in vise 10 Use Snap Ring Pliers J 4880 to remove snap ring on air valve fig 5 9C 11 Set up Power Ram and Hydraulic Pump with J 9746 Press Plate Insert power piston tube down in press plate and remove air valve assembly using a 3 8 drive SNAP RING POWER PISTON REACTION LEVERS REACTION BUMPER BRAKES 5 13 PUSH ROD REACTION zen 7 LOCK RING O RING REACTION PLATE AIR VALVE SPRING Qe anr VALVE O RING FLOATING CONTROL VALVE ASSEMBLY AIR FILTER AIR SILENCER RETAINER CLIP JAM NUT CLEVIS Fig 5 3C Power Piston Assembly Exploded View extension as a remover fig 5 10C 12 Removal of air valve push rod assembly disassembles the following parts from power piston floating control valve a
20. AUTOMATIC TRANSMISSIONS Fig 7A 6C Removing Speedometer Driven Gear Retainer 3 Remove speedometer driven gear attaching screw and retainer Fig 7A 6C 4 Withdraw speedometer driven gear assembly from case 5 Remove bottom pan attaching screws bottom pan and bottom pan gasket Discard gasket 6 Remove the filter retainer bolt Fig 7A 7C 7 Remove filter and intake pipe assembly from case Fig 7A 8C and discard filter 8 Remove intake pipe to case O ring seal from intake pipe or case and discard Fig 7A 7C Removing Filter Retainer Bolt STRAINER ASSEMBLY Fig 7A 8C Removing Filter Assembly and Ring Removal of Control Valve Assembly Solenoid Connector Governor Pipes Governor Screen Assembly and Detent Spring Assembly Remove control valve body attaching screws and detent roller and spring assembly Fig 7A 9C Do not remove solenoid attaching screws NOTICE If transmission is in the vehicle the front servo parts may drop out as the control valve assembly is removed DETENT ROLLER AND SPRING ASSEMBLY Fig 7A 9C Removing Detent Roller and Spring Assembly GOVERNOR CONTROL VALVE PIPES Fig 7A 10C Removing Control Valve Assembly and Governor Pipes from Case 2 Remove control valve assembly and governor pipes Fig 7A 10C Do not drop manual valve 3 Remove governor screen assembly from governor feed pipe hole in the case or from end of governor feed pip
21. Fig 7B 7B Removing Front Bearing MAINSHAFT DISASSEMBLY 1 Remove snap ring from front of output shaft and remove Second Third synchronizer assembly and second gear Mark hub and sleeve for correct assembly 2 Remove snap ring and tabbed thrust washer from shaft and remove first gear and blocking ring 3 Remove First Reverse hub retaining snap ring Observe position of spring and keys before removal also mark hub and sleeve for correct assembly BEARING REMOVER TOOL J 8157 01 Fig 7 B 8B Removing Rear Bearing OVERHAUL MANUAL Fig 7B 9B Rotating Shift Rail 4 Remove sleeve and gear spring and three keys from hub Fig 7B 13B 5 Using an arbor press remove hub from output shaft CLEANING AND INSPECTION Transmission Case 1 Wash the transmission thoroughly inside and outside with cleaning solvent then inspect the case for cracks 2 Check the front and rear faces for burrs and if present dress them off with a fine mill file FIRST REVERSE SLEEVE AND GEAR IN FORWARD POSITION TO CLEAR CASE Fig 7B 10B Removing Output Shaft Assembly MANUAL TRANSMISSION 7B 13 O RING LOCATION Fig 7B 11B Shift Fork Shafts Front and Rear Bearings 1 Wash the front and rear ball bearings thoroughly in a cleaning solvent 2 Blow out bearings with compressed air NOTICE Do not allow the bearings to spin turn them slowly by hand Spinning bearings may damage the race and balls 3 Make su
22. 1 Using tool J 21424 9 with Driver Handle J 8092 remove bushing Fig 7A 186A 2 Using tool J 21424 9 with Driver Handle J 8092 drive or press new bushing to a distance of approximately 17 3mm 11 16 between rear end of the bushing and rear end of the case Fig 7A 186A 4 8092 J 21424 9 CASE Fig 7A 186A Removing or Installing Case Bushing OVERHAUL MANUAL AUTOMATIC TRANSMISSION SPECIAL TOOLS 200 7A 49 e x090psp9N J25015 J25016 J25020 01 J25023 J25012 J25018 325019 425014 425021 425025 425013 3725010 425011 Oil Pump Body and Cover Alignment Band Front Oil Pump Seal Installer Converter Stator and Turbine End Play Checking Fixture Reverse Clutch Selective Shim Group Reverse Clutch Housing Installer and Remover Forward Clutch Spring Compressor Bushing Service Set Intermediate Band Apply Pin Gauge Turbine Shaft and Direct Clutch Installer Alignment Pin and Stud Set Output Shaft and Rear Unit Support Fixture Direct Clutch Seal Protector Reverse Clutch Seal Protector J25022 J 23327 J22269 01 J21426 425024 J21427 01 J24773 J8092 J7004 J8001 J8433 J8763 02 J3289 20 Fig 7A 5T 200 Special Tools End Play Checking Fixture Adapter Clutch Spring Compressor Direct Clutch Spring Compressor Rear Oil Seal Installer Forward Clutch Spring Compressor Speedo Gear Puller Gaging Fixture Driver Handle Slide Hammer Dial Indicator Set Puller
23. 1 Piston AND AXIAL PLATE in following manner a Select a suitable combination of well oiled Feeler Gage leaves to fit snugly between ball and axial plate b Attach Tension Gage 1 9661 3 to the feeler gage distribution point checking scale or Spring Scale J 544 may be used c Pull on Spring Scale to slide Feeler Gage stock out from between ball and axial plate and note reading on Spring Scale as Feeler Gage is removed Figure 1D 45 Reading should be between 4 and 8 ounces 6 195 d If reading in Step above is under 4 or over 8 ounces reduce or increase thickness of Feeler Gage leaves and repeat Steps a through c above until a reading of 4 to 8 ounces is obtained Record the clearance between ball and axial plate that results in the desired 4 to 8 ounce pull on Spring Scale 16 Now rotate shaft 120 and repeat Step 15 between this same No 1 Piston Rear Ball and axial plate Record this measurement If shaft is hard to rotate install shaft nut onto shaft and turn shaft with wrench REAR BALL FEELER Figure 1D 45 Gaging 6 Rear Piston Ball 17 Rotate shaft another 120 and again repeat Step 15 between these same parts and record measurements 18 Select a NUMBERED SHOE disc corresponding to minimum feeler gage reading recorded in the three checks just made above See example in Figure 1D 47 Place the selected shoe discs in Parts Tray J 9402 compartment corresponding to Piston No 1 and rear
24. 2 Check pinion bearing preload as described under Drive Pinion Reassembly Record the result If there is no preload reading check for loosenes of pinion assembly s by shaking the companion flange Looseness indicates the need for bearing replacement 3 Remove the pinion bearing retainer bolts from the housing as shown in figure 7E 4 Remove the pinion and bearing retainer assembly It may be necessary to rap on the pilot end of the pinion to assist the assembly from the carrier 5 Record the thickness of the shims removed from between the bearing retainer flange and the carrier housing Disassembly 1 Clamp the pinion assembly in vise 2 Install Holder J 8614 11 on flange by using two bolts with flat washers as shown in figure 8E Position J 8614 11 on flange so that the four notches are toward the flange 3 Use a suitable sized socket to remove the pinion nut and washer Discard the pinion nut and use a new one upon reassembly 4 Thread end of J 8614 3 into small O D end of J 8614 2 Then with J 8614 11 installed as a step 2 insert J 8614 2 into J 8614 11 and turn it 1 8 of a turn to locked position Remove flange by turning J 8614 3 while holding J 8614 11 as shown in figure 9E 5 Support the bearing retainer as shown in figure 10 and press out the drive pinion Do not allow drive pinion to fall onto the floor 6 Separate the pinion flange the oil seal the front bearing and the bearing retainer The oil sea
25. 2 Install Tool J 22832 or suitable press plates on countershaft open side to spacer Fig 7B 20L support assembly in an arbor press and press countershaft out of clutch countergear assembly Countergear is a slip fit and pressing may not be required 3 Remove clutch countergear rear retaining ring Discard snap ring 4 Remove 3rd speed countergear retaining ring Discard snap ring 5 Position assembly on an arbor press and press shaft from 3rd speed countergear Assembly 1 Position 3rd speed countergear and shaft in arbor press and press the gear onto the shaft Install gear with marked surface toward front of shaft 2 Install new 3rd speed countergear retaining ring using 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 7B 21L Using Tool J 22873 push down on snap ring until it engages groove on shaft Using snap ring pliers carefully expand ring until it just slides onto splines then push ring down shaft until it engages groove on shaft NOTICE Do not over stress snap ring or damage may occur 4 Position clutch countergear and spacer on shaft and press countergear onto shaft against snap ring using Tool J 22873 Fig 7B 22L Countergear is a slip fit and pressing may not be required 5 Install clutch countergear thrust washer and front retaining ring
26. 7B 103 9 Install a blocker ring with notches downward so they align with the keys of the 1 2 synchronizer assembly 10 Install first gear with clutching teeth downward 11 Install first gear thrust washer steel Be sure the notches of the blocker ring align with the keys of the synchronizer assembly 12 Install first gear spring washer 13 Install rear ball bearing with snap ring slot downward press onto mainshaft Fig 7B 17J 14 Install rear bearing to mainshaft snap ring Fig 7B 8J 15 Install speedometer drive gear and clip This completes the assembly of the mainshaft ASSEMBLY OF TRANSMISSION Fig 7B 18J 1 Using Tool J 22246 load a row of roller bearings 27 and a bearing thrust washer at each end of the countergear Use heavy grease to hold them in place Fig 7B 197 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 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 mainshaft and onto rear bearing Seat snap ring in rear bearing groove Fig 7B 4J 5 Load the mainshaft pilot bearings 14 into the clutch gear cavity
27. AUTOMATIC TRANSMISSION 350 7A 31 Governor Driven Gear Replacement To facilitate governor repair in the field a governor driven gear and replacement pins are available for service use The service package contains a nylon driven gear two governor weight retaining pins and one governor gear retainer split pin Replacement of gear must be performed with care in the following manner 1 Drive out governor gear retaining split pin using small punch 2 Support governor on 3 16 inch plates installed in exhaust slots of governor sleeve place in arbor press and with a long punch press gear out of sleeve 3 Carefully clean governor sleeve of chips that remain from original gear installation 4 Support governor on 3 16 inch plates installed in exhaust slots of sleeve position new gear in sleeve and 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 on shoulder 5 A new pin hole must be drilled through sleeve and gear Locate hole position 90 degrees from existing hole center punch and then while supporting governor in press drill new hole through sleeve and gear using a standard 1 8 inch drill 6 Install split retaining pin 7 Wash governor assembly thoroughly to remove any chips that may have collected Assembly 1 Install governor valve in bore of sleeve large land end first 2 Install governor weights
28. Fig 7A 62B Separating Pump Cover From Pump Body 7 Remove pump cover and stator shaft assembly from pump body fig 7A 62B 8 Remove pump drive gear and driven gear 9 Remove pump outside diameter to case square cut O ring seal Discard seal Inspection 1 Wash all parts in cleaning solvent and blow out all oil passages DO NOT USE RAGS TO DRY PARTS Some solvents may be harmful to rubber seals Fig 7A 63B Checking Pump Body to Gear Face Clearance AUTOMATIC TRANSMISSION 350 7A 19 2 Inspect pump gears for nicks or damage 3 Inspect body and cover faces for nicks or scoring Inspect cover hub O D for nicks or burrs which might damage clutch drum bushing journal 4 Inspect body bushing for galling or scoring Check clearance between body bushing and converter pump hub Maximum clearance is 005 If the bushing is damaged the oil pump body should be replaced 5 Inspect converter housing hub O D for nicks or burrs which might damage pump seal or bushing Repair or replace as necessary 6 If hub lip seal is damaged or is leaking and the pum body is p otherwise suitable for reuse replace seal 7 With parts clean and dry install pump gears in pump body and check pump body face to gear face clearance Clearance should be 0005 0015 fig 7A 63B Reassembly 1 Replace hub lip seal if defective figs 7A 64B and 7A 65B PUMP TO CONVERTER HUB LIP SEAL n SCREWDRIVER S Fig 7A
29. SIDE COVER PRELOAD 1 ADJUSTER A HOUSING 4 75 amp 5 kA Jd PITMAN Os SHAFT SEAL y SHAFT PITMAN SHAFT SEAL SCREWDRIVER Checking end clearance If clearance is greater than 05 mm 002 a steering gear lash adjuster kit is available FEELER GAUGE Select to get proper clearance J 21421 01 PITMAN SHAFT SEAL Install seal LUBRICATION The steering gear requires 3118 kg 11 0z of lubricant GM4673M or equivalent Fig 3B2 2 Manual Gear Overhaul Chart A 3 REMOVE AND INSTALL WORMSHAFT AND BALL NUT REMOVE INSTALL 1 Loosenlock nut Usepunch 1 install parts as shown against edge of slot 2 Remove parts as shown NOTICE Use care that the ball nut does not run down to either end of the worm Damage may be done to the ends of the ball guides if the ball nut is allowed to rotate until stopped at the end of the worm WORM BEARING ADJUSTER LOCKNUT WORMSHAFT UPPER WORM WORM BEARING BEARING ADJUSTER Ce BALL GUIDES Oct amp CLAMP UPPER WORM BEARING CUP See below Free Ee Remove bearing cup from housing only if necessary Remove Cup Install Cup STEERING 3B 3 DISASSEMBLE AND ASSEMBLE WORM BEARING ADJUSTER DISASSEMBLE ASSEMBLE Pry lower bearing re 1 Press cup into adjuster tainer out with screw using J 5755 driver Install parts as shown Remove cup using J 5822 puller and slide hammer WORM BEARING A
30. __ X25019 14 PUMP COVER Fig 7A 170A Removing Pump Cover Bushing Rear OVERHAUL MANUAL 2 Using tool J 25019 2 with Driver Handle J 8092 drive or press new bushing into place until tool bottoms Fig 7A 169A Rear Bushing 1 Using tool J 25019 14 with Slide Hammer J 7004 1 remove bushing Fig 7A 170A 2 Using tool J 25019 6 with Driver Handle J 8092 drive or press new bushing until tool bottoms Fig 7A 171A PUMP BODY BUSHING 1 Place pump body with the machined face down on two blocks of wood to prevent damaging the machined surface 2 Using tool J 25019 4 with Drive Handle J 8092 remove bushing Fig 7A 172A 3 Using tool J 25019 12 with Driver Handle J 8092 drive or press new bushing into place until tool bottoms Fig 7A 173A DIRECT CLUTCH HOUSING Front Bushing 1 Using tool J 25019 16 with Slide Hammer J 7004 1 remove bushing Fig 7A 174A 2 Place bushing chamfered inside diameter end first over tool J 25019 9 Using tool J 25019 9 with Driver Handle J 8092 drive or press new bushing into place until tool bottoms Fig 7A 175A Rear Bushing 1 Place direct clutch housing with the thrust washer face down on a block of wood to prevent damaging the thrust washer surface 2 Using tool J 25019 4 with Driver Handle J 8092 remove bushing Fig 7A 176A 3 Using tool J 25019 6 with Driver Handle J 8092 drive or press new bushing into place until tool bottoms Fig 7A
31. goci PUMP COVER TO PUMP BODY ATTACHING BOLTS 5 eumr i Fig 7 57 Assembly Exploded View OVERHAUL MANUAL 350 7A 18 AUTOMATIC TRANSMISSION INTERMEDIATE CLUTCH SPRING SEAT RETAINER PUMP COVER TO 3 BODY BOLTS 5 Fig 7A 58B Removing Pump Cover to Pump Body Bolts 2 Remove pump cover to body attaching bolts 5 16 x 18 1 1 2 fig 7A 58B 3 Remove intermediate clutch spring retainer twenty 20 intermediate clutch return springs and the intermediate clutch piston assembly fig 7A 59B 2 RETURN SPRINGS 20 INTERMEDIATE CLUTCH PISTON SPRING RETAINER Fig 7A 59B Intermediate Clutch Spring Retainer Return Springs and Piston OVERHAUL MANUAL INTERMEDIATE CLUTCH PISTON OUTERSEAL INTERMEDIATE CLUTCH PISTON INNER SEAL Fig 7A 60B Removing Intermediate Clutch Piston Inner and Outer Seal 4 Remove intermediate clutch piston inner and outer seals fig 7A 60B 5 Remove two 2 forward clutch housing to pump hub hook type oil seal rings and three 3 direct clutch drum to pump hub hook type oil rings fig 7A 61B Forward clutch oil seal rings are teflon on JA and JH models 6 Remove pump cover to direct clutch drum housing torrington bearing fig 7A 61B FORWARD CLUTCH reni OIL SEAL BRINGS PUMP COVER TO DIRECT CLUTCH NEEDLE BEARING d Fig 7A 61B Pump Hub Oil Seal Rings PUMP COVER AND STATOR SHAFT ASSEMBLY
32. gt m J 23062 5 OVERHAUL MANUAL 350 7A 38 AUTOMATIC TRANSMISSION SPECIAL TOOLS Transmission Holding F ixture 16 Used with J 3289 20 Base Transmission Holding Fixture 17 Base 18 Driver Handle Threaded type Driver Handle Extension Used with J 8092 19 Sun Gear and Reaction Carrier Bushing 20 Output Shaft Bushing Installer Stator Shaft Front Bushing 21 Remover Used with J 8092 Direct Clutch Bushing Installer Output Shaft Bushing Remover Clutch Spring Compressor Stator Shaft Rear Bushing installer Both Rear Case Bushing Remover and Installer Extension Housing Bushing Remover and Installer Used with J 8092 Stator Shaft Front Bushing Installer Used with J 8092 Input Ring Gear Bushing Remover and Installer J 5154 or J 21426 J 21359 J 7004 J 22269 01 J 23069 J 2619 01 Not Illustrated J 21369 J 8001 J 21427 1 J 9539 J 8105 J 5586 J 24367 J 24675 21 Extension Housing Oil Seal Installer Pump Oil Seal Installer Slide Hammers Pair For Pump Body removal 3 8 x 16 tread Direct Clutch Accumulator Piston Remover and Installer THM 350 only Intermediate Accumulator Cover Remover and Installer Slide Hammer 5 8 x 18 with 1 2 x 13 Adapter Converter Pressure Check Fixture Dial Indicator Set 001 Increments 001 Travel Speedo Gear Remover Slide Hammer Bolts 3 8 16 Threads Speedo Gear Remover Puller Snap Ring Pliers Trans
33. lbs and recheck pin to make certain it does not bind b Apply 25 ft lb torque and select proper servo pin to be used from scale on tool 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 Fig 7A 180C Installing Rear Accumulator Spring Fig 7A 181C Installing Rear Servo Assembly There are three selective pins identified as follows 1 If both steps are below the gage surface the long pin identified by 3 rings should be used 2 If the gage surface is between the steps the medium pin identified by 2 rings should be used If both steps are above the gage surface the short pin identified by 1 ring should be used 3 Install rear accumulator spring into case Fig 7A 180C 4 Lubricate and install rear servo assembly into case Fig 7A 181C 5 Install rear servo gasket and cover Fig 7A 182C 6 Install attaching screws Torque bolts to 15 20 ft lbs REAR SERVO COVER REAR SERVO GASKET Fig 7A 182C Installing Rear Servo Cover and Gasket 400 7A 56 AUTOMATIC TRANSMISSIONS GOVERNOR SCREEN GOVERNOR FEED PIPE HOLE Fig 7A 183C Installing Governor Screen Assembly INSTALLATION OF CONTROL VALVE ASSEMBLY GOVERNOR PIPES AND GOVERNOR SCREEN ASSEMBLY 1 Install governor pipes on control valve assembly Governor pipes are interchangeable 2 Install governor screen assembly ope
34. n n 4 HOUSING Br Fig 7A 117A Installing Forward Clutch Piston DIRECT CLUTCH PISTON DIRECT CLUTCH HOUSING GER Fig 7A 118A Installing Forward Clutch Piston 200 7A 30 AUTOMATIC TRANSMISSION 6 Remove J 23327 1 and J 25018 7 Oil and install the forward clutch plates into the forward clutch housing starting with the waved steel plate and alternating composition faced and flat steel clutch plates See Fig 7A 119A and Clutch Plate Usage Chart Fig 7A 82A 8 Install backing plate chamfered side up 9 Install snap ring Fig 7A 112A Make sure composition clutch plates turn freely 10 Install forward to direct clutch thrust washer and retain with petrolatum Fig 7A 111A 11 If removed install new turbine shaft seal rings making sure cut ends are assembled in the same relationship as cut and rings are seated in their groove Retain with petrolatum See Fig 7A 120A for correct way to position cut ends Intermediate Band Assembly 1 Inspect band for burning flaking or damage 2 Install intermediate band locating band apply lug and anchor pin lug in case slots Fig 7A 125A FLAT STEEL PLATES COMPOSITION FACED PLATES WAVED STEEL PLATE FORWARD CLUTCH HOUSING Fig 7A 119A Installing Clutch Plates Into Forward Clutch HOusing WRONG Fig 7A 120A Teflon Oil Seal Rings OVERHAUL MANUAL 0 Forward and Direct Clutch Installation 1 Position direct clut
35. the serrations ADJUSTMENT SPECIFICATIONS MANUAL STEERING TORQUE TO ADJUSTMENT TURN WORM SHAFT Worm Bearing Over Center Preload 5 8 In Lbs 4 10 In Lbs in excess of Worm Bearing Preload 16 In Lbs Maximum MANUAL STEERING GEAR Gear to Frame Bolts Pitman Shaft Nut Starfire Omega and Cutlass Side Cover Bolts Pitman Shaft Adjusting Screw Locknut Coupling Flange Nuts 525 Coupling Flange To Gear Pinch Bolt Coupling Clamp Nut 515 Clamp To Ball Nut Screw J 21421 01 Seal Installer J 5755 Worm Bearing Cup Installer J 5822 Worm Bearing Adjuster Cup Puller J 21421 01 Fig 3B2 4 Manual Gear Overhaul Chart C OVESHAUL MANUAL STEERING 38 5 POWER STEERING PUMP CAUTION If when overhauling a power cleaned and flushed before servicing is steering gear pump broken completed components or foreign material are encountered the remaining components of the entire hydraulic system should be disassembled inspected thoroughly 4A 1 6 AND SMALL V 8 1 6 7 8 97 10 Union 10 Spring Mounting Stud Square Ring Seals Union O Ring Seal 11 Pressure Plate Flow Control Valve Mounting Studs 12 Pump Ring Flow Control Valve Spring Reservoir Mark Engine amp Truck 13 Vanes Flow Control Valve Square Reservoir L 6 and Small V 8 Only 14 Drive Shaft Retaining Ring Ring Seal Dip Stick and Cover 15 Rotor Pump Housing Element Corvette only 16 Thrust Plate Magnet Filter A
36. 2 Inspect machined face for pitting scoring or damage 3 Install front sun gear face with the identification mark a drill spot or groove against input drum to rear sun gear snap ring Fig 7A 87A and 7A 88A 4 Thoroughly clean air dry and inspect front sun gear to front carrier thrust race and thrust bearing for pitted or rough conditions 5 Install front sun gear to front carrier thrust bearing and race assembly with roller thrust bearing against the front sun gear Fig 7A 89A This thrust bearing requires only 1 thrust race FRONT SUN GEAR THRUST BEARING amp RACE ASSEMBLY NEEDLE BEARINGS AGAINST GEAR Fig 7A 89A Installing Thrust Bearing Assembly Against Front Sun Gear FRONT CARRIER FEELER GAGE Fig 7A 90A Checking Front Carrier Pinion End Play Front Carrier Assembly Inspection 1 Inspect front carrier for damage Fig 7A 90A 2 Inspect pinions for damage rough bearings or tilt 3 Check pinion end play Pinion end play should be 0 24mm 0 69mm 0 009 to 0 027 Fig 7A 90A 4 Thoroughly clean air dry and inspect closely front carrier to front internal gear roller thrust bearing assembly for pitted or rough conditions Reassembly 1 Install front carrier to front internal gear roller thrust bearing assembly by placing the smaller diameter race against carrier Retain with petrolatum Fig 7A 91A 2 Install front carrier and thrust bearing assembly Fig 7A 93A Front Intern
37. 2 70 2 81 0 106 2 83 2 94mm 0 111 2 96 3 07 0 1174 3 09 3 20mm 0 122 3 22 3 33mm 0 127 3 35 3 46mm 0 132 Green 3 48 3 59mm 0121 Gray Black Light Green Scarlet Purple Cocoa Brown Orange Yellow Light Blue Fig 7A 140A Front Unit End Play Washer Thickness Chart J 25013 5 J 25013 1 Fig 7A 14 1A Installing Tools on Rear End of Case GOVERNOR COVER GOVERNO ASSEMBLY ee O RING SEALS Fig 7A 142A Installing Governor and Cover Assembly OVERHAUL MANUAL 200 7A 36 AUTOMATIC TRANSMISSION INTERMEDIATE BAND ANCHOR PIN Fig 7A 143A Installing Intermediate Band Anchor Pin Rotate governor and cover assembly and output shaft slightly The governor cover fits tight in the bore the last 1 5mm 1 16 NOTICE Governor shaft is not aligned with case hole if retaining ring cannot be installed 5 Install governor retaining ring Align ring gap with an end showing in case slot Intermediate Band Anchor Pin 1 Inspect anchor pin for damage 2 Install anchor pin stem end first making sure stem locates in hole of intermediate band lug Fig 7A 143A INTERMEDIATE SERVO COVER AND PISTON USAGE SERVO INNER OIL SEAL SPRING RING INTERMEDIATE SERVO COVER OIL SEAL SNAP OIL SEAL 1 SE BAND APPLY SERVO CUSHION OUTER SERVO PIN SELECTIVE SPRING PISTON SERVO INNER SERVO SPRING PISTON RETAINER RETAIN
38. 21795 with J 9539 slide hammer Fig 7A 42C 16 Remove shaft to case thrust washer from rear of output shaft or inside case 17 Place gear unit assembly with output shaft facing down through hole in work bench washer from 18 Remove rear unit selective transmission case Fig 7A 43C Fig 7A 43C Removing Selective Washer LOCATE SPACER GAP ADJACENT TO BAND ANCHOR PIN Fig 7A 44C Removing Center Support to Case Spacer 19 Remove center support to case spacer Fig 7 44C 20 Remove rear band assembly Fig 7A 45C Disassembly of Gear Unit Assembly CL Model spur gears disassembly procedure is identical as illustrated 1 Remove center support assembly Fig 7A 46C Fig 7A 45C Removing Rear Band AUTOMATIC TRANSMISSIONS 400 7A 13 Fig 7A 46C Removing Center Support Assembly 2 Remove center support to reaction carrier thrust washer Fig 7A 47C 3 Remove center support to sun gear races and thrust bearing One race may have been removed with center support THRUST WASHER CONSTANT BLEED ORIFICE PLUG Fig 7A 47C Removing Center Support Thrust Washer 400 7A 14 AUTOMATIC TRANSMISSIONS ROLLER CLUTCH ASSEMBLY REACTION E CARRIER SUN GEAR PLASTIC GEAR RING OUTPUT CARRIER Fig 7A 48C Removing Reaction Carrier and Roller Clutch from Output Carrier 4 Remove reaction carrier and roller clutch assembly Fig 7A 48C Lift roller clutch assem
39. 47 Thrust Washer Snap Ring Front Countershaft Bearing Countergear Front Cover Pilot Bearing Rollers Clutch Gear Oil Slinger Snap Ring 3rd Speed Gear Bushing Thrust Washer 2nd Speed Gear Bushing 1st Speed Gear Bushing IVANY gun pepojdx3 uoissiusuej peeds p 12Z g Big go Drive Gear Bearing Retainer Retainer Gasket Lip Seal Snap Ring Drive Gear Bearing Oil Slinger Drive Gear and Pilot Bearings Power Take Off Cover Gasket Power Take Off Cover Retaining Screws 1st 2nd Speed Blocker Ring Synchronizer Spring 1st 2nd Speed Synchronizer Hub Synchronizer Keys Synchronizer Spring Reverse Driven Gear 1st Gear Bushing 1st Gear Thrust Washer Rear Main Bearing Bearing Snap Ring Speedometer Gear Rear Mainshaft Lock Nut 2nd Speed Bushing On Shaft Mainshaft 26 27 29 30 31 32 35 2nd Speed Gear 3rd Gear Bushing Thrust Washer 3rd Speed Gear 3rd Speed Blocker Ring Synchronizer Spring Synchronizer Keys 3rd 4th Synchronizer Hub Synchronizer Spring 3rd4th Speed Blocker Ring 3rd Ath Speed Synchronizer Sleeve 46 47 Snap Ring Snap Ring Thrust Washer Clutch Countergear Spacer Snap Ring Snap Ring 3rd Speed Countergear Countergear Shaft Countergear Rear Bearing Snap Ring Bearing Outer Snap Ring 50 Rear Retainer Gasket Rear Retainer Retainer Bolts Retainer Lip Seal Reverse Idler Shaft Drain Plug Reve
40. 6 3mm 4 EASY OUT Fig 7A 47A Removing Parking Pawl Shaft Cup Plug from Case OVERHAUL MANUAL 200 7A 12 AUTOMATIC TRANSMISSION LINE REVERSE DRIVE PUMP INTAKE ge COOLER PARKING 4mm 43 PAWL SHAFT EASY OUT TO CO Fig 7A 48A Removing Parking Pawl Shaft from Case 2 Inspect orifice plug in the intermediate servo bore If the plug requires replacement place the new plug orifice end first into plug hole in case Drive plug flush to slightly below top of plug hole 3 Inspect the exhaust vents for being opened Fig 7A 50A Oil Passages Front of Case 4 Inspect reverse clutch lugs governor bore intermediate servo bore speedometer bore and snap ring grooves for damage LINE E EXHAUST RNDI PEE INTERMEDIATE M O SA RAS Wi iz lj L 1 af S INTERMEDIATE a CLUTCH ex pa re amp REV ren BR DRIVE covenNon LINE BOOST 10 157 PUMP 7 REVERSE 1 2 ACCUMULATOR BOOST PART INTERMEDIATE i THROTTLE BOOST B M E m 4 DIRECT CLUTCH TV EXHAUST DIRECT CLUTCH ACCUM 3RD ACCUM SHIFT TV DIRECT 2ND hear VALVE foe NAUST CLUTCH ASSY Fig 7A 49A Oil Passages Bottom of Case OVERHAUL MANUAL J 21426 REAR OIL SEAL PA Fig 7A 51A Installing Rear Oil Seal 5 Inspect reverse clutch
41. 7 Assemble anti rattle springs in cover See Fig 7C 9E The spring to the left is in operating position 8 Lower the cover on top of the assembled parts as in Fig 7C 10E Be sure that the anti rattle springs are correct position and also that the punch marks made before dismantling are matched to insure retaining the original balance 9 Place a bar across the cover and slowly compress guiding the holes in the cover over the pressure plate lugs and all springs into their spring seats in the cover 10 Assemble adjusting nuts on the eyebolts and screw them down until their tops are flush with the tops of the eyebolts Slowly release pressure of spindle and remove cover assembly from press RELEASE LEVER Fig 7C 4E Grasping Lever and Strut CVERHAUL MANUAL EYEBOLT Fig 7C 5E Removing or Installing Lever ADJUSTING LEVERS While no wear adjustment is needed because of the coil spring design it is imperative that the clutch release levers are each set to exactly the same height at the time of rebuild to insure uniform clutch application To obtain exactly the same adjustment at each release lever use gauge plate J 1048 and release lever height gauge J 6456 as follows 1 Place gauge plate J 1048 on the flywheel in position normally occupied by driven plate See Fig 7C 11E NOTICE It is recommended that a spare flywheel be obtained so that this operation may be performed at the bench 2 Bolt cover o
42. Countergear Shaft Key Idler Shaft Key Reverse Idler Shaft Snap Ring Reverse Idler Gear Side Cover Gasket 2 3 Shift Fork 1 Rev Shift Fork 2 3 Shifter Shaft Retaining E Ring 1 Rev Shifter Shaft with O Ring 2 3 Detent Cam Detent Cam Spring 1 Detent Cam Shift Cover TCS Switch and Gasket Shifter Shaft Seal Shifter Shaft Seal Shift Cover Bolts and Washers Damper Assembly Fig 7B 18A 3 Speed 76mm Transmission Exploded View MANUAL TRANSMISSION 7B 9 3 SPEED 77MM TRANSMISSION INDEX Overhaul Operations esee 7B 9 Repairs teret atti dede iain 7B 14 Transmission Disassembly sees 7 9 Synchronizer Keys and Spring 7B 14 Mainshaft Disassembly ENEE 7B 12 Extension Oil Seal or Bushing 7B 14 Cleaning and Inspection eset 7B 12 Clutch Bearing Retainer Qil Seal 7B 14 Transmission Case eee 7 12 Mainshaft Assembly 2 22 22 4 7B 14 Front and Rear vides 7B 13 Transmission Assembly NEEN 7B 15 Roller Bearings asiri e 7 13 eases EES Ins 7B 13 TRANSMISSION DISASSEMBLY 1 Remove lower extension housing bolt and drain transmission Fig 7B 3B 2 Remove top cover and gasket from c se 3 Remove long spring that retains the detent plug in the case Fig 7B 4B Remove
43. J 2619 Slide Hammer Used with J 21465 2 Part of Bushing Tool Set 2619 4 Adapter J 21465 1 Part of Bushing Tool Set and Remover Tools J 21465 01 J 21465 17 Part of Bushing Tool Set J 5154 Extension Oil Seal Installer J 21465 8 Part of Bushing Tool Set J 6585 Slide Hammer Weights J 21465 13 Part of Bushing Tool Set J 9539 Slide Hammer Bolts 3 8 16 J 21465 6 Part of Bushing Tool Set Threads 4 21465 15 Part of Bushing Tool Set J 5590 Speedo Gear Installer J 21485 16 Part of Bushing Tool Set J 21867 Pressure Gauge and Hose J 21465 9 Part of Bushing Tool Set J 21370 6 Rear Band Apply Fixture J 21465 10 Part of Bushing Tool Set J 21370 5 Rear Band Apply Pin J 22182 Ext Bushing Rem and Inst J 21795 1 Gear Unit Assembly Holding Not Illustrated Tool Fig 7 15 400 Special Tools 400 7A 60 J 8763 J 3289 14 J 21427 1 J 9539 J 8105 J 22269 01 J 21369 J 21362 J 21363 J 21409 AUTOMATIC TRANSMISSIONS Transmission Holding Fixture Holding Fixture Base Speedo Gear Remover Side Hammer Bolts 3 8 16 Threads Speedo Gear Remover Puller Accumulator Piston Remover and Installer Converter Pressure Check Fixture Seal Protector Forward and Direct Clutch Inner Seal Protector Intermediate Clutch Inner Seal Protector Forward Clutch Outer 12 4670 13 J 8059 14 J 5586 15 J 5403 16 J 1313 Not Illustrated J 24684 J 24675 Fig 7A 2ST 400 Special Tools Clutch Sprin
44. Loctite RC 75 Loctite 601 or equivalent to threads of pulley rim mounting screws Install screws and new special lock washers but do not torque the Screws J B092 DRIVER HANDLE ROTOR ANDP BEARING ASM INSTALLER 0942 J 25008 1 HOLDING FIXTURE Figure 1D 88 Installing R 4 Rotor and Bearing Assembly On Bench 1D 32 AIR CONDITIONING COMPRESSOR OVERHAUL 7 Rotate the pulley rim and rotor to insure that pulley rim is rotating in line If pulley rim is distorted does not rotate in line adjust or replace pulley rim 8 Tighten pulley rim mounting screws to 100 inch pounds torque and lock screw heads in place by bending special lock washers Figure 1D 88 9 Reinstall Clutch Plate and Hub assembly as described in R 4 Compressor Clutch Plate and Hub Replacement procedures RA COMPRESSOR CLUTCH COIL AND OR PULLEY RIM NOTICE If original pulley rim was equipped with an inertia ring either bolted or welded on or if a ring is to be added refer to INERTIA RING INSTALLATION following Remove 1 Perform Steps 1 through 4 of RA Compressor Clutch Rotor and or Bearing Removal procedure but do not loosen or remove the pulley rim mounting screws until the Clutch Rotor Coil and Pulley Rim assembly have been removed from the Front Head Be careful not to drop the Puller Guide J 25031 1 when removing the assembly 2 Remove the pulley rim mounting screws and special lock washers
45. O RING CYLINDER TO SHELL I TEE ert SHAFT SEAL SHELL SEAL SEAT RING SEAL FRONT HEAD FRONT HEAD TO CYLINDER SCREW WASHER ASSEMBLY Des j 7 FRONT HEAD MOUNTING SHAFT SEAL KIT RETAINER RING LCQL INVHYSAO YOSSAYdWOD ONINOILIGNOS 1D 28 AIR CONDITIONING COMPRESSOR OVERHAUL THRUST AND BELLEVILLE WASHERS COMPRESSOR SHELL MAIN BEARING FRONT PULLEY RIM o CLUTCH COIL TERMINALS PULLEY RIM DISCHARGE PORT L4 PULLEY RIM MTG dees 4 SCREW LOCKWASHER Hi ROTOR BEARING ROTOR BEARING SUCTION PORT l RETAINER SEAL SEAT aai RETAINER 11 SHAFT KEY Ke NUT MAIN BEARING REAR ER tar SN SHAFT SEAL ees meee SEAL SEAT EH SEAL SEAT PISTON ASSEMBLY i O RING KS CLUTCH DRIVE ASSEMBLY N ROTOR AND HUB FRONT HEAD ASSEMBLY SHELL RETAINER a d CLUTCH COIL AND HOUSING ASSEMBLY VALVE PLATE VALVE PLATE RETAINER RING ASSEMBLY Figure 1D 75 R 4 Compressor Cross Section J 25030 HARGE CLUTCH HUB EOS HOLDING TOOL J 9399 SHAFT NUT SOCKET CLUTCH ASSEMBLY J 25008 1 HOLDING FIXTURE HOLDING HIGH PRESSURE FIXTURE RELIEF VALVE Figure 1D 76 R 4 In Holding Fixture Figure 1D 77 Removing R 4 Shaft Nut AIR CONDITIONING COMPRESSOR OVERHAUL 1D 29 DRIVE PLATE INSTALLER 19401 HUB AND CLUTCH DRIVE PLATE ASM REMOVER DRIVE PLATE INSTALLER BEARING CLUTCH PLATE AND
46. OVERHAUL MANUAL 350 7A 12 AUTOMATIC TRANSMISSION Fig 7A 38B Removing Input Ring Gear 10 Remove input ring gear fig 7A 38B 11 Remove input ring gear rear output carrier thrust washer fig 7A 39B eee e OUTPUT CARRIER ST n M Fig 7A 39B Removing Input Ring Gear Rear Thrust Washer OVERHAUL MANUAL Fig 7A 40B Removing Output Carrier Assembly 12 Remove output carrier assembly fig 7A 40B 13 Remove sun gear drive shell assembly fig 7A 41B SUNGEAR DRIVE SHELL ASSEMBLY Fig 7A A1B Removing Sun Gear Drive Shell pt LOW amp REVERSE CLUTCH SUPPORT Fig 7A 42B Removing Low and Reverse Clutch Support Retaining Ring 14 Remove low and reverse roller clutch support to case retaining ring fig 7A 42B 15 Remove low and reverse clutch support and race assembly and anti clunk spring 16 Remove low and reverse clutch plates and steel reaction plates fig 7A 43B LOW AND REVERSE CLUTCH PACK Fig 7A 43B Removing Low and Reverse Clutch Pack AUTOMATIC TRANSMISSION 350 7 13 OUTPUT RING GEAR AND SHAFT ASSEMBLY REACTION CARRIER ASSEMBLY Fig 7A 44B Removing Reaction Carrier Assembly 17 Remove reaction carrier assembly from output ring gear and shaft assembly fig 7A 44B 18 Remove output ring gear and shaft assembly from case fig 7A 45B On models so equipped also remove grease pack sleeves from output shaft before taking shaft f
47. OVERHAUL MANUAL DIAL INDICATOR J 8001 Fig 7A 16A Checking for Proper Intermediate Band Apply Pin c Install dial indicator J 8001 and position diai indicator point Fig 7A 16A on top of J 25014 2 zero post and set dial indicator to zero Seat J 25014 2 squarely against the servo retaining snap ring d Align stepped side of pin J 25014 1 with torquing arm of J 25014 2 Arm must stop against step of pin J INTERMEDIATE BAND APPLY PIN SELECTION CHART APPLY PIN I DIAL INDICATOR TRAVEL IDENTIFICATION 0 72 0 029 1 Ring 22mm 1 44mm 0290577 2 Rings 1 44mm 2 16mm 057 086 3 Rings 2 16mm 2 88mm 086 114 Wide Band Fig 7A 17A Intermediate Band Apply Pin Selector Chart J 25013 5 J 25013 1 Fig 7A 18A Installing Tools on Rear End of Case AUTOMATIC TRANSMISSION 200 7 5 DIAL INDICATOR J 8001 Fig 7A 19A Checking Front Unit End Play 25014 1 If band selection pin does not register between the high and low limits look for possible problem with the intermediate band direct clutch or case e Apply 12 100 in lbs of torque to hex nut on side of gauge Slide dial indicator over pin J 25014 1 Fig 7A 16A Read dial indicator and see chart in Fig 7A 17A for proper size Dial indicator travel is reversed making the indicator readings backwards On an indicator that ranges from O 100 a 5 m 020 travel will read 2mm m 080 a 1 5mm 060 travel will read Im
48. ROLLER amp SPRING ASSEMBLY Fig 7A 163A Installing Manual Detent Roller and Spring Assembly Reassembly 1 If removed install new ring on housing 2 Install speedometer driven gear into housing 3 Install speedometer driven gear assembly into case Fig 7A 167A 4 Install speedometer retainer and attaching bolt align slot in speedometer driven gear housing with retainer Torque bolt to 8 0 14 0 N m 6 10 ft Ibs 5 Place transmission in cradle or transmission jack Remove holding fixture J 8763 02 from transmission BUSHING REPLACEMENT PUMP COVER BUSHINGS Front Bushing 1 Using tool J 24036 with Slide Hammer J 7004 1 remove bushing Fig 7A 168A TV EXHAUST VALVE LIFTER SPRING LEVER TV EXHAUST THROTTLE TO CABLE LINK VALVE LIFTER Fig 7A 164A Throttle Lever and Bracket Assembly AUTOMATIC TRANSMISSION 200 7A 43 THROTTLE LEVER amp BRACKET ASSEMBLY THROTTLE LEVER TO CABLE LINK Fig 7A 165A Installing Throttle Valve and Bracket Assembly OIL SCREEN wow e a Fig 7A 166A Installing Oil Screen O RING SEAL SPEEDOMETER DRIVEN GEAR ASSEMBLY Fig 74 167 A Removing and Installing Sper Driven Gear Typical OVERHAUL MANUAL 200 7A 44 AUTOMATIC TRANSMISSION Fig 7A 168A Removing Pump Cover Bushing Front J 25019 2 PUMP COVER AA Fig 7A 169A Installing Pump Cover Bushing Front g J 7004 1
49. Remove dial indicator and with the use of a pry bar remove differential case from carrier Remove spreader Disassembly 1 Remove differential bearing cups and identify with a tag for reassembly 2 Place differential in vise and drive out pinion shaft lock pin 3 Remove differential bearing cone and roller using Puller J 22888 with Plug J 8107 3 as in figure 16F Tag cone and rollers for assembly If ring gear and pinion are to be reassembled note position of shims and replace accordingly 4 Remove spacer pinion shaft pinions side gears and thrust washers from differential case 5 Remove screws attaching ring gear to differential case Remove gear DRIVE PINION Removal 1 Separate rear universal joint tape trunnion bearings to joint position propeller shaft to one side and tie propeller shaft to frame side rail 2 Using Holding Bar J 8614 11 attach d to pinion shaft flange remove self e locking nut and washer from pinion shaft 3 Install Tool J 8614 2 and 3 into holding bar as shown in figure 17F and remove flange from drive pinion Remove drive pinion from carrier 4 With 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 long drift and hammer Remove shims and oil slinger which are located
50. Remove low and reverse clutch piston center and applying compressed air in passage shown on Figure 7A inner seal fig 7A 52B 50B 26 Install tool J 23069 to compress intermediate clutch accumulator piston cover and remove retaining ring fig 24 Remove low and reverse clutch piston outer seal 7A 53B fig 7A 51B 27 Remove intermediate clutch accumulator piston cover and remove OT ring seal from case 28 Remove intermediate clutch accumulator piston spring J 23069 REVERSE CLUTCH PISTON Fig 7A 51B Removing Low and Reverse Clutch Piston Outer Fig 7A 53B Removing Accumulator Piston Cover Retaining Seal Ring OVERHAUL MANUAL 350 7A 16 AUTOMATIC TRANSMISSION lt SPRING 1 2 ACCUMULATOR PISTON ASSEMBLY PISTON COVER AND RING SEAL Fig 7A 54B Intermediate Clutch Accumulator Components RETAINING RING 29 Remove intermediate clutch accumulator piston assembly fig 7A 54B 30 Also remove inner and outer hook type oil seal rings if required VALVE BODY DISASSEMBLY INSPECTION AND REASSEMBLY FIG 7A 56B Disassembly 1 Position valve body assembly with cored face up and direct clutch accumulator piston pocket positioned as shown in Figure 7A 56B MANUAL VALVE PRESSURE REGULATOR VALVE PRESSURE REGULATOR VALVE SPRING REVERSE AND MODULATOR BOOST VALVE INTERMEDIATE BOOST VALVE BOOST VALVE SLEEVE RETAINING PIN 2 3 SHIFT VALVE 2
51. contact between ring gear and drive pinion for low noise level and long life can be assured 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 FRONT WHEEL DRIVE 4 7 CONCAVE SIDE COAST CONVEX SIDE DRIVE QI Fig 4C 11 Gear Tooth Nomenclature of tooth is smaller than heel end See Figure 4C 11 Test 1 Wipe oil out of carrier and carefully clean each tooth of ring gear 2 Use gear marking compound and apply this mixture sparingly to all ring gear teeth using a medium stiff brush When properly used the area of pinion tooth contact will be visible when hand load is applied 3 Tighten bearing cap bolts to 55 Ib ft 4 Apply a load until a torque of 40 50 Ib ft is required to turn the pinion test made without loading the gears will not give a satisfactory pattern Turn companion flange with wrench so that ring gear rotates one full revolution then reverse rotation so that ring gear rotates one revolution in opposite direction Excessive turning of ring gear is not recommended 5 Observe pattern on ring gear teeth and compare with Figure 4C 12 Adjustments Affecting Tooth Contact Two adjustments can be made which will affect
52. engaging the drive chain to the sprocket Rotate clutch drive gear to asist in positioning chain on the drive sprocket 9 Install the shift fork on the clutch assembly and the shift rail then push the clutch assembly fully into the drive sprocket Install roll pin retaining shift fork to shift rail OVERHAUL MANUAL 7D 18 TRANSFER CASES Fig 7D 22S Drive Gear and Lockout Clutch Assemlby Installed 10 Install front output shaft bearing 11 Install front output shaft bearing retainer gasket and retaining bolts 12 Install the front output shaft flange gasket seal washer and retaining nut Tap dust shield back in place after installing bolts in flange 13 Install front output shaft rear bearing retainer gasket and retaining bolts If rear bearing was removed Fig 7D 23S Installing Intermediate Housing to Range Box OVERHAUL MANUAL Fig 7D 24S Checking Rear Output Shaft End Play position new bearing to outside face of cover and press into cover until bearing is flush with opening 14 Install differential carrier assembly on the input shaft Carrier bolt heads should face rear of shaft 15 Position rear output shaft to differential carrier assembly load bearings in pinion shaft Install rear output housing front assembly gasket and retaining bolts b Install speedometer gear and shims approximately 050 inch thickness on output shaft c Position rear output housing rear assembly
53. eos eer ie ttc eene 7 58 Pinion Replacement TA AO Special iceberg 7 59 OVERHAUL MANUAL 400 7 2 AUTOMATIC TRANSMISSIONS Fig 7 1 400 Automatic Transmission Side Cross Section Typical J 8763 01 Fig 7A 2C Transmission in Holding Fixture DISASSEMBLY OF MAJOR UNITS 1 With transmission in cradle on portable jack remove converter assembly by pulling straight out Converter contains a large amount of oil 2 Install holding Fixture J 8763 01 on transmission so that modulator assembly will be located on side of holding fixture nearest bench Fig 7A 2C Do not over torque holding screw This will bind center support 3 Install fixture and transmission into holding Tool Base J 3289 14 with bottom pan facing up Fig 7A 2C Fig 7A 3C Removing Modulator Retainer AUTOMATIC TRANSMISSIONS 400 7 A 3 VACUUM MODULATOR Fig 7A 4C Removing Vacuum Modulator and Valve 4 Remove modulator assembly attaching screw and retainer Fig 7A 3C 5 Remove vacuum modulator assembly and O ring seal from case Fig 7A 4C Discard O ring 6 Remove modulator valve from transmission case Fig 7A 4C Removal of Governor Speedometer Driven Gear Pan Filter and Intake Pipe 1 Remove attaching screws governor cover and gasket Fig 7A 5C Discard gasket 2 Withdraw governor assembly from case Fig 7A 5C Removing Governor Cover Attaching Screws OVERHAUL MANUAL 400 7 4
54. excessive wear is indicated those parts should be replaced with new parts SUBASSEMBLY REPAIRS Refer to Figures 7D 11S and 70 125 for exploded view of subassemblies Differential Carrier Assembly Fig 70 125 Disassembly 1 Remove bolts from carrier assembly and separte carrier sections 2 Lift the pinion gear and spider assembly from carrier Observe that undercut side of pinion gear spider faces toward front side gear 3 Remove the pinion thrust washers pinion roller washers pinion gears and roller bearings from the spider unit 4 Clean and inspect all components Replace all worn or broken parts Fig 7D 8S8 Removing Front Output Shaft OVERHAUL MANUAL Fig 7D 9S Removing Intermediate Chain Housing TRANSFER CASES 70 11 Assembly 1 Using a petroleum jelly load roller bearings pinion gears 132 required 33 each pinion 2 Install pinion roller washer pinion gear roller washer and thrust washer on each leg of spider 3 Place the spider assembly in the carrier front half with undercut surface of spider thrust surface facing downward or toward gear teeth 4 Align marks on carrier sections and position carrier halves together Install retaining bolts and tighten to specifications Lockout Clutch Assembly Fig 70 115 Disassembly 1 Remove front side gear from input shaft assembly and remove thrust washer roller bearings 123 and spacers from front side gear bore Note position
55. extremely careful not Se Ka NOTICE The black to score the housing excessive Wear balls are smaller than the bore HOUSING ASSEMBLY silver balls The black Inspect for burrs and silver balls must be Remove retaining ring installed alternately into with snap ring pliers the rack piston and J 4245 return guide to maintain rack piston to worm gear preload DISASSEMBLE ASSEMBLE 2 Install parts as shown Using screw driver pry seals and washers from bore TEFLON SEAL AND RING PITMAN SHAFT SEAL If replaced lubricate new seal SINGLE LIP and O ring with power steering fluid PITMAN SHAFT SEAL DOUBLE LIP RETAINING RING Turn worm until worm groove is aligned with the lower SEAL BACK UP WASHER ball return guide hole NEEDLE BEARING Remove only if it 1 needs replacing Bearing WORM Slide all the way remover into the rack piston J 6278 M Lubricate balls with power steering fluid Install balls through Before assembling rack ball return guide hole in housing ball retainer while rotating worm J 21552 must be inserted counterclockwise into rack to allow removal of worm 1 GUIDE Alternately install remainder of balls and retain with M acl Installer l grease at each end of guide J 22407 When tool bottoms on housing bearing is fully installed SCREW Tighten t
56. facing front of transmission case drive replacement bushing into case until 040 to 055 above selective washer face Stake bushing with tool J 21465 10 Stake marks to be in bushing lubrication grooves INSPECTION OF CONVERTER 1 Check converter for leaks as follows Fig 7A 138C a Install Tool J 21369 and tighten b Apply 80 psi air pressure to tool c Submerge in water and check for leaks 2 Check converter hub surfaces for signs of scoring or wear Converter End Clearance Check Figs 7 139 and 7A 140C 1 Fully release collet end of Tool J 21371 8 2 Install collet end of Tool J 21371 8 into converter J 21371 8 J 8001 Fig 7A 140C Checking Converter End Clearance AUTOMATIC TRANSMISSIONS 400 7A 45 SNAP SPEEDOMETER DRIVE GEAR FLANGED THRUST WASHER LD FLANGE FLANGE See RACE RACE C REAR BEARING INTERNAL Ale GEAR Ce a O D FLANGE RACE LD FLANGE RACE e SNAP RING f MAIN SHAFT ab C m3 d a OUT PUT M CARRIER LD FLANGE es v ASSEMBLY RACE BEARING THRUST WASHER 1 NON METAL Cro FRONT INTERNAL REACTION GEAR RING S J ROLLER CARRIER J SUN GEAR ASSEMBLY ASSEMBLY SUN GEAR D FLANGE SHAFT RACE Fig 7A 141C Gear Unit Assembly Exploded View hub until it bottoms then tighten cap nut to 5 Ib ft Fig 7A 139C 3 Install Tool J 21371 3 and tighten hex nut to 3 Ib ft Fig 7A 140C 4 Install Dial Indicator J 8001 and set
57. in a vise 18 With Snap Ring Pliers J 4880 assemble snap ring into groove in air valve 19 Place air valve spring retainer on snap ring Assemble reaction bumper into groove in end of air valve 20 Position air valve return spring large end down on spring retainer 21 The three reaction levers are now placed into position with ears on wide end in slots in power piston The narrow ends will rest on top of air valve return spring 22 Position reaction plate with numbered side up on top of reaction levers Press down on plate until large ends of reaction levers pop up so plate rests flat on levers Be sure reaction plate is centered 23 Master cylinder piston rod and reaction retainer assembly is now assembled to the power piston 24 With round end of piston rod up and with reaction retainer held toward top of piston rod place small end of piston rod in hole in center of reaction plate Line up ears on reaction retainer with notches in power piston and push reaction retainer down until ears seat in notches 25 Maintain pressure on reaction retainer and position large lock ring down over master cylinder push rod 26 There is a lug on the power piston which has a raised divider in the center One end of lock ring goes under lug and on one side of divider 27 As you work your way around power piston either way the lock ring goes over ear of reaction retainer under a lug on power piston and so forth until other end of lo
58. shim These shims cannot be used when rebuilding the carrier as they may break when tapped into place J 22888 Fig 3B Differential Bearing Removal OVERHAUL MANUAL Fig 4B Differential Bearing Installation 10 Install left shim first then wedge right shim between bearing cup and spacer Position shim so that chamfered side is outward or next to spacer If shim does not have sufficient chamfer or lead around O D to allow easy installation without scraping spacer file or grind chamfer before installing 11 If difficulty is encountered in installing shim partially remove case and slide case and shim into position Tap shim into position using a soft faced hammer while rotating differential case with free hand as shown in figure 9B 12 Install bearing caps in original position and torque to 60 ft Ibs At this point the differential side bearings are properly preloaded If any adjustments are required in later procedures make sure the preload remains as established in step 9 If backlash is changed in later steps be sure the total thickness of the two shim packs does not change 13 Mount a dial indicator on the carrier and check the backlash between the ring gear and pinion as shown in figure 10B The backlash should be within the range of 0 005 0 008 Check gear lash at four different equally L PRESS RAM ADAPTOR PLUG Fig 5B Ring Gear to Case Installation Fig 6B Installing Gaging Tool space
59. thrust washers and roller needle bearing 5 Inspect pinion pocket thrust faces for burrs and remove if present 6 Install eighteen 18 needle bearings into each pinion Fig 7A 130C Removing Planet Pinion Pin using petrolatum to hold bearings in place Use pinion pin as guide Fig 7A 131C 7 Place a bronze and steel washer on each side of pinion so steel washer is against pinion hold them in place with petrolatum 8 Place pinion assembly in position in carrier and install a pilot shaft through rear face of assembly to hold parts in place 9 Drive a new pinion pin into place while rotating pinion from front being sure that headed end is flush or below face of carrier Fig 7A 132C 10 Place a large punch in a bench vise to be used as an anvil while staking opposite end of pinion pin in three places Both ends of pinion pins must lie below face of carrier or interference may occur OUTPUT SHAFT REAR INTERNAL GEAR SUN GEAR AND SHAFT Output Shaft 1 Inspect bushing for wear or galling If replacement is necessary proceed as follows a Thread Tool J 21465 16 into bushing and using Slide Hammer J 2619 remove bushing b Using Tool J 21465 1 with drive handle J 8092 install bushing into place until tool bottoms 2 Inspect bearing and thrust washer surfaces for damage 3 Inspect governor drive gear for rough or damaged teeth 4 Inspect splines for damage 5 Inspect drive lugs for damage 6 Inspe
60. 1 Install parts as shown shown See below VALVE ASSEMBLY Retaining ring access hole SHAFT TO WORM O RING SEAL SHAFT TO WORM RETAINING RING Assemble worm to valve RETAINING RING Install with curved in end on same side as access hole 8 DISASSEMBLE AND ASSEMBLE VALVE DISASSEMBLE 1 Disassemble parts as shown ASSEMBLE 2 Assemble parts as shown VALVE BODY RING VALVE BODY VALVE SPOOL in STUB SHAFT Y Q Jh VALVE BODY 5 ci 7 Shaft cap A RING teflon SPOOL TO BODY O RING B Remove and install stub shaft Pull cap out approx 6 mm Y4 Zn lightly on wood block Pin on shaft and hole in spool Disengage to remove C Remove and install spoo D Engage stub shaft Rotate while removing or installing N Z 1 ne Le SE Lubricate spool and body with power steering fluid Notch must fully engage pin and cap must seat against shoulder Fig 3B3 3C Overhaul 605 Gear Chart C OVERHAUL MANUAL 3B 10 STEERING 9 REMOVE AND INSTALL STUB SHAFT SEALS AND BEARINGS Clean end of housing to prevent dirt from entering gear Remove parts as shown being careful not to score housing bore Remove stub shaft needle bearing and upper thrust bearing if required Put a finger into the stub shaft cavity and hook it onto the upper thrust bearing race Turn the race while p
61. 1 2 modulator valve into the 1 2 modulator bushing aligning the spring in the bore of the modulator valve Install parts into the valve body bore b All other models Install the 1 2 regulator valve regulator spring and 1 2 detent valve open hole first into the 1 2 modulator bushing aligning the spring in the bore of the detent valve 15 Compress bushing against spring and install repa retaining pin er Lk 16 Install manual valve with detent pin groove to the 1 right DETENT REGULATOR DETENT VALVE VALVE Fig 7A 68C Installing Detent Regulator Valve and Detent Valve 400 7 22 AUTOMATIC TRANSMISSIONS r REGULATOR BOOST VALVE BRO BUSHING AND VALVE REGULATOR SPRING Fig 7A 69C Removing Pump Regulator Valve Snap Ring Oil Pump Disassembly Inspection and Assembly Disassembly 1 Place oil pump assembly in hole in bench or holding fixture J 6116 with J 21364 adapter 2 Compress regulator boost valve bushing against pressure regulator spring and remove snap ring using J 5403 pliers Fig 7A 69C 3 Remove regulator boost valve bushing and valve 4 Remove pressure regulator spring 5 Remove regulator valve spring retainer and spacer s if present Fig 7A 70C 6 Remove pump cover to body attaching bolts SPRING RETAINER WASHER PRESSURE REGULATOR SPACER REGULATOR VALVE PUMP ASSEMBLY J 6116 Fig 7A 70C Removing Pressure Regulator Valve PUMP DR
62. 1 66 1 77mm 1 79 1 90mm 1 92 2 03mm 2 05 2 16mm 2 18 2 29 2 31 2 42mm 2 44 2 55mm 2 57 2 68 2 70 2 81mm 2 83 2 94mm Black Light Green Scarlet Purple Cocoa Brown 8 Orange Yellow Light Blue 2 96 3 07mm 3 09 3 20mm 3 22 3 33mm a Pink 3 35 3 46mm 3 48 3 59mm Gray Fig 7A 20A Front Unit End Play Washer Chart Fig 7A 22A Removing Pump Assembly j Do not remove J 25013 5 or J 250131 1 2 Pump a If necessary remove pump oil seal and discard Fig 7A 21A b Remove remaining pump to case bolts and washers discard washers TURBINE SHAFT amp FORWARD CLUTCH c Using J 24773 tool remove pump assembly pump ASSEMBLY to case gasket and discard gasket Fig 7A 22A 3 Forward and Direct Clutch a Grasp turbine shaft and remove direct and forward clutch assemblies Fig 7A 23A b Lift direct clutch assembly off forward clutch assembly The direct to forward clutch thrust washer may stick to the end of the direct clutch housing when it is removed from the forward clutch housing DIRECT CLUTCH HOUSING Fig 7 A 23A Removing Forward and Direct Clutch 4 Remove intermediate band assembly Fig 7A 24A Assemblies PUMP SEAL INTERMEDIATE BAND A 38 Fig 7A 24A Removing Intermediate Band Assembly Fig 7A 21A Removing Oil Pump Seal IAUL MANUAL INTERMEDIATE ANCHOR PIN Fig 7A 25A Removing Intermediate Band Anchor Pin 5 Remove band a
63. 10 Check valve operating at entry 020 minimum with a feeler gage holding governor as shown with governor weights extended completely outward Fig 7A 58C 11 Check valve opening at exhaust 020 minimum with a feeler gage holding governor as shown with governor weights completely inward Fig 7A 59C Governor Driven Gear Replacement To facilitate governor repair in the field a governor driven gear and replacement pins are available for service use The service package contains a nylon driven gear two governor weight retaining pins and one governor gear retainer split pin Replacement of gear must be performed Fig 7A 59C Checking Valve Opening With Weight Inward AUTOMATIC TRANSMISSIONS 400 7 17 Fig 7A 60C Removing Governor Gear Retaining Pin with care in the following manner 1 Drive out governor gear retaining split pin using small punch Fig 7A 60C 2 Support governor on 7 64 inch plates installed in exhaust slots of governor sleeve place in arbor press and 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 7 64 inch plates installed in exhaust slots of sleeve position new gear in sleeve and 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 on shoulder 5 A new pin hole
64. 13 install bushing from interior of case to 3 16 from front surface with crimpled line in bushing located between the 10 o clock and the 2 o clock position Stator Shaft Front Bushing With stator shaft properly supported remove front bushing using tool J 21465 16 and slide hammer with adapter J 2619 01 fig 7A 100B Using tool J 21242 7 and drive handle J 8092 install bushing to 250 from face fig 7A 101B J 8092 DRIVE HANDLE 1 21424 7 AND STATOR SHAFT ASSEMBLY Fig 7A 101B Installing Stator Shaft Front Bushing 1 23062 2 Fig 7A 102B Installing Inner and Outer Stator Shaft Bushing Stator Shaft Rear Bushing With stator shaft properly supported remove front bushing fig 7A 102B Place tool J 21424 7 and drive handle J 8092 with extension J 21465 13 through front of stator shaft and drive out two 2 rear bushings Using tool J 23062 2 and extension J 21465 13 install inner bushing to approximately 1 5 32 below front face and outer bushing 3 32 below front face fig 7A 102B Install new front bushing fig 7A 101B Input Ring Gear Bushing With input ring gear properly supported remove bushing using tool J 23062 5 and drive handle J 8092 Using tool J 23062 5 and drive handle J 8092 install bushing to approximately 1 16 below rear face inside gear end fig 7A 103B J 23062 5 INPUT RING GEAR Fig 7A 103B Installing Input Ring Gear Support Bushing AUTOMATIC TR
65. 17B Installing Pinion Front Bearing Cup REAR AXLE DIFFERENTIAL 4B 9 Ki ESSI E E cu SES CS Fig 18 Plate Installed 6 Tighten nut until all end play is removed from drive pinion When no further end play is detectable and when Holder J 8614 11 will no longer pivot freely as pinion is rotated preload specifications are being neared Further tightening should be done only after nut and washer installation and preload has been checked 7 While observing the preceding caution carefully set preload drag at 20 25 inch pounds on new bearings or 10 15 inch pounds on reused bearings Use an inch pound torque wrench such as J 5853 as shown in figure 24B to measure the rotating torque After torque has been checked final tightening should be done very carefully For example if when checking torque was found to be 5 inch pounds additional tightening of the pinion nut as little as 1 8 turn can add 5 additional inch pounds drag Therefore the pinion nut should be further tightened only a little at a time and torque should be checked after each slight amount of tightening Exceeding torque specifications may compress the collapsible spacer too far and require its replacement Fig 19B Measuring Rotating Torque OVERHAUL MANUAL 4B 10 REAR AXLE DIFFERENTIAL 1 21777 45 DIAL INDICATOR rM LZ LARGE STEP NOTE SELECT THE GAUGING BUTTON WITH THE WORDS 10 SERIES TRUCK
66. 26271 without driver handle in position and Rotor and Bearing assembly aligned with the Front Head as illustrated drive the assembly part way onto the head Figure 1D 87 AIR CONDITIONING COMPRESSOR OVERHAUL 1D 31 BEARING STAKE LOCATIONS Figure 1D 85 R 4 Rotor and Bearing Assembly C Plug clutch coil connector onto Clutch Coil D Position the Clutch Coil so the 3 locating tabs will align with the holes in the head and continue to drive the Rotor and Bearing assembly onto the front head E Install the retainer ring Figure 1D 81 F Reassemble the Clutch Plate and Hub with the shaft key onto the shaft with Installer J 9480 1 until 020 to 040 air gap is obtained J J 8092 DRIVER HANDLE J 9481 PULLEY BEARING AND PULLEY INSTALLER ROTOR BEARING Figure 1D 86 Installing R 4 Clutch Rotor Bearing G Install shaft lock nut Torque to 12 ft Ibs 4 REPLACE ROTOR AND BEARING ASSEMBLY ON BENCH Reassemble the Rotor and Bearing assembly to the front head of the compressor using Rotor Bearing Installer J 26271 With Installer assembled to the Universal Handle J 8092 as shown in Figure 1D 88 Figure 1D 87 Installing R 4 Rotor and Bearing Assembly On Car force will be applied to the inner race of the bearing when installing the assembly onto the front head of the compressor 5 Install rotor and bearing assembly retainer ring using Snap Ring Pliers J 6083 324 see Figure 1D 81 6 Apply sealer
67. 3 Install vacuum modulator and retainer clip Torque bolt to 130 inch pounds NOTICE Position retainer with tangs pointing toward modulator Intermediate Clutch Accumulator Refer to Figures 7A 54B and 7A 55B l Install intermediate clutch accumulator piston assembly 2 Install intermediate clutch accumulator spring 3 Install new O ring seal in groove in case before installing cover 4 Install intermediate clutch accumulator cover and retaining ring using tool J 23069 AUTOMATIC TRANSMISSION 350 7A 37 SPECIFICATIONS TORQUE SPECIFICATIONS Pump Cover to Pump Body 17 ft Pump Assembly to Case Valve Body and Support Plate Parking Lock Bracket Oil Suction Screen Oil Pan to 130 in Extension to Case Modulator Retainer to Case Inner Selector Lever to Shaft Detent Valve Actuating Bracket Converter to Flywheel Bolts Under Pan to Transmission Case Transmission Case to Engine Oil Cooler Pipe Connectors to Transmission Case Straight Pipe Fitting Tapered Pipe Fitting Oil Cooler Pipe to Connectors Gearshift Bracket to Frame Gearshift Shaft to Swivel Manual Shaft to Bracket Detent Cable to Transmission Intermediate Band Adjust Nut OVERHAUL MANUAL J 8763 02 J 3289 20 J 8092 J 21465 13 J 23062 3 J 23062 7 J 21465 15 J 23329 J 9534 01 J 23327 J 23062 2 TOWO ORO J 23062 1 J 21424 9 CRM ZS WN J 21424 7
68. 35 36 37 38 39 40 41 42 43 First and Second Speed Clutch Sliding Sleeve First Second Speed Clutch Assembly First Speed Gear Synchronizing Ring First Speed Gear First Speed Gear Sleeve Rear Bearing Snap Ring Thrust Washer Rear Bearing Rear Bearing Retainer Washer Selective Fit Snap Ring Reverse Gear Snap Ring Speedometer Drive Gear Reverse Idler Front Thrust Washer Flat Reverse Idler Gear Front Snap Ring Reverse Idler Gear Rear Thrust Washer Tanged Reverse Idler Shaft Reverse Idler Shaft Lock Pin and Welch Plug A4 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 Rear Bearing Retainer Case Extension Gasket Reverse Shifter Shaft Detent Ball Reverse Shifter Shaft Ball Detent Spring Case Extension Extension Bushing Rear Oil Seal Reverse Shifter Shaft Lock Pin Reverse Shifter Shaft Ring Seal Reverse Shift Fork Reverse Shifter Shaft and Detent Plate Reverse Shifter Lever Speedometer Driven Gear and Fitting Retainer and Bolt O Ring Seal Washer Tanged Spacer 050 Bearing Rollers 28 Countergear Countergear Roller Spacer Fig 7B 2K Exploded View of 4 Speed 83mm Transmission 63 64 65 66 67 68 69 70 71 72 73 Lip Seals 75 76 77 78 Countershaft Countershaft Woodruff Key Gasket Forward Speed Shift Forks First and Second Speed Gear Shifter Shaft and D
69. 4 CLUTCH SUPPORT LOW AND REVERSE CLUTCH SUPPORT RETAINER SPRING inn Fig 7A 107B Installing Low and Reverse Clutch Support Assembly OVERHAUL MANUAL 3 Install spring retainer and retaining ring Using tool J 23327 compress return seat so spring retainer retaining 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 torrington bearing into output ring gear support 6 Install output shaft assembly int case o 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 alternating with face plates Install low and reverse clutch support retainer anti clunk spring 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 7A 107B Make certain the splines on inner race of the roller clutch align with splines on reaction carrier 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 thrust washer and sun gear drive shell assembly 13 Install output carrier a
70. 5 Without installing any O rings or bushings assemble one end of the new Service Discharge Cross Over Tube into the hole in the front cylinder half Figure 1D 58 and 1D 59 Be sure the flattened protion of this tube faces the inside of the compressor to allow for axial plate clearance Figure 1D 59 Cylinder Half 6 Now rotate the shaft to position the pistons in a stairstep arrangement then carefully place the Rear 1D 20 AIR CONDITIONING COMPRESSOR OVERHAUL J 24608 5 J 24608 2 RING INSTALLER RING INSTALLER J 24608 6 GUIDE RING SIZING TOOL J 24608 1 PISTON RING GAGE Q J 24608 5 RING INSTALLER e J 24608 3 O RING Figure 1D 50 A 6 Teflon Piston Ring Installing Sizing and Gaging Tools TEFLON PISTON RING ei J 24608 2 RING INSTALLER GUIDE TEFLON RING Figure 10 51 A 6 Teflon Piston Ring Positioned on Ring Installer Figure 1D 52 Installing A 6 Teflon Piston Ring Guide Cylinder Half over the shaft and start the pistons into the 8 When all parts are in proper alignment tap with a cylinder bore Figure 1D 60 clean wooden block and mallet to seat the rear half of the cylinder over the locating dowel pins If necessary clamp the cylinder in Compressing Fixture J 9397 to complete drawing the cylinder halves together 7 When all three Piston and Ring assemblies are in their respective cylinders align the end of the discharge cross over tube with the hole in the rear half of the
71. 56 REAR AXLE DIFFERENTIAL SPECIAL TOOLS 4 G Q ees 1 J 6266 n OVERHAUL MANUAL J 23597 1 22779 22175 J 22761 J 25299 J 9458 J 5590 J 8001 J 5748 8 9 10 1 12 13 15 19 Pinion Setting Gauge 9 J 6266 28 Barrel Adapter 10 J6266 25 Plug TT J 6266 52 Gauge Plate 12 J 6266 53 Gauge Plate J 6266 31 Adapter Rings 13 Pinion Setting Gauge 7 1 2 J21777 1 Arbor 14 J 21777 45 Side Discs J 21777 29 Gauge Plate 15 J 21777 42 Front Bearing Plug 16 J 21777 43 Stud 17 Side Bearing Shim Gauge 322779 Strap Side Bearing Installer 8 3 4 8 7 87 18 8 1 2 7 1 2 19 Companion Flange Installer Passenger Car 20 Pinion Rear Bearing Cup Installer Truck Axle 21 Dial Indicator Set 22 Positraction Torque Measuring Adapter Fig 1T Special Tools 8 1 2 and 8 7 8 lt L 20 22 21 J 22888 Differential Bearing Remover J 7079 2 Driver Handle Insert Type J 8092 Driver Handle Threaded Type J 8609 01 Pinion Rear Bearing Installer Passenger Car J 5590 7 1 2 J 8612 Rear Pinion Bearing Remover J 253200 7 1 2 J 8608 Pinion Rear Bearing Cup Installer J 7817 7 1 2 J 1313 0 150 Ft Lbs Torque Wrench 55853 In Lbs Torque Wrench J 7137 Pinion Front Bearing Cup Installer Used with J 8092 J 7817 7 1 2 J 8107 4 Differential Bearing Remover Installer Used with J 9537 and J 22779 J 8614 Companion
72. 6 Low Speed Gear 27 Washer 49 Front Output Shaft Seal 7 Thrust Washer amp Locating Pin 28 Locknut 50 Front Output Brg Retainer 8 Gasket 29 Rubber Spline Seal 51 Rubber Spline Seal 9 Input Brg Retainer 30 Rear Output Yoke 52 Locknut 10 Input Brg 31 Rear Output Seal 53 Front Output Yoke 11 Brg Outer Ring 32 Shims 54 Countergear 12 Brg Retaining Ring 33 Input Shaft O Ring 55 Countergear Spacers and Bros 13 Thrust Washer Locating Pin 34 Input Shaft Pilot Bearings 56 Countergear Shaft Lubricating Washer amp Spacer 35 Differential Carrier Assembly 57 Countergear Thrust Washer 14 Intermediate Chain Housing 36 Spring Washer Cup 58 Gasket 15 Drive Shaft Sprocket 37 Lockout Clutch Spring 59 Brg Retainer Gasket 16 Gasket 38 Snap Ring 60 Brg Outer Ring 17 Sliding Lock Clutch 39 Snap Ring 61 Input Gear Brg 18 Rear Output Housing 40 Front Output Rear Brg Cover 62 Input Gear Seals 2 19 Rear Output Front Brg 41 Front Output Rear Brg 63 Brg Snap Ring 20 Vent 42 Front Output Drive Sprocket 64 Input Gear 21 Oil Seal 43 Gasket 65 Input Gear Brg Retainer Fig 7D 10S Model 203 Transfer Case Cross Sectional View OVERHAUL MANUAL TRANSFER CASES 7D 13 46 ional Two Piec Construction Ces 6 3 HA 17199010000 lt 51 52 53 54 55 56 57 58 59 60 2 a 5 J H d 19 i SZ 62
73. 7A 32 Oil 7 17 Stator Shaft Front Bushing esee 7 32 Disassembly aan Ee 7 17 Stator Shaft Rear Busbhing see 7 33 Insp cti n 5252 1e EE ER cs 7A 17 Input Ring Gear 7A 33 EE 7A 17 Sun Gear Bushing eee 7A 33 Direct Clutch and Intermediate Overrun Reaction Carrier Bushing sess 7A 33 Roller 7 21 Direct Clutch Bushing 7 33 Disassembly ce toe ia 7 21 Transmission Assembly eee 7 34 Inspection iter E RP eR 7A 23 Transmission Internal Components 7A 34 Reassembly hee ed 7A 23 Speedometer Drive Gear and Extension 7 35 Forward Clutch eere esee 7A 24 Manual Linkage nete etti 7A 35 Disassembly 20 tese epe 7A 24 Intermediate Servo Piston Insp ctiOn i oe ette tote 7A 25 Valve Body Oil Pan and 74 35 Reassembly It ade i enter ten 7A 26 Governor and Vacuum 7 36 Sun Gear and Sun Gear Drive Shell 0 seeeeeee 7 27 Intermediate Clutch Accumulator 7 36 Disassembly n p nie 7A 28 Specifications ue 7A 37 Inspection 2o eei 7 28 Kg EE 7 38 Assembly EET rre aa 7 28 OVERHAUL MANUAL 350 7A 2 AUTOMATI
74. DIFFERENTIAL 48 41 Fig 9D Assembling Clutch Pack 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 See figure 13D 19 Install the pinion shaft and lock screw to retain side gears until axle shafts are installed 20 Check alignment of spring retainer with side gears Slight movement of the spring pack can be made if necessary 21 Install side bearings and ring gear to case using procedure outlined for the conventional differential 22 Place differential in carrier and adjust bearings and backlash as outlined for the conventional differential 23 Check operation of unit as follows a Raise rear of vehicle until rear wheels are off the ground and remove one wheel and tire assembly b Attach Adapter J 5748 to axle shaft flange and install a 1 2 13 bolt into adapter shown in figure 14D c With wheel and tire assembly still on vehicle held firmly to prevent turning measure torque required to rotate opposite axle shaft with a 0 150 Ib torque wrench attached to J 5748 Torque required to rotate axle shaft should be no less than 40 ft Ibs Fig 8D Removing Side Gear Fig 10D Measuring Pinion Gear Tooth Clearance OVERHAUL MANUAL 4B 42 REAR AXLE DIFFERENTIAL IN Fig 11D Spring Pack Compressed for Installation Fig 12D Installing Spring Pack Compression Tool Corvette Fig 13D
75. Disassembly of Transfer 7D 8 Input Gear Bearing 1 7D 15 Cleaning and Inspection eese 7D 10 Input Gear Bearing Retainer Seal Replacement 70 16 Subassembly seen 7D 10 Rear Output Shaft Housing Assembly 7D 16 Differential Carrier 7D 10 Front Output Shaft Bearing Retainer Seal Lockout Clutch Assembly esses 7D 11 Replacement 70 17 Input Shaft Assembly sees 7D 11 Front Output Shaft Rear Bearing Replacement 7D 17 Range Box Assembly 7D 11 Assembly of Transfer 7D 17 DISASSEMBLY OF TRANSFER CASE Refer to Figs 7D 10S 7D 11S 7D 12S for cross sectional and exploded views of the transfer case 1 Position transfer case on work bench or suitable work table If lubricant was not drained from unit prior to removal from vehicle remove front output rear cover and P T O cover lower bolts and drain lubricant into waste container 2 Using Tool J 8614 1 loosen rear output shaft flange retaining nut Fig 7D 3S 3 Using Tool J 8614 1 remove front output shaft flange retaining nut washer and flange Tap dust shield rearward on shaft away from bolts to obtain clearance to remove bolts from flange and allow installation of Tool J 8614 1 4 Remove b
76. FOR C C O T A C SYSTEMS see Air Conditioning Section CONTENTS OF THIS SECTION Minor Repair Procedures for the A 6 COM PLESSOF E 1D 2 A 6 Compressor Clutch Plate and Hub Assembly eee eene 10 2 A 6 Compressor Pulley and Bearing Assembly sites etd eo Ee AE 1D 5 A 6 Compressor Pulley 1D 7 A 6 Compressor Clutch Coil and Housing Assembly eseeessesesssrersrsrsesersrserrsrss 1D 7 Major A 6 Compressor Repair Procedures coiere amo 1D 8 A 6 Compressor Shaft 1D 9 Seal Leak Detection 1D 9 A 6 Compressor Pressure Relief Valve or Pressure Switch 10 11 6 Compressor Cylinder and Shaft ASSEMBLY rentre erri ees 1D 11 nne teneret 1D 12 Disassembly AEN 1D 14 Gaging 0 24 4 1D 15 A 6 Teflon Piston Ring Replacement 1D 19 Assernibly 5 rnnt rire 1D 19 sachen 1021 Minor Repair Procedures for the RA CORIDEeSSOF nere extis ete deu 1D 26 R 4 Compressor Clutch Plate and Hub Assembly onis ee 1D 26 R 4 Compressor Clutch Rotor and or Bearing eee 1D 26 Replace Rotor and Bearing For all practical purposes all vehicles make use of the same air conditioning 4 and 6 cylinder compressors Actual differences between compressors are found in their mounting brackets pulleys c
77. Fig 20B Gaging Tools Installed in Carrier 8 Rotate the pinion several times to assure that bearings have been seated Check preload again If drag has been reduced re set preload to specifications CHECKS AND ADJUSTMENTS Four adjustments are essential for proper operation of the differential and its related parts These adjustments are a Pinionn Bearing Preload b Side Bearing Preload c Pinion Depth and d Ring Gear to Pinion Backlash Pinion Bearing Preload is set to specifications in step 7 of Drive Pinion Installation and Adjustment Side Bearing Preload is set to specifications in step 9 of Differential Case Installation and Adjustment Following service to the Differential Case or to the Drive Pinion and Ring Gear a Gear Tooth Contact Pattern Check must be made to verify the accurace of the work in setting the pinion depth and the ring gear to pinion backlash Gear Tooth Contact Pattern Check Prior to final assembly of the differential a Gear Tooth Contact Pattern Check is necessary to verify the correct relationship between ring gear and drive pinion Gear sets which are not positioned properly may be noisy or have short life or both With a pattern check the most desireable contact between ring gear and drive pinion for low noise level and long life can be assured 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 sid
78. Fig 7B 16J Turn the front of the mainshaft upward Install the following components on the mainshaft 1 Install the third speed gear with clutching teeth upward the rear face of the gear will butt against the flange on the mainshaft 2 Install a blocking ring with clutching teeth downward over the synchronizing surface of the third speed gear All four blocker rings used in this transmission are identical 3 Install the 3rd and 4th synchronizer assembly with the fork slot downward on the mainshaft until it bottoms out against flange Be sure the notches of the blocker ring align with the keys at the synchronizer assembly Fig 7B 13J Installing Extension Oil Seal OVERHAUL MANUAL 7B 22 MANUAL TRANSMISSION SCREWDRIVER Fig 7B 14J Removing Bearing Retainer Oil Seal 4 Install synchronizer hub to mainshaft snap ring Fig 7B 7J Both synchronizer snap rings are identical Turn the rear of the mainshaft upward Install the following components on the mainshaft 5 Install the second speed gear with clutching teeth upward the front face of the gear will butt against the flange on the mainshaft 6 Install a blocker ring with clutching teeth downward over synchronizing surface of the second speed gear 7 Install the first and second synchronizer assembly with fork slot downwards Fig 7B 15J Installing Bearing Retainer Oil Seal OVERHAUL MANUAL 8 Install synchronizer hub to mainshaft snap ring Fig
79. Flange Holder J 22864 1 2 Pinion Seal Gauge Plate 7 1 2 8 1 2 8 7 8 J 23911 Pinion Oil Seal Installer 7 1 2 8 1 2 8 7 8 J 0270 14 Pinion Rear Bearing Cup Installer Truck Axle Used with J 8092 Ring Gear Differentials 11 12 17 J 22912 J 1453 J 8107 J 8107 3 J 22888 J 1364 J 1488 J 8608 J 5853 J 8092 J 8614 J 22281 Press Plate Pinion Bearing Press Plate Differential Bearing Puller Set Adapter Plug Differential Side Bearing Remover Pinion Bearing Ring Drive Differential Side Bearing Replacer Drive Pinion Rear Bearing Cup Installer Used with J 8092 In Lbs Torque Wrench Drive Handle Companion Flange Holder and Remover Pinion Flange Oil Seal Installer 13 14 15 16 17 18 19 20 21 22 23 24 REAR AXLE DIFFERENTIAL 48 57 J 8001 J 0972 J 24381 J 24383 J 24384 J 24385 J 24430 J 24432 J 23322 J 24429 J 24434 J 24433 22 Dial Indicator Set Differential Nut Wrench Pinion Rear Bearing Cup Installer Side Bearing Installer Pinion Oil Seal Installer Case Spreader Tool Side Bearing Installer Pinion Rear Cup Installer Pinion Straddle Bearing Installer Adjusting Nut Wrench Pinion Oil Seal Installer Pinion Rear Bearing Installer Fig 2T Special Tools 10 1 2 and 12 1 4 Ring Gear Differentials OVERHAUL MANUAL FRONT WHEEL DRIVE 4 1 SECTION 4C FRONT AXLE DIFFERENTIAL 4 WHEEL DRIVE CONTENTS Front Axle Differential
80. Gear Washer Rear Bearing Snap Ring Mainshaft Fig 7B 8K Mainshaft Assembly Components OVERHAUL MANUAL 7B 30 MANUAL TRANSMISSION Fig 7B 9K Removing 3 4 Clutch Assembly Retainer 4 Coat I D of bushing and seal with transmission lubricant Install new seal using Tool J 21359 Fig 7B 15K Drive Gear Bearing Retainer Oil Seal Replacement 1 Pry out old seal 2 Using a new seal install new seal into retainer using Tool J 21359 until it bottoms in bore Fig 7B 16K Lubricate LD of seal with transmission lubricant Reverse Shifter Shaft and or Seal Replacement 1 With case extension removed from transmission the reverse shifter shaft lock pin will already be removed see Step 5 under Transmission Disassembly 2 Remove shift fork 3 Carefully drive shifter shaft into case extension allowing ball detent to drop into case Remove shaft and ball detent spring Remove ring seal from shaft BEARING RETAINER SNAP RING PLIERS Fig 7B 10K Removing Rear Bearing Retainer OVERHAUL MANUAL Fig 7B 11K Removing Rear Bearing Snap Ring 4 Place ball detent spring into detent spring hole and start reverse shifter shaft into hole in boss 5 Place detent ball on spring and while holding ball down push the shifter shaft into place and turn until the ball drops into place in detent on the shaft detent plate 6 Install O ring seal on shaft 7 Install shift fork Do not drive the shi
81. HUB ASM CLUTCH PLATE AND HUB ASM Figure 1D 80 Installing R 4 Clutch Plate and Hub Assembly J 25008 1 HOLDING FIXTURE Figure 1D 78 R 4 Clutch Plate Hub Assembly Removal CLUTCH ROTOR RETAINER RING Figure 1D 81 Removing R 4 Rotor and Bearing Assembly Retainer Ring If the Clutch Rotor and or Rotor Bearing only are to be replaced bend the lockwashers away from the pulley rim mounting screws see Figure 1D 79 and remove the six mounting screws and special lock washers before proceeding with Step 3 Discard the lock washers 3 Install Rotor and Bearing Puller J 25031 2 down into the rotor until the Puller arms engage the recessed edge of Figure 1D 79 Installing R 4 Shaft Key the rotor hub Hold the Puller and arms in place and tighten the Puller screw against the Puller Guide to remove the Clutch Rotor and Bearing assembly Figure 10 82 and 1D 83 being careful not to drop the Puller Guide 1D 30 AIR CONDITIONING COMPRESSOR OVERHAUL 4 If the pulley rim mounting screws and washers were removed in Step 2 only the Clutch Rotor and Bearing assembly will be removed for replacement The Clutch Coil and Housing assembly is pressed onto the Front Head of the compressor with a press fit and will not be removed unless the pulley rim mounting screws are left securely in place and the pulley rim pulls the Coil and Housing assembly off with the total Clutch Rotor and Pulley Rim Assembly 5 Place the Rotor and B
82. Hydro Boost Explode Typical The Bendix Hydraulic Brake Booster utilizes the hydraulic pressure supplied by the power steering pump to provide power assist for brake applications The dual master cylinder is mounted to the output push rod end of the booster The procedures below include removal of the mounting bracket even though it is not necessary to remove the bracket for overhaul of the internal assembly Disassembly Fig 5 1 1 Secure the booster in a vise bracket end up and use a hammer and chisel to cut the bracket nut that secures the mounting bracket to the power section cut the nut at the open slot in the threaded portion of the housing Be careful to avoid damage to the threads on the booster hub Spread the nut and remove it from the power section Then remove the mounting bracket 2 Remove the pedal rod boot if equipped by pulling it off over the pedal rod eyelet 3 Place Tool J 24569 around the pedal rod and resting on the input rod end as shown in Figure 5 2 4 Place a punch or similar tool through the pedal rod from the lower side of Tool J 24569 Push the punch on through to rest on the higher side of the tool Lift up on the punch to shear the pedal rod retainer remove the pedal rod 5 Remove the remnants of the rubber grommet from the groove near the end of the pedal rod and from the groove inside the input rod end 6 With a small screwdriver pry the plastic guide out of the output push rod retai
83. Install Pulley and Bearing assembly as described in A 6 Compressor Pulley and Bearing Assembly Replacement procedure 4 Install Clutch Plate and Hub assembly as described in A 6 Compressor Clutch Plate and Hub Assembly Replacement procedure A 6 COMPRESSOR CLUTCH COIL AND HOUSING ASSEMBLY Remove 1 Remove Clutch Plate and Hub assembly as described in Compressor Clutch Plate and Hub Assembly Removal procedure 2 Remove Pulley and Bearing assembly as described in A 6 Compressor Pulley and Bearing Assembly Removal procedure NOTICE Position of terminals on coil housing and scribe location on compressor front head casting 3 Remove coil housing retaining ring using Snap Ring Pliers J 6435 3 26 Figure 1D 18 1D 8 AIR CONDITIONING COMPRESSOR OVERHAUL UNIVERSAL HANDLE J 8092 4 THIS RIDGE OF TOOL MUST BE UP WHEN INSTALLING BEARING PULLEY AND BEARING INSTALLER J 9481 4952 J 21352 Figure 1D 17 Installing Bearing on A 6 Pulley 4 Lift Coil and Housing assembly off compressor Replace 1 Position coil and housing assembly on compressor front head casting so that electrical terminals line up with marks previously scribed on compressor Figure 10 19 2 Align locating extrusions on coil housing with holes in front head casting 3 Install coil housing retainer ring with flat side of ring facing coil using Snap Ring Pliers J 6435 26 4 Install Pulley and Bearing assembly
84. Installer See Figure 1D 24 3 Coat the O ring and seal face of the new Seal assembly with clean 525 viscosity refrigerant oil Carefully mount the Seal assembly to Seal Installer J 9392 by engaging the tabs of the Seal with the tangs of the Installer Figure 1D 23 4 Place Seal Protector J 22974 Figure 1D 23 over end of compressor shaft and carefully slide the new Seal assembly down onto the shaft Gently twist the Installer 7 9392 CLOCK WISE while pushing the seal assembly down the shaft until the Seal assembly engages the flats on the shaft and is seated in place Disengage the Installer by pressing downward and twisting counter clockwise 5 Attach the ceramic Seal Seat to the Seal Seat Remover and Installer J 23128 and dip the ceramic Seat in clean 525 viscosity refrigerant oil to coat the seal face and outer surface Carefully install the Seat over the compressor shaft end and Seal Protector J 22974 and push the Seat into place with a rotary motion Take care not to dislodge the seat O ring However be sure Seal Seat makes a good seal with O ring Remove Installer J 23128 and Seal Protector J 22974 Figure 1D 22 6 Install the new seal seat retainer ring with its flat side against the Seal Seat using Snap Ring Pliers J 5403 21 See Figure 1D 21 Use the sleeve from Seal Seat Remover Installer J 23128 Figure 1D 22 to press in on the seal seat retainer ring so that it snaps into its groove 7 Install Compressor Leak Test F
85. Installing Spring Pack Fig 14D Measuring Positraction Rotating Torque CHEVROLET LIMITED SLIP FIGURE 15D Disassembly 1 Remove ring gear and side bearings following the procedures established for the conventional differential unit Remove pinion shaft 2 Using a wide blunt instrument such as a drift or block of wood drive the preload spring from the case 3 Support an axle shaft in a vise and slide the case into the shaft then turn the case to remove both pinions and thrust washers 4 Remove the case from the axle shaft and remove both side gears clutch packs and shims Mark the gears clutch packs and shims for reinstallation in same positions OVERHAUL MANUAL Inspection Check the clutch plates and discs for wear and signs of overheating Check the condition of the preload spring Check the gear teeth for signs of wear Replace parts as needed Clean all parts to be used for assembly The force required to compress the preload spring to 1 5 16 inches should be 300 30 Ibs Reassembly 1 Lubricate the clutch discs and plates with limited slip lubricant 2 Alternately position clutch plates and discs on a side gear beginning and ending with a clutch plate 3 Position the side gear clutch pack and original shim into the case PINION SHAFT PINION BOLT RING GEAR SIDE BEARING REAR AXLE DIFFERENTIAL 48 43 SPLINED DISC 3 FIXED DISC 4 THRUST Fig 15D Chevrolet L
86. OFF CAR 1 Follow applicable ON CAR PROCEDURES 2 For Leak Test use Compressor Test Fixture J 9625 as described in Step 7 of A 6 Compressor Shaft Seal Replacement procedure 3 See Figures 1D 99 1D 100 and 1D 101 R 4 COMPRESSOR PRESSURE RELIEF VALVE OR PRESSURE SWITCH When necessary to replace the Pressure Relief Valve or Pressure Switch if so located located in the compressor rear head casting Figures 1D 27 and 102 the valve switch assembly should be removed after PURGING THE SYSTEM OR REFRIGERANT A new valve switch and O ring coated with 525 viscosity refrigerant oil should be installed see DISCHARGING ADDING EVACUATING AND CHARGING PROCEDURES FOR A C SYSTEMS the AIR CONDITIONING section J 23128 SEAL SEAT REMOVER AND INSTALLER CERAMIC 0 SHAFT SEAL PROTECTOR Figure 10 99 Removing and Installing 4 Seal Seat Off J 9392 SHAFT SEAL REMOVER AND INSTALLER SHAFT SEAL PROTECTOR Figure 10 100 Removing and Installing 4 Seal Off Car R 4 COMPRESSOR FRONT HEAD AND OR O RING Remove 1 Discharge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR C C O T A C SYSTEM in the AIR CONDITIONING section 2 Perform steps through 4 of RA Compressor Clutch Rotor and or Bearing Removal procedure but do not loosen or remove the pulley rim mounting screws so as to remove the Clutch Rotor and Bea
87. Ob WD Clutch Gear Bearing Retainer Retainer Lip Seal Snap Ring and Washer Clutch Gear Bearing Clutch Gear 4th Speed Synchronizer Ring 3rd amp 4th Speed Clutch Assy 3rd Speed Synchronizer Ring 3rd Speed Gear 2nd Speed Gear 2nd Speed Synchronizer Ring 12 30 29 1st amp 2nd Speed Clutch Assy Ist Speed Synochronizer Ring Ist Speed Gear 15 Speed Gear Bushing Spacer Rear Main Bearing Snap Ring and Washer Reverse Gear Snap Rings Speedometer Gear Mainshaft 13 14 15 16 17 27 Thrust Washer Thrust Washer Idler Shaft Roll Pin Rear Gear Spacer Front Idler Gear Reverse Idler Shaft Countergear Countergear Sleeve Countergear Bearing Rollers Thrust Washers 9cuL NOISSIINSNV Yl MANUAL TRANSMISSION 78 27 14 15 16 17 18 19 20 21 22 Bearing Retainer Gasket Selective Fit Snap Ring Spacer Washer Bearing Snap Ring Main Drive Gear Bearing Transmission Case Reor Bearing Retainer Gasket Main Drive Gear Bearing Rollers 16 Washer Snap Ring Third and Fourth Speed Clutch Sliding Sleeve Fourth Speed Gear Synchronizing Ring Clutch Key Spring Clutch Hub Third Speed Gear Synchronizing Ring Third Speed Gear Mainshaft Clutch Keys 3 Second Speed Geor Second Speed Gear Synchronizing Ring 23 24 25 26 27 28 29 30 31 32 33 34
88. Place power unit with Holding Fixture J 22805 in an arbor press with rear housing up and secure to plate of press by a suitable means of holding Tool J 22805 fig 5 4B By using a 1 1 2 open end wrench on Tool J 22805 and allowing unit to turn against back of arbor press press will hold unit from turning 13 Place Spanner Wrench J 9504 over studs on rear shell fig 5 4B Use three washers and nuts to attach wrench to housing Use a suitable piece of pipe of approximately two inches I D and approximately three inches in length Place over plastic diaphragm plate hub Place a piece of flat stock steel over end of pipe and press rear housing down far enough to relieve tension of diaphragm rubber lip and spring 14 Rotate spanner bar counterclockwise until the lances in the edge of the rear housing are aligned with the cut outs in the front housing Considerable effort may be required to rotate the front housing CAUTION The diaphragm return spring is compressed in the power section and expands as the pressure on the housings is removed the housings do not separate when the screw has been turned slightly to reduce the pressure tap the housings with a rubber hammer to break the bond 15 Slowly release press to permit the two housings to separate 16 Continue to release press until diaphragm spring tension has been removed VALVE POPPET K Fig 5 2B Air Valve Rod Assembly SILENCER S x POPPET R
89. Place the three keys into hub slots and on top of spring then push sleeve fully onto hub to engage keys in sleeve Fig 7B 14B 5 Install remaining spring in exact same position as first spring Ends of both spring must cover same slots in hub and not be staggered Keys have small lip on each end When correctly installed this lip will fit over spring Fig 7 14 Extension Oil Seal Bushing If bushing in rear of extension requires replacement remove seal and use Tool J 5778 to drive bushing into extension housing Fig 7B 15B Using the same tool drive new bushing in from the rear Coat I D of bushing and seal with transmission lubricant then install new oil seal using Tool J 5154 Fig 7B 16B Clutch Bearing Retainer Oil Seal If the lip seal in the retainer needs replacement pry the old seal out and replace with a new seal using Installer Tool J 25233 or similar tool until seal seats in its bore Fig 7B 17B OVERHAUL MANUAL Fig 7B 16B Installing Extension Housing Seal ASSEMBLY OF MAINSHAFT 1 Install First Reverse synchronizer hub on output shaft splines by hand Slotted end of hub should face front of shaft Use an arbor press to complete hub installation on shaft and install retaining snap ring in most rearward groove NOTICE DO NOT attempt to drive hub onto shaft with hammer Hammer blows could damage hub and splines OIL RETURN TOOL SLOT J 25233 FRONT BEARING CAP Fig 7B 178 I
90. Plate 7 9625 on Rear Head of compressor 2 Attach center hose of Manifold Gage Set on Charging Station to a refrigerant drum standing in an upright position and open valve on drum 3 Connect Charging Station HIGH and LOW pressure lines to corresponding fittings on Test Plate J 9625 using J 5420 Gage Adapters NOTICE Suction port low side of compressor has large internal opening Discharge port hi side has smaller internal opening into compressor 4 Open LOW pressure control HIGH pressure control and REFRIGERANT control on Charging Station to allow refrigerant vapor to flow into compressor 5 Using Leak Detector check for leaks at Pressure Relief Valve Pressure Switch if so located on compressor compressor Shell to cylinder compressor front head seal and also rear head seal and oil charge port on 6 compressor and compressor Shaft Seal After checking shut off LOW pressure control and HIGH pressure control on Charging Station 6 If an external leak is present perform the necessary corrective measures and recheck for leaks to make certain the leak has been corrected 7 Loosen the Manifold Gage hose connections to the Gage Adapters J 5420 connected to the LOW and HIGH sides and allow the vapor pressure to release from the compressor 8 Disconnect both Gage Adapters J 5420 from the Test Plate J 9625 9 Rotate the COMPLETE compressor assembly not the crankshaft or drive plate hub slowly several turns to d
91. RACE Fig 7A 148C installing Center Support to Sun Gear Thrust Bearing and Races NOTICE When a new output carrier and or reaction carrier is being installed and if the front internal gear ring prevents assembly of the carriers replace the front internal gear ring with the SERVICE ring 16 Install center support to sun gear thrust races and bearings as follows Retain with petrolatum a Install large race center flange up over sun gear shaft b Install thrust bearing against race c Install second race center flange up Fig 7A 148C 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 7A 149C Fig 7A 149C Installing Roller into Roller Clutch Cage 400 7A 48 AUTOMATIC TRANSMISSIONS ROLLER CLUTCH ASSEMBLY Fig 7A 150C Installing Roller Clutch to Reaction Carrier 18 Install roller clutch assembly Fig 7A 150C into reaction Carrier 19 Install center support to reaction carrier thrust washer into recess in center support Retain with petrolatum Fig 7A 47C 20 Install center support into roller clutch in reaction carrier Fig 7A 151C With reaction carrier held center support should only turn counter clockwise after installation See Fig 7A 152C for check of roller clutch 21 Install J 21795 on gear unit assembly to hold units in place 22 Install output shaf
92. Removing Extension Housing Lip Seal OVERHAUL MANUAL EXTENSION HOUSING BUSHING Fig 7A 8B Removing Extension Housing Bushing REMOVAL OF EXTENSION SPEEDOMETER DRIVEN GEAR GOVERNOR OIL PAN AND SCREEN 1 Remove four housing to case attaching bolts 2 Remove extension housing form case and remove square cut 0 ring seal from extension housing 3 Remove extension housing lip seal using screw driver fig 7A 7B 4 If extension housing bushing is to be replaced collapse bushing fig 7A 8B and refer to Figure 7A 98B for installation 5 Install speedometer drive gear remover tool J 21427 01 and J 9539 bolts with J 8105 or suitable puller on output shaft and remove speedometer drive gear Remove retaining 6 Using a screwdriver and hammer gently tap along governor cover lip fig 7A 9B remove governor cover fig 7A 10B Do not attempt to pry the screwdriver between the case and governor cover as this could cause damage to the case Fig 7A 9B Removing Governor Cover APPLY SEALANT Fig 7A 10B Governor Cover and O Ring Seal NOTICE When reinstalling cover apply anaerobic sealant to cover sealing surface Be sure to install a new bail wire retainer since the loss of the governor cover could result in loss of fluid and damage to the transmission 7 Withdraw governor assembly from case fig 7A 11B and check governor bore and governor sleeve for scoring ASSEMBLY Fig 7A 1
93. TRANSMISSION 200 7A 33 Fig 7A 134A Checking Pump Body to Gear End Clearance 4 Inspect for chips in pressure regulator bore 5 Inspect stator shaft for damaged splines or damaged bushings 6 Inspect orifice plug see Fig 7A 135A If the plug requires replacement place new plug orifice end first into plug hole from the rough casting side Drive the plug flush to 25mm 010 below top of hole rough casting side Stake the top of hole two places to retain the plug Reassembly 1 Place pump body over hole in bench 2 Assemble pump cover to pump body with attaching bolts finger tight 3 Align pump cover and pump body using J 25015 Fig 7A 137A and place bolt or screwdriver through pump to case bolt hole and bench 4 Torque pump cover attaching bolts to 20 0 27 0 15 20 ft Ibs 5 Remove J 25015 6 Install pressure regulator spring guide valve with stem end out and bore plug hole side out Fig 7A 126A 7 Compress pressure regulator valve spring by pushing on bore plug with small screwdriver and install retaining ring Fig 7A 128A AIR BLEED ORIFICE CONVERTER 4 CONVERTER FEED OIL PRESSURE CONTROL ORIFICE SEAL DRAIN BACK HOLE REVERSE Fig 7A 135A Pump Cover Assembly OVERHAUL MANUAL 200 7A 34 AUTOMATIC TRANSMISSION Fig 7A 136A Pump Cover Oil Passages Fig 7A 137A Aligning Pump Cover and Pump Body GUIDE PINS 8 If removed install 3 new oil seal ri
94. amount To decrease backlash decrease right shim and increase left shim an equal amount OVERHAUL MANUAL l 2 3 4 m J 24385 J 22888 J 22175 J 5590 J 6368 8092 J 9276 2 Spreader Axle Carrier Puller Side Bearing Installer Side Bearing Installer Pinion inner and outer bearing cone Installer Pinion outer bearing cup use with J 8092 Driver Handle use with J 6368 Installer Pinion inner bearing 11 12 13 J 8614 01 J 23476 J 5341 J 8001 J 22912 J 23494 Fig 4C 13 Special Tools Chart 4C A FRONT WHEEL DRIVE 4 9 Holder and Remover Companion Flange Installer Companion Flange Gauge Pinion Depth Consists of Parts 1 SE 1065 1 2 5 2 6 2 9SS 1 10 1 58 with 1 micrometer Dial Indicator Set Press Plate Pinion bearing Installer Pinion oil seal use with J 23476 OVERHAUL MANUAL BRAKES 5 1 SECTION 5 BRAKES The following caution applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology See Caution on page 1 of this section CAUTION This fastener is an important attaching part in that it could affect the performance of vital components and systems and or could result in major repair expense It must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement
95. and cover These marks must be aligned in assembly to maintain balance 1 Remove three drive strap to pressure plate bolts and retracting springs and remove pressure plate from clutch cover 2 The clutch diaphragm spring and two pivot rings are riveted to the clutch cover Spring rings and cover should be inspected for excessive wear or damage and if there is a defect it is necessary to replace the complete cover assembly INSPECTION 1 Check drive straps for looseness at the clutch cover and evidence of looseness at pressure plate bolt holes 2 Wash all parts except driven disk and throwout bearing in cleaning solvent NOTICE The throwout bearing is permanently packed with lubricant and should not be soaked in cleaning solvent as this will dissolve the lubricant 3 Inspect pressure plate and flywheel for scores on the contact surfaces Use a straight edge and check for flatness of contact surfaces 4 Check throwout bearing for roughness and free fit on the sleeve of the transmission clutch gear bearing retainer Replace retainer if rough 5 Inspect clutch disc for worn loose or oil soaked facings broken springs loose rivets etc Replace if necessary PILOT BEARING REPLACEMENT The clutch pilot bearing is an oil impregnated type bearing pressed into the crankshaft This bearing requires attention when the clutch is removed from the vehicle at which time it should be cleaned and inspected for excessive wear or da
96. and increase left shim an equal amount DANA 9 3 4 RING GEAR INDEX General Ke EE 4B 27 Differential Case Removal and 4B 27 Drive Pinion Removal and Disassembly sss 4B 28 Differential Case Reassembly 0 440 4B 29 Drive Pinion Installation and Adjustment 4B 29 Differential Case Installation and Adjustment 4B 30 OVERHAUL MANUAL GENERAL DESCRIPTION This Dana Spicer axle is similar in design to other Salisbury type axles with the following exceptions 1 The differential side bearing shims are located between the side bearing cone and roller assembly and the differential case See figure 14F These bearings are of the tapered roller design and are preloaded In order to remove the differential case the carrier must be spread Shims Inner Pinion Bearing Cup Inner Pinion Bearing Cone and Roller Inner Pinion Ring and Pinion Gasket Housing Cover Screw and Washer Cover 1 2 Washer 3 Companion Flange 4 Pinion Oil Seal 5 Gasket 6 7 Outer Pinion Oil Slinger and 8 Cone and Roller Outer Pinion Bearing 9 Shims Outer Pinion Bearing 10 Inner Pinion Oil Slinger REAR AXLE DIFFERENTIAL 4 27 2 The pinion assembly incorporates an inner and outer bearing shim The inner shim is used to maintain proper pinion depth The outer shim is used to maintain pr
97. as described in R 4 Compressor Clutch Plate and Hub Removal procedure 3 Perform Steps 1 through 4 of RA Compressor Clutch Rotor and or Bearing Removal procedure but do not loosen or remove the pulley rim mounting screws 50 as to remove the Clutch Rotor and Bearing Clutch Coil and Pulley Rim as a TOTAL assembly Be careful not to drop the Puller Guide J 25031 when removing the assembly 4 Remove the Shaft Seal as described in R 4 Compressor Shaft Seal Removal procedure 5 Remove the Front Head as described in R 4 Compressor Front Head Removal procedure 6 Remove the Thrust and Bellville Washers as described RA Compressor Thrust and Bellville Washers Removal procedures 7 Remove the compressor Shell as described in R 4 Compressor Shell Removal procedure 8 Remove the Discharge Valve Plate and Retainer as described in R 4 Compressor Discharge Valve Plate and or Retainer Removal procedure 9 Remove the High Pressure Relief Valve and Pressure Switch if so equipped as described in R 4 Compressor High Pressure Relief Valve or Pressure Switch Removal procedure Replace 1 Replace above parts in opposite order 2 Evacuate and Charge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR A C SYSTEMS the AIR CONDITIONING section A 6 AND R 4 COMPRESSOR LEAK TESTING EXTERNAL AND INTERNAL Bench Check Procedure l Install Test
98. as described in A 6 Compressor Pulley and Bearing Assembly Replacement procedure CLUTCH COIL AND HOUSING ASSEMBLY SNAP RING PLIERS J 6435 26 RETAINER RING Figure 1D 18 Removing A 6 Coil Housing Retainer Ring ELECTRICAL TERMINALS Figure 1D 19 Installing A 6 Coil Housing 5 Install Clutch Plate and Hub assembly as described in A 6 Compressor Clutch Plate and Hub Assembly Replacement procedure MAJOR A 6 COMPRESSOR REPAIR PROCEDURES Service repair procedures to the Compressor Shaft Seal Pressure Relief Valve Pressure Switch or disassembly of the Internal Compressor Cylinder and Shaft Assembly are considered Major since the refrigeration system must be completely purged of refrigerant before proceeding and or because major internal operating and sealing components of the compressor are being disassembled and serviced Should an A 6 compressor it s compressor shaft seal or any other component ever be removed for servicing because it was determined to be the cause of excessive signs of oil leakage in the A 6 A C system then the oil in the compressor must be drained measured and replaced according to C C O T Refrigerant Oil Distribution in the Air Conditioning section to determine oil loss The accumulator in this A 6 system must then also be removed oil drained measured etc according to same section When replacing the shaft seal assembly see Figure 1D 20 pressure relief valve see Figu
99. at center of travel check torque to turn stub shaft reading 1 Fig 3B3 11C Overhaul 800 and 808 Gears Chart F 1 torque to turn stub shaft is 0 6 to 1 2 Newton Metres 6 to 10 in Lbs more than reading 1 Torque adjuster lock nut to 27 Newton Metres 20 Ft Lbs Prevent adjuster screw from turning while torqueing lock nut OVERHAUL MANUAL 3B 18 STEERING RECOMMENDED TORQUE SPECIFICATIONS NEWTON METRES FOOT POUNDS Gear to Frame Bolts 1st Design High Pressure Line Fitting At Gear 2nd Design High Pressure Line Fitting At Gear 1st Design Oil Return Line Fitting At Gear 2nd Design Oil Return Line Fitting At Gear Adjusting Screw Locknut Side Cover Bolts Adjuster Plug Locknut Coupling Flange Nuts Return Guide Clamp Screws Rack Piston Plug Pitman Shaft Nut Coupling Flange Bolt SPECIAL TOOLS Snap Ring Pliers J 8058 0 125 Newton metre Torque Wrench Connector Seat Installer 0 50 foot pounds Pitman Shaft Seal Installer J 8092 Handle Pitman Shaft Bearing Remover J 8524 1 Adjuster Plug Bearing Installer Pitman Arm Puller J 8524 2 Adjuster Plug Bearing Remover Handle J 8947 Rack Piston Seal Compressor Rack Piston Seal Compressor 70 mm 234 Piston Bore 79 mm 3747 Piston Bore J 21552 Ball Retainer Spanner Wrench J 22407 Pitman Shaft Bearing nstaller 0
100. ball pocket position Shoe discs are provided in 0005 one half thousandths variations There are a total of 11 sizes available for field servicing All shoe discs are marked wtih the shoe size which corresponds to the last three digits of the piece part number See Shoe Disc Size Chart in Figure 1D 46 Once a proper selection of the shoe has been made the matched combination of shoe disc to rear ball and spherical cavity in piston must be kept in proper relationship during disassembly after Gaging operation and during final assembly into the internal Cylinder and Shaft Assembly 19 Repeat in detail the same Gaging Procedure outlined in Steps 15 through 18 for Piston No 2 and No 20A Mount Dial Indicator J 8001 edge of Compressing Fixture J 9397 with Clamp J 8001 and Sleeve J 8001 2 Figure 1D 48 Position Dial Indicator on rear end of axial shaft and adjust to zero From bottom apply full hand force at end of shaft a few times before reading clearance This will help squeeze the oil out from between mating parts Now push upward again and record measurement Dial Indicator increments are 001 therefore reading must be estimated to nearest 0005 1D 18 AIR CONDITIONING COMPRESSOR OVERHAUL SHOE DISC THRUST BEARING RACE IDENTIFICATION STAMP MIN FEELER GAGE READING PART NO ENDING IN PART NO ENDING IN IDENTIFICATION DIAL INDICATOR STAMP READING 0000 0175 0180 0185 019
101. be installed in the same relative positions Fig 3E Loosening Adjusting Nuts OVERHAUL MANUAL Fig 4E Differential Bearing Removal Inspection l Inspect the differential gears pinions thrust washers spider and all mating surfaces for evidence of abnormal wear 2 Clean all parts thoroughly in suitable solvent 3 Replace parts as necessary Reassembly of Differential 1 Lubricate internal parts with hypoid gear lubricant 2 Place differential pinions and thrust washers onto spider 3 Assemble differential gears and washers to case and cover 4 Assemble differential case and cover making sure scribe marks align 5 Install ring gear and attaching bolts and lockwashers and torque alternately to specifications Fig 5E Differential Bearing Installation REAR AXLE DIFFERENTIAL 4B 15 Fig 6E Measuring Backlash 6 The differential may be installed into the carrier at this point or may be installed after servicing the drive pinion Installation and Adjustment 1 Place bearing cups over side bearings and lift the differential assembly into the carrier Install bearing caps making sure marked caps are installed in original positions Secure the cap bolts snugly 2 Loosen the right side adjusting nut and tighten the left side nut using J 24429 as shown in figure 3E until the ring gear contacts the drive pinion Do not force the gears into contact so as to bind them At this point zero lash is
102. be slipped to left or right without contacting studs The center section of gage has two levels The piston rod end should always touch the longer section of gage which extends into front housing The piston rod end should never touch the shorter section of gage fig 5 14C 2 Any variation beyond these two limits must be compensated for by obtaining the service adjustable piston rod and adjusting the screw in end to match height of gage BENDIX SINGLE DIAPHRAGM POWER BRAKE UNIT UNIT REPAIR Disassembly Figs 5 1D and 5 20 1 Scribe a line across front rear housings to facilitate reassembly 2 Remove the front housing seal fig 5 2D pulling the piston rod from the front housing will also remove the seal assembly Remove the piston rod 3 Attach base of Holding Fixture J 22805 to front housing with nuts and washers and draw down tight to eliminate bending or damage to studs Clamp base in bench vise with power section up fig 5 OVERHAUL MANUAL CAUTION Be sure to align tool so that the check valve in the front housing is not damaged 4 Loosen locknut and remove push rod clevis and locknut if so equipped 5 Remove the mounting bracket from the rear housing 1 so equipped 6 Remove the dust boot retainer dust boot and silencer from the diaphragm plate extension 22 21 Master Cylinder Vacuum Check Valve Grommet Diaphragm Diaphragm Plate Rear Housing Diaphragm Spr
103. begin turning It is important that brakes or clutch be released slowly enough to start the free wheel turning and allow the free wheel to gradually increase in speed As speed of the free wheel is increased the differential will lock causing the rotating wheel to stop or both wheels to turn at the same speed The engine may stall if equipped with a manual transmission It may be necessary to accelerate engine until approximately 10 mph is indicated on vehicle speedometer to cause differential lock If indicated speed can be increased beyond 20 mph 32 km h without causing differential lock the unit is not functioning properly Rapid release of brakes or clutch or rapid acceleration of engine willinvalidate test 9 Lock opposite rear wheel and repeat procedure The following chart provides guidelines for diagnosis and repair of differential complaints OVERHAUL PROCEDURES 8 7 8 RING GEAR AXLE 1 2 TON TRUCKS NOTICE Due to critical internal clearance dimensions differential side gears and case cannot be serviced separately If any side gear or case damage is found the entire differential must be replaced Internal clearances are such that shims reaction block and thrust rings should not be replaced unnecessarily even if slight wear indications are present If shims reaction block or thrust ring must be replaced due to damage correct measurement and replacement pro cedures must be followed Failure to do so may disturb critic
104. behind the inner bearing cup Tag shims for reassembly OVERHAUL MANUAL J 22888 Fig 16F Removing Differential Side Bearings 6 Remove inner pinion cone and roller using Tool J 22912 installed as shown in Figure 18F and press pinion from bearing Inspection 1 Clean all gears and bearings in cleaning solvent and inspect all bearing cups races and rollers for scoring chipping or evidence of excessive wear On pinion bearing rollers inspect large end of rollers for wear This is where wear is most evident on tapered roller bearings NOTICE The pinion bearings are of the tapered type and the natural wear pattern is a frosted condition with occasional slight scratches on races or rollers This does not indicate a defective bearing 2 Inspect pinion splines and flange splines for evidence of excessive wear 3 Inspect ring gear and pinion teeth for possible scoring cracking or chipping 4 Inspect differential case for carcks or scores Inspect side gears thrust washers and pinion thrust faces J 8614 1 8614283 Fig 17F Removing Flange A Fig 18F Removing Inner Pinion Bearing Cone and Roller 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 DIFFERENTIAL CASE Reassembly 1 Position differential side gears and new thrust washers in
105. bore 8 Install previously selected front unit selective thrust washer over pump cover delivery sleeve 9 Install two 2 hook type oil seal rings 10 Assemble pump cover to pump body with attaching bolts Fig 7A 78C Leave bolts one turn loose at this time 11 To align the pump body and cover place the pump assembly less rubber seal ring upside down into the pump bore of the case Fig 7A 78C 12 Tighten pump cover bolts to 18 foot pounds Remove pump assembly from case bore 13 Install pump to case O ring seal FORWARD CLUTCH DISASSEMBLY INSPECTION AND ASSEMBLY See Clutch Chart Fig 7A 79C for details of clutch components by specific model designations Fig 7A 78C Aligning and Installing Pump Cover to Pump Body 400 7A 26 AUTOMATIC TRANSMISSIONS 1979 CLUTCH APPLICATION CHART 400 475 Forward Clutch Direct Clutch Intermediate Clutch Flat Steel plates AA AB AC AE AH AT BB OB OD NOTE For Service use only the 1979 Direct and Forward Composition faced clutch plates Refer to the parts catalog for correct usage Models CB CL and CD have intermediate clutch plates which are different than other models Refer to the parts catalog for correct usage Fig 7A 79C Clutch Chart Component Details FORWARD CLUTCH HOUSING DIRECT CLUTCH HUB SNAP RING Fig 7A BOC Removing Forward Clutch Housing to Direct Clutch Hub Snap Ring Disassembly 1 Place forward clutch assembly with
106. bore NOTICE Reasonable care should be exercised in installing the piston into the cylinder bore to prevent damage to the Teflon ring A 6 COMPRESSOR INTERNAL CYLINDER AND SHAFT ASSEMBLY Assembly After properly performing the Gaging Procedure choosing the correct shoe discs and thrust races and installing any needed Teflon piston rings the cylinder assembly may now be reassembled Be sure to install all NEW seals and O rings All are included in the compressor O Ring Service Kit Assembly procedure is as follows 1 Support the FRONT half of the cylinder assembly Compressing Fixture J 9397 Install the shaft and axial plate threaded end down with its front bearing race pack ZERO race bearing NUMBERED race if this was not already done at the end of the Gaging Procedure 2 Apply a light smear of petroleum jelly to the numbered shoe discs chosen in the Gaging Procedure and install all balls and shoe discs in their proper place in the piston assembly 3 Rotate the axial plate so that the high point is above cylinder bore No 1 a Carefully assemble Piston No 1 complete with BALL AND ZERO SHOE DISC ON THE FRONT and BALL AND NUMBERED SHOE DISC ON THE REAR over the axial plate b Hold front thrust bearing pack tightly against axial plate hub while lifting hub c Insert the Piston Assembly into the Front Cylinder Half Figure 1D 56 4 Repeat this operation for Pistons No 2 and No 3 Figure 1D 57
107. case and drain lubricant from transmission 3 Remove nine 9 shift cover attaching bolts cover assembly and gasket Remove both shift forks 4 Remove four 4 drive gear bearing retainer bolts retainer and gasket from front of transmission 5 Remove lock pin from reverse shifter lever boss Fig 7B 3K and pull shifter shaft partially out to disengage the reverse shifter fork from the reverse gear 6 Remove five 5 rear extension attaching bolts tap extension rearward with a soft hammer to start removal Slide extension rearward until reverse idler shaft is clear of reverse idler gears Then rotate extension to the left to free shift fork from collar of reverse gear and remove the case extension Remove and discard gasket 7 Remove speedometer gear outer snap ring Fig 7B 4K Tap or slide speedometer gear from mainshaft then remove second snap ring 8 Slide the reverse gear from the mainshaft Fig 7B 5K and slide the rear portion of the reverse idler gear from the transmission case 9 Remove four 4 front bearing retainer bolts gasket and front bearing retainer from case 10 Remove front bearing snap ring selective fit snap ring and spacer washer 11 Using Tool J 6654 01 remove front main drive gear bearing from transmission case Fig 7B 6K 12 Remove the rear retainer lock bolt OVERHAUL MANUAL IWAN TOW WHIAO uoissiusuejj peedg p jo agin jeuonoesS y g4 4
108. damage 7 Inspect piston for cracks 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 ROLLER ASSEMBLY CENTER SUPPORT ASSEMBLY INTERMEDIATE CLUTCH Y INNER SEAL INTERMEDIATE CLUTCH RELEASE SPRINGS THRUST WASHER SNAP V S SUPPORT Y TEFLON OIL E SH CASE SPACER SEAL RINGS INTERMEDIATE CLUTCH OUTER SEAL INTERMEDIATE CLUTCH PISTON INTERMEDIATE CLUTCH INTERMEDIATE CLUTCH SPRING RETAINER SPRING GUIDE Fig 7A 118C Center Support Assembly Exploded View 400 7 38 AUTOMATIC TRANSMISSIONS INTERMEDIATE CLUTCH PISTON CLUTCH INNER SEAL Fig 7A 119C Installing Intermediate Clutch Inner Seal Assembly 1 Lubricate and install new inner and outer seals on piston with lip of seal facing away from spring pocket Fig 7A 119C and 7A 120C INTERMEDIATE CLUTCH PISTON CLUTCH OUTER SEAL Fig 7A 120C Installing Intermediate Clutch Outer Seal PISTON CENTER SUPPORT Fig 7A 121C Installing Intermediate Clutch Piston 2 Install inner seal protector Tool J 21363 on center support hub install piston indexing spring pockets of piston into cored areas of the center support Fig 7A 121C 3 Install intermediate clutch spring guide Fig 7A 122C INTERMEDIATE CLUTCH SPRING GUIDE Fig 7A 122C Installing Intermediate Clutch Spring Guide INTERMEDIATE CLUTC
109. determine the correct dimension for the remaining shim first refer to the dimension obtained in step 8 of Gaging Procedures Side Bearing Shims From that figure subtract the size of the shim installed in step 9 above then add 006 inch for preload and backlash For example if the reading in step 18 was 329 inch and the shim just installed on the ring gear side of the case was 172 inch the correct shim dimension would be 329 172 157 006 163 inch 11 Spread the differential carrier as shown in figure 2 12 Assemble the shim determined step 10 into place between the bearing cup and the carrier 13 Remove the spreader and the dial indicator 14 Install the bearing caps in marked positions and torque cap screws to specifications 15 Install dial indicator and check ring gear backlash at four equally spaced points around the ring gear Backlash must be held to 004 to 009 and must not vary more than 002 between positions checked 16 Whenever backlash is not within limits differential bearing shim pack should be corrected to bring backlash within limits a Low backlash is corrected by decreasing the shim on the ring gear side and increasing the opposite side shim an equal amount b High backlash is corrected by increasing the shim on the ring gear side and decreasing the opposite side shim an equal amount 17 Check gear tooth contact as described in Gear Tooth Contact Pattern Check 18 U
110. drive install rear lock nut and washer using Tool J 23070 Fig 7B 26L Torque lock nut to 120 ft 16 and bend washer tangs to fit slots in nut 14 Install parking brake drum and or universal joint flange Apply light coat of oil to seal surface 15 Lock transmission in two gears at once Install universal joint flange locknut and tighten to 90 120 ft Ibs OVERHAUL MANUAL 7B 44 MANUAL TRANSMISSION 3RD amp 4TH Se lee Fig 7B 15L Disassembly of Mainshaft J 22873 2ND GEAR BUSHING Mum Fig 7B 17L Installing 3rd Speed Gear Bushing 16 Move all transmission gears to neutral except the reverse idler gear which should be engaged approximately 3 8 of an inch leading edge of reverse idler gear teeth lines up with the front edge of the 1st speed gear Install cover assembly with new gasket to transmission case Shifting forks must slide into their proper positions on clutch sleeves and reverse idler gear Forks must be positioned as in removal 17 Install cover attaching olts and torque to 20 25 ft Ibs Fig 7B 16L Installing 2nd Speed Gear Bushing b 18 Using Tool 1 8109 replace gearshift lever and check operation of transmission OVERHAUL MANUAL MANUAL TRANSMISSION 7B 45 J 22875 3RD amp 4TH GEAR SYNCHRONIZER NM GEAR BUSHING J 22832 Fig 7B 18L Installing 3rd Speed Gear Bushing SPACER Fig 78 201 Positioning Tool J 22832 on Countersh
111. drum fig 7A 77B Inspection 1 Inspect drive and driven clutch plates for signs of burning scoring or wear 2 Inspect seventeen 17 springs for collapsed coils or signs of distortion 3 Inspect piston for cracks 4 Inspect clutch housing for wear scoring open oil passages and free operation of ball check 5 Inspect roller clutch inner and outer race for scratches or indentations CLUTCH PISTON CENTER SEAL Fig 7A 77B Removing Direct Clutch Piston Center Seal AUTOMATIC TRANSMISSION 350 7A 23 020 PIANO WIRE CRIMPED INTO COPPER TUBING IRECT CLUTCH HOUSING Fig 7A 78B Installing Direct Clutch Piston 6 Inspect roller cage for wear and roller springs for distortion Reassembly 1 Install new direct clutch piston outer seal and inner seals 2 Install new direct clutch piston center seal on drum with lip facing upward 3 Install direct clutch piston into housing with aid of a feeler gage or a piece of 020 piano wire crimped into copper tubing fig 7A 78B 4 Install seventeen 17 clutch return coil springs 5 Install piston return spring seat Compress spring seat with tool 1 23327 and install retaining ring fig 7A 79B FORWARD CLUTCH PISTON RETAINING RING Fig 7A 79B Installing Direct Clutch Springs Spring Seat and Retaining Ring OVERHAUL MANUAL 350 7A 24 AUTOMATIC TRANSMISSION CLUTCH PLATES IN CBC 350 Intermediate Direct Forward Low Reverse AJ
112. in thicknesses of 003 005 and 010 NOTICE If baffle or slinger is bent or mutilated it should be replaced J 8614 1 J 8614 2 amp 3 Fig 4C 5 Removing Pinion Flange FRONT WHEEL DRIVE 4 5 Fig 4C 6 Removing Inner Pinion Bearing Cone and Roller Measure each shim separately with a micrometer and add together to get total shim pack thickness from original build up If a new gear set is being used notice the plus or minus etching on both the old and new pinion and adjust the thickness of the old shim pack to compensate for the difference of these two figures For example If the old pinion reads 2 and the new pinion is 2 add 004 shims to the original shim pack 1 Determine proper inner shim pack for setting pinion depth by using chart fig 4C 8 2 Install inner shim pack and oil slinger in inner cup bore and drive inner cup into position using Tool J 21059 used with J 8092 3 To the outer shim pack for setting preload add or remove an equal amount as was added or removed from the inner shim pack 4 Install outer cup in carrier bore using installer J 7818 with Drive Handle J 8092 5 Press inner pinion bearing cone and roller onto pinion shaft using Installer J 9772 on arbor press as shown in Figure 4C 9 Fig 4C 7 Checking Runout OVERHAUL MANUAL 4C 6 FRONT WHEEL DRIVE Old Pinion New Pinion Marking Marking
113. install piston rotating piston on drum until seated Fig 7A 87C 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 compressor Tools J 4670 and J 21664 install snap ring 7 If removed install turbine shaft in forward clutch housing using arbor press 8 Install forward clutch hub washers on forward clutch hub Retain with petrolatum 9 Place forward clutch hub into forward clutch housing 10 Oil and install the composition plates flat steel plates and waved steel clutch plate with U notches starting with waved steel and then alternating composition and steel clutch plates as shown in Fig 7A 88C Models CD and CL do not use a waved steel clutch plate AUTOMATIC TRANSMISSIONS 400 7A 29 FORWARD CLUTCH ASSEMBLY FLAT STEEL FORWARD DIRECT SNAP PLATES 4 CLUTCH HUB CLUTCH HUB RING COMPOSITION PLATES 5 THRUST WASHERS Fig 7A 86C Forward Clutch Assembly Exploded View NOTICE Do not confuse the flat steel clutch plate plate with V notch with the waved steel clutch plate plate with U notch or damage may occur COMPOSITION PLATES FORWARD i CLUTCH HOUSING FORWARD ica CLUTCH PISTON Sh 21409 Fig 7A 88C Installing Forward Clutch Composition and Steel Fig 7A 87C Installing Forward Clutch Piston Plates 400 7A 30 AUTOMATIC TRANSMISSIONS FORWARD CLUTCH A
114. it at zero while its plunger rests on the cap nut of Tool 7 21371 8 5 Loosen hex nut while holding cap nut stationary With the hex nut loosened and holding Tool J 21371 3 firmly against the converter hub the reading obtained on the dial indicator will be the converter end clearance End clearance should be less than 050 If the end clearance is 050 or greater the converter must be replaced ASSEMBLY OF REAR UNIT FIG 7A 141C 1 Install rear internal gear on end of main shaft 2 Install rear internal gear retaining snap ring Fig 7 142 3 Install sun gear to internal gear thrust races bearings against inner face of rear internal gear as follows and retain with petrolatum INTERNAL GEAR SNAP RING MAIN SHAFT Fig 7A 142C Installing Rear Internal Gear Snap Ring 400 7A 46 AUTOMATIC TRANSMISSIONS O D FLANGED RACE LD FLANGED RACE THRUST BEARING Fig 7A 143C Installing Rear Internal Gear to Sun Gear Bearing and Races a Place large race against internal gear with outer flange facing forward or up Fig 7A 153C b Place thrust bearing against race c Place small race against bearing with inner flange facing into bearing or down 4 Install output carrier over mainshaft so that pinions mesh with rear internal gear 5 Place above portion of build up through hole in bench so that mainshaft hangs downward 6 Install rear internal gear to output shaft thrust races and bearin
115. lock washers which retain the carrier assembly to the axle housing Support the differential housing with a floor jack and roll it from under truck OVERHAUL MANUAL Disassembly 1 Mount carrier assembly a bench vise or holding fixture 2 Loosen ring gear thrust pad locknut and remove thrust pad 3 Remove differential adjusting nut locks and bearing cap bolts and lock washers 4 Mark bearing caps and carrier for reassembly in same position Remove bearing caps and adjusting nuts by tapping on bosses of caps with a soft faced hammer until caps are free from dowels NOTICE Do not attempt to pry cap off as this may damage machined face of cap REAR PINION BEARING PINION Fig 2G Pinion Rear Bearing Removal 5 Remove differential and ring gear assembly from the carrier Exercise care that differential bearing outer races are not dropped while removing assembly from carrier 6 Remove the bolts which attach the pinion bearing retainer to the carrier 7 Remove the pinion and bearing assembly from the carrier It may be necessary to drive this unit from carrier Use brass drift against pilot end of pinion Repairs Pinion Disassembly 1 Clamp pinion drive flange in bench vise 2 Remove cotter pin nut and washer from end of pinion 3 Remove drive flange and bearing retainer assembly from pinion 4 Drive oil seal from retainer Discard seal as new parts should be used at assembly 5
116. of spacers to facilitate reassembly 2 Using snap ring pliers remove the snap ring retaining drive sprocket to clutch assembly Slide the drive sprocket from the front side gear 3 Using snap ring pliers remove lower snap ring 4 Remove sliding gear spring and spring cup washer from front side gear 5 Clean and inspect all components Replace all worn or defective parts Assembly 1 Install spring cup washer spring and sliding clutch gear on front side gear 2 Install snap ring retaining sliding clutch to front side gear 3 Using a petroleum jelly load roller bearings 123 and spacers in the front side gear 4 Install thrust washer in gear end of front side gear 5 Slide drive sprocket on to clutch splines and install retaining ring Input Shaft Assembly Fig 70 115 Disassembly 1 Slide thrust washer and spacer from shaft 2 Using snap ring pliers remove snap ring retaining input bearing retainer assembly to shaft Fig 7D 13S and remove bearing retainer assembly from shaft 3 Support low speed gear large gear and tap shaft from gear and thrust washer Observe thrust washer pin s located in shaft Fig 7D 11S 4 Using a screw driver pry behind open end of large snap ring retaining input bearing in bearing retainer Fig 7D 14S and remove ring from retainer Tap bearing from retainer 5 Remove pilot roller bearings 15 from end of input shaft 6 Remove O ring from end of shaft and disca
117. of the cam gear clutch pack using grease for retention 2 Install cam gear assembly and original shim in flange end of case If a new thrust ring has been pressed on the cam gear reshimming may be necessary Measure the overall length of the new cam gear assembly including the shim and compare to the dimension obtained in Step A of cam gear service section If the length of the new assembly varies by more than 003 larger or smaller than the original dimension reshimming will be necessary Select a shim which will result in a reading closest to the original NOTICE Incorrect shimming will disturb critical clearance dimensions and may result in differential failure OVERHAUL MANUAL 3 Lock an axle shaft in vise in a vertical position Mount the differential case over the end of the axle shaft engaging the spline of the side gear with the shaft Grease the two pinion gear thrust washers and locate them in their proper position Install the opposite end side gear and original shim NOTICE Original shim must be used to maintain proper clearance dimensions 4 Insert one pinion gear through the small window opening in the case while at the same time inserting the reaction block and other pinion gear through the large window opening Rotate the two pinion gears and thrust block 90 so as to position the reaction block with the open side towards the small window opening in the case Be sure the two pinion gears and thrust washer
118. or wear 2 Inspect sixteen 16 springs for collapsed coils or signs of distortion FORWARD CLUTCH HOUSING i CLUTCH CENTER SEAL Fig 7A 85C Removing Forward Clutch Center Seal 3 Inspect clutch hubs for worn splines proper lubrication holes or scored thrust faces 4 Inspect piston for cracks 5 Inspect clutch housing for wear scoring open oil passages 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 Turbine shaft and clutch housing are serviced separately Shaft may be removed from housing by using a suitable size socket in an arbor press Fig 7A 82C Assembly Fig 7A 86C NOTICE The forward and direct clutch pistons have identical inside and outside diameters It is possible to reverse the pistons during reassembly therefore care should be exercised to make certain the proper piston be installed in the clutch assemblies as shown in Figure 7A 102C 1 Place new inner and outer oil seals on clutch piston lips face away from spring pockets Fig 7A 84C 2 Place a new center seal on clutch housing as shown in Fig 7A 85C Apply automatic transmission oil to all seals and clutch plates 3 Place seal protector Tool J 21362 over clutch hub and install outer clutch piston seal Protector J 21409 into clutch drum and
119. plate Reassembly 1 Install 6 clutch pack guide clips on the ears of the cam gear clutch pack using grease for retention OVERHAUL MANUAL SS NNMNNMMMMMMCKKUTUAT n aPOaOEOEOOGnm DODC C UJO BHOGILTPHBPRDIITITIHPTHUUUUUGRUHUTUTUTEUIGUBUBURUU E 7 2 Install cam gear assembly and original shim in right side case half If a new thrust ring has been pressed on the cam gear reshimming may be necessary Measure the overall length of the new cam gear assembly including the shim and compare to the dimension obtained in Step A of cam gear service section If the length of the new assembly varies by more than 003 larger or smaller than the original dimension reshimming will be necessary Select a shim which will result in a reading closest to the original NOTICE Incorrect shimming will disturb critical clearance dimensions and may result in differential failure 3 Install right side reaction block on gear face with button side of block facing up Use original block unless severely scored or worn If new block is used determine face to face thickness of original block with calipers and replace with a service block of the same thickness NOTICE Incorrect block thickness will disturb critical clearances and may result in differential failure 4 Preassemble pinions and pinion thrust wahsers on pinion yoke Index yoke to proper position and install in housing with center over button e
120. right without contacting the studs fig 5 11A 5 The center section of the gage has two levels The piston rod should always contact the longer section lower level of the gage The piston rod should never contact the shorter section higher level of the gage Move gage from side to side to check piston rod height 6 Any variation beyond these two limits must be compensated for by obtaining the service adjustable piston rod and adjusting the self locking screw to meet gaging specifications 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 Remove power brake unit from Tool J 23456 9 Place the silencer in the closed end of the push rod boot Push the boot retainer over the boot Stretch the boot over the push rod and over the flange in the center of the rear housing 10 Refer to Power Brake Unit Installation OVERHAUL MANUAL 5 6 BRAKES FRONT HOUSING SEAL VACUUM CHECK VALVE 9g POWER PISTON BEARING PUSHROD BOOT GROMMET BOOT RETAINER FRONT HOUSING POWER PISTON RETURN SPRING POWER PISTON ASSEMBLY REAR HOUSING Fig 5 10A Delco Tandem Power Brake Unit Explode Fig 5 11A Gaging Piston Rod OVERHAUL MANUAL BRAKES 5 7 BENDIX TANDEM POWER BRAKE UNIT UNIT REPAIR Disassembly 1 Scribe a line across the front and rear housings to facilitate reassembly 2 Carefully remove hydraulic push rod a
121. rod for cracks or broken spring retainer lugs Fig 7A 135C 2 Inspect actuator spring for damage 3 Inspect actuator for free fit on actuator rod 4 Inspect parking pawl for cracks or wear 5 Inspect manual shaft for damaged threads rough oil surface or loose lever 6 Inspect inside detent lever for cracks or a loose pin 7 Inspect parking paw shaft if removed for damaged retainer groove 8 Inspect parking pawl return spring for deformed coils or end 9 Inspect parking bracket for cracks or wear 10 Inspect detent roller and spring assembly INSPECTION OF CASE ASSEMBLY FIGS 7A 136C 7A 137C If the case assembly requires replacement make sure the center support to case spacer is removed from the old case and reinstalled in the new case AUTOMATIC TRANSMISSIONS 400 7 43 RETAINING ONG LOCK NUT INSIDE DETENT PARKING LOCK BRACKET DETENT ROLLER AND SPRING ASM lt SS PARKING LOCK 5 ACTUATOR ASSEMBLY MANUAL PARKING LOCK d CH PAWL SHAFT MG e f spring RETAINER PARKING LOCK PAWL SHAFT L CUP x d us Jt PARKING LOCK PAWL Ae E RETURN SPRING Fig 7A 135C Manual and Parking Linkage Exploded View DRIVE REVERSE LINE DRIVE MODULATOR OR INTERMEDIATE CLUTCH Fig 7A 137C Inspect Transmission Case Fig 7A 136C Case Front View Passage Identification AUTOMATIC TRANS
122. shaft downward 3 Install J 25022 on J 24773 tool and locate on end of turbine shaft Fig 7A 139A 4 Mount dial indicator on bolt and position indicator point against cap nut of J 24773 5 Move output shaft forward by turning the adjusting screw on J 25013 5 until the white or scribed line on sleeve DIAL INDICATOR J 8001 Fig 7A 138A Installing Pump Assembly OVERHAUL MANUAL Fig 7 139 Front Unit End Play J 25013 1 begins to disappear then set dial indicator to Zero 6 Pull turbine shaft upward and read end play Front unit end play should be 0 56mm 1 30mm 022 051 The selective washer controlling this end play is located between the output shaft and turbine shaft If more or less washer thickness is required to bring end play within specifications select proper washer from Fig 7A 140A 7 Remove front unit end play checking tools 8 Install remaining pump to case bolt and new washer torquing bolt to 20 0 27 0 N m 15 20 ft 165 9 Remove J 25013 5 and J 25013 1 from rear end of transmission Fig 7A 141A 10 Turn transmission to horizontal position oil pan side up EXTERNAL PARTS Governor Assembly Inspection 1 Inspect governor cover for damage scored or worn bore or plugged oil passage 2 Wash in cleaning solvent and blow out oil passage 3 Inspect governor driven gear for nicks or damage 4 Inspect governor shaft seal ring for cuts damage and free fit i
123. small magnet may be used to remove ball from case 10 Push shift rail down lift up on lockout clutch and remove shift fork from clutch assembly 11 Remove bolts retaining front output shaft rear bearing retainer to transfer case Tap on front of shaft or carefully pry retainer away from case Remove retainer from shaft and discard gasket Recover any roller bearings which may fall from rear cover Fig 7D 3S Removing Rear Output Shaft Flange Nut TRANSFER CASES 70 9 Fig 7D 4S Removing Front Output Shaft Front Bearing Retainer Fig 7D 5S Positioning Transfer Case for Disassembly Fig 7D 6S Removing Shift Fork Retaining Pin OVERHAUL MANUAL 7D 10 TRANSFER CASES Fig 7D 7S Removing or Installing Poppet Ball Plug If necessary to replace rear bearing support cover and press bearing from cover Position new bearing to outside face of cover and press bearing into cover with a 06 inch overhang 12 From lower side of case remove pry output shaft front bearing 13 Disengage front output shaft from chain and remove shaft from transfer case Fig 7D 8S 14 Remove bolts attaching intermediate chain housing to range box Lift or using a chain hoist remove intermediate housing from range box Fig 70 98 15 Remove chain from intermediate housing 16 Remove lockout clutch drive gear and input shaft assembly from range box A 1 1 2 to 2 hose clamp may be installed on end of the input shaft to pr
124. snap ring from mainshaft and remove clutch assembly third gear blocker ring and third speed gear from front of mainshaft Fig 7B 7J 2 Depress speedometer retaining clip and slide gear from mainshaft 3 Remove rear bearing snap ring from mainshaft groove Fig 7B 8J 4 Support first gear with press plates and press on rear of mainshaft to remove first gear thrust washer spring washer and rear bearing from rear of mainshaft Fig 7B 9J 5 Remove the ist and 2nd sliding clutch hub snap ring from the mainshaft and remove the clutch assembly 2nd speed blocker ring and 2nd speed gear from the rear of the Fig 7B 3J Removing Clutch Gear and Mainshaft MANUAL TRANSMISSION 7B 19 Fig 7B 4J Removing Extension to Rear Bearing Snap Ring mainshaft Fig 7B 10J CLEANING AND INSPECTION Transmission Case 1 Wash the transmission thoroughly inside and outside with cleaning solvent then inspect the case for cracks 2 Check the front and rear faces for burrs and if present dress them off with a fine mill file Front and Rear Bearings 1 Wash the front and rear ball bearings thoroughly in a cleaning solvent 2 Blow out bearings with compressed air NOTICE Do not allow the bearings to spin turn them slowly by hand Spinning bearings may damage the race and balls 3 Make sure bearings are clean then lubricate with light engine oil and check them for roughness by slowly turning the race by hand Bearing Rol
125. that each cone gear is installed in proper case half since tapers and surfaces become matched and their positions should not be changed 2 Place one spring block in position over gear face in alignment with pinion gear shaft grooves Install pinion shaft pinion gears and thrust washers into cap half or differential case in such a manner that pinion shaft retaining dowel can be inserted through pinion gear shaft into differential case This prevents pinion shaft from sliding out and causing damage to carrier Fig 4B 18D Be certain that pinion gears are installed in their original locations 3 Insert five springs into spring block that is already installed into case then place second spring block over springs Fig 4B 19D REAR AXLE DIFFERENTIAL 4B 45 PINION PINION PINION THRUST GEAR SHAFT Fig 4B 18D Pinion Shaft Position 4 Install second cone gear assembly face down on spring block so that gear will mesh with pinion gears 5 Install flange half of differential case over cone insert case bolts finger tight Fig 4B 20D 6 Tighten bolts one turn at a time in sequence shown Fig 4B 21D Then torque case bolts to 30 ft lbs 7 If side bearings were removed lubricate outer bearing surfaces and press on bearings as shown in the Service Manual 8 After making sure that matching surfaces are clean and free of burrs position ring gear on case so holes are in line 9 Lubricate NEW attaching
126. the Pulley Rim prevents the installation of the Inertia Ring the raised edge may be filed off to remove the excess metal and facilitate installation DO NOT use undue force or cock the ring in assembling the Inertia Ring in place over the Pulley Rim that could cause ring distortion or stress 4 Assemble the Inertia Ring onto the Pulley Rim being careful to align the inertia ring mounting holes with the mounting holes in the pulley rim If the Inertia Ring must be rotated on the Pulley Rim for centering the mounting holes and cannot be shifted by hand use a drift punch or blunt tool and a hammer to carefully tap the Inertia Ring at a clearance notch Figure 1D 92 to move the ring into position 5 Install a special lockwasher onto each 1 4 28 X 17 32 mounting screw 6 Apply Loctite 601 or equivalent sealer to the screw threads of each mounting screw and threads of the mounting holes in the Clutch Rotor Wet the threads thoroughly to ensure complete thread coverage 7 Install the screws into the mounting holes and tighten finger tight Torque each screw to 100 in Ibs torque 8 Lock the three screws in place by flattening the special washer against two sides of the hex head screw using vise grip pliers and one portion of the lockwasher bent down over the edge of the inertia ring slot Figure 1D 92 DO NOT move the screw heads from the torqued position Locking of the screws must be similar to the production forming of the lockwa
127. the case to center support bolt to 20 25 ft lbs using 3 8 12 point thin wall deep socket Fig 7A 160C NOTICE When using the locating tool care should be taken not to raise burrs on the case valve body mounting face 12 Install intermediate clutch plates a All models except CB CD and CL Lubricate with transmission oil two 2 flat steel and one 1 waved steel plates and three 3 composition faced intermediate clutch plates and install starting with waved steel plate and alternating composition faced and flat steel plates Fig 7A 161C CENTER SUPPORT LOCATING TOOL Fig 7A 160C Installing Center Support Bolt TN COMPOSITION PLATES STEEL PLATES Fig 7A 161C Installing Intermediate Backing Plate and Clutch Plates b Models CB CD and CL Lubricate with transmission oil three 3 flat steel and three 3 composition faced intermediate clutch plates and install starting with flat steel and alternating composition faced and flat steel plates Fig 7A 161C The models CB CD and CL intermediate composition faced plates are different from the other models Refer to parts catalog for correct usage 13 Install intermediate clutch backing plate ridge up Fig 7A 161C 14 Install intermediate clutch backing plate to case snap ring locating gap opposite band anchor pin Both sides of this snap ring are flat and it is 093 thick 15 Check rear end play as follows a Install a 3
128. the detent plug with a small magnet 4 Remove extension housing and gasket 5 Press down on speedometer gear retainer and remove speedometer drive gear and retainer from output shaft 6 Remove fill plug from right side of case Fig 7B 3B Working through the plug opening drive out countergear roll pin with a 3 16 inch pin punch that has been chamfered slightly Do not attempt to retrieve pin at this time Pin can easily be retrieved after output shaft assembly is removed 7 Insert dummy shaft tool J 25232 into bore at front of case tap lightly on tool to push countershaft out rear of case Fig 7B 5B With countershaft removed allow countergear to lie at bottom of case 8 Punch alignment mark in front bearing retainer and transmission case to ensure correct assembly and remove front bearing retainer and gasket Fig 7B 6B 9 Remove large locating snap ring from front bearing and smaller snap ring from clutch gear shaft 10 Remove clutch shaft front bearing using tool J 6654 01 and tool J 8433 1 Fig 7B 7B It may be necessary to alternate the tightening of the bolts between tools J 6654 01 and J 8433 1 to remove the front bearing 11 Remove large locating snap ring from rear bearing and smaller retaining snap ring from output shaft It may be necessary to place a screwdriver or a piece of bar stock between the case and the first reverse sleeve and gear assembly This will hold the output shaft assembly in place
129. this dimension as carrier may be permanently damaged 8 Remove the dial indicator and use a prybar to remove the differential case from the carrier Record the REAR AXLE DIFFERENTIAL 4B 21 Fig 2F Spreading the Carrier dimensions and location of the side bearing shims Remove the spreader tool Disassembly 1 Remove differential side bearings by placing J 22912 under bearings and supporting plates on a press bed Apply force to pilot plug J 8107 3 to drive the case from the bearing Use care not to damage case hubs with tool J 22912 2 Remove the ring gear bolts and the ring gear Tap the ring gear with a soft faced hammer to free it from the case 3 Scribe both case halves for reassembly in same position 4 Remove bolts holding case halves together as shown in figure 3F 5 Tap lightly on top half of case to free it from the bottom half Remove top half of case 6 Lift out all internal parts Fig 3F Separating Case Halves Fig 4F Internal Parts Inspection Inspection 1 Clean all gears and bearings in solvent Inspect cups races and rollers for scoring chipping or evidence of excessive wear 2 Inspect ring gear teeth and machined surfaces Examine fit of internal gears 3 Inspect pinion cross shaft 4 Replace parts as required DRIVE PINION Removal and Disassembly 1 Remove differential as previously outlined 2 Check pinion bearing preload as described under Drive Pinion Ins
130. to rear output housing front Be sure O ring is in proper position on front section of output housing Be sure vent is in upward position d Install flange washer and retaining nut Leave nut loose approximately 060 inch until shim requirements are determined 16 Install shim pack onto shaft in front of rear bearing to control end play to within 001 to 005 Hold rear flange and rotate front output shaft to check for binding of the rear output shaft Fig 7D 24S 17 Install speedometer driven gear in housing 18 Install lockout clutch shift rail poppet ball spring and screw plug in case 19 Install poppet plate spring gasket and plug if not installed during reasseambly of range box 20 Install shift levers on the range box shifter shaft if not left on linkage in vehicle 21 Torque all bolts locknuts and plugs except filler plug to specifications 22 Fill transfer case to proper level with specified lubricant 23 Install and tighten filler plug to specifications TRANSFER CASES 70 19 ADAPTER ASSEMBLIES ADAPTERS USED WITH MANUAL TRANSMISSIONS Disassembly of Adapter 1 Using a brass drift or other suitable tool tap sleeve from adapter 2 Using a brass drift punch out oil seal from adapter bore 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 brok
131. while removing the rear bearing 12 Remove rear bearing from output shaft using tool J 8157 01 Fig 7B 8B 13 Remove set screw from First Reverse shifter fork and slide shift rail out rear of case 14 Shift First Reverse sleeve and gear all the way forward and rotate First Reverse shifter fork upward and out of case Remove First Reverse Detent plug from case 15 Shift Second Third Shifter fork rearward to gain access to setscrew remove setscrew rotate shift rail 90 with pliers to clear bottom detent plug and remove interlock plug with magnet Fig 7B 9B Fig 7B 1B 3 Speed 77mm Transmission OVERHAUL MANUAL 7B 10 OVERHAUL MANUAL MANUAL TRANSMISSION 1 2 3 4 5 8 7 B 9 MAINSHAFT ROLLER BEARINGS 2ND SYNCHRONIZER RETAINING RING SYNCHRONIZER BLOCKER RINGS 2ND amp SYNCHRONIZER SPRING 2ND amp 3RD SYNCHRONIZER SLEEVE 2ND amp 3RD SYNCHRONIZER KEYS 2ND amp 3RD SYNCHRONIZER HUB SECOND SPEED GEAR 1ST SPEED GEAR RETAINING RING 1ST SPEED GEAR TABBED WASHER UST SPEED GEAR REVERSE SYNCHRONIZER SPRING IST amp REVERSE SYNCHRONIZER SLEEVE amp GEAR REVERSE SYNCHRONIZER KEYS IST 6 REVERSE SYNCHRONIZER HUB IST amp REVERSE SYNCHRONIZER RETAINING RING REAR BEARING RETAINING RING TRANSMISSION MAINSHAFT REVERSE SYNCHRONIZER ASSEMBLY ACCESS COVER BOLTS ACCESS COVER ACCESS COVER GASKET BEARING RETAINER CASE BOLTS BEARING RETAINE
132. with either the center support to case snap ring one side beveled or the intermediate clutch backing plate to case snap ring 093 thick and both sides flat Fig 7A 156C Installing Rear Band AUTOMATIC TRANSMISSIONS 400 7A 49 Reg LOCATE SPACER GAP ADJACENT TO Fig 7A 157C Installing Center Support to Case Spacer 8 Install proper rear selective washer proper washer determined by previous end play check into slots provided inside rear of transmission case 9 Install complete gear unit assembly into case using Tool J 21795 Fig 7A 158C 10 Install center support to case retaining snap ring with bevel side up flat surface against the center support Fig 7A 158C Installing Center Support and Gear Unit 400 7A 50 AUTOMATIC TRANSMISSIONS Fig 7A 159C Installing Center Support to Case Snap Ring and locating gap adjacent to band anchor pin Make certain ring is properly seated in case Fig 7A 159C 11 Install case to center support bolt by placing the center support locating tool into the case direct clutch passage with the handle of the tool pointing to the right as viewed from the front of the transmission and parallel to the bell housing mounting face Apply pressure downward on the tool handle which will tend to rotate the center support counterclockwise as viewed from the front of the transmission While holding the center support firmly counterclockwise against the case splines torque
133. 0 0195 0200 0205 0210 0215 0220 000 0 0000 050 5 0050 055 5 1 2 0055 060 6 065 6 1 2 070 7 075 7 1 2 080 8 8 1 2 0913 Figure 10 46 Available A 6 Service Shoes and Thrust Races SELECT AND USE SHOE NO POSITION POSITION POSITION 1 2 3 PISTON NO 1 019 PISTON 2 020 PISTON NO 3 021 0914 Figure 1D 47 Selection of Proper A 6 Shoe Disc 20B An alternate method of selecting a proper race is to use Gage Set J 9661 01 selecting a suitable feeler gage leaf until the result is a 4 to 8 ounce pull on the scale between the rear thrust bearing and upper which also happens to be the outer rear thrust race Fig 1D 49 If the pull is just less than 4 ounces add 0005 to the thickness of the feeler Stock used to measure the clearance If the pull on the scale reads just over 8 ounces then subtract 0005 from the thickness of the feeler stock 21 For either method used select a thrust race with a number corresponding to TWO 2 FULL SIZES LARGER than Dial Indicator or Feeler Gage measurement of the amount of end play shown If measurement is 007 select a No 9 or 090 race Place thrust race in right hand slot at bottom center of parts tray J 9402 Fifteen 15 thrust races are provided in increments of 0005 one half thousandths thickness and one ZERO gage thickness providing a total of 16 sizes available for field service The thrust race number also corresponds to
134. 0 to 1 1 96 to 1 2 00 to 1 4 Lo All wheel underdrive 4 Lo Lock all wheels N Neutral 2 Hi Rear wheel drive 4 Hi All wheel direct drive Ratios Hi Range Lo Range Lever Positions locked underdrive 4 Lo All wheels underdrive N Neutral 4 Hi All wheels direct drive 4 Hi Lock all wheels locked direct drive Rear of trans shift lever Floor right of center SAE 6 bolt Left side Power Take Off Data Opening amp Location Lubricants Oil capacity 5 2 pints 8 2 pints See Owner s Manual Type grade OVERHAUL MANUAL TRANSFER CASES 70 21 SPECIAL TOOLS J 22836 Front Output Shaft Bearing Retainer Seal Installer J 22388 Rear Output Shaft Seal Installer J 21359 Input gear Bearing Retainer Seal Installer J 24745 Cluster Gear Loading Tool J 8614 1 Companion Flange Remover Fig 7D 1ST Mode 205 Part Time Transfer Case Special Tools OVERHAUL MANUAL mengn 30 wHMAAOD 51001 ase sajsuess eui INJ EOZ IePOW 1Sz Q Bu BON J 22836 Front Output Shaft Bearing Retainer Seal Installer J 22388 Rear Output Shaft Seal Installer J 21359 Input gear Bearing Retainer Seal Installer J 24745 Cluster Gear Loading Tool J 8614 1 Companion Flange Remover 638579 345 1
135. 025 a new thrust washers must be installed ASSEMBLY OF MAINSHAFT 1 From rear of mainshaft assemble the 2nd speed gear with hub of gear toward rear of shaft 2 Install 1st 2nd synchronizer clutch assembly sliding clutch sleeve taper toward rear hub to front on the mainshaft together with a synchronizer ring on both sides of the clutch assemblies 3 Position the Ist gear sleeve on the shaft and press the sleeve onto the mainshaft until the 2nd gear clutch assembly and sleeve bottom against the shoulder of the mainshaft Fig 7B 21K ROLLERS SPACER SPACERS Fig 7B 19K Countergear Cross Section Fig 7B 20K Checking Countergear End Play 4 Install 1st speed gear with hub toward front and supporting inner race press the rear bearing onto the mainshaft with the snap ring groove toward front of the transmission Fig 7B 22K 5 Install spacer and new correct selective fit thickest that will assemble snap ring in mainshaft behind rear bearing 6 Install the 3rd speed gear hub to front of transmission and the 3rd speed gear synchronizing ring notches to front of transmission 7 Install the 3rd and 4th speed gear clutch assembly hub and sliding sleeve with taper toward the front making sure that the keys in the hub correspond to the notches in the 3rd speed gear synchronizing ring 8 Install new selective fit snap ring thickest that will install in the groove in mainshaft in front of the 3rd a
136. 1 Install new check valve grommet in front housing with beveled edge of grommet inside of housing Dip new check valve in clean denatured alcohol and install in grommet check valve stem is to be outside of housing 2 Position and secure Holding Fixture 1 22805 to mounting studs and place tool and front housing in a vise Be sure to align tool so that check valve is not damaged NOTICE If either or both of the housings are Fig 5 4D Installing Rear Housing Seal replaced make sure alignment marks are transferred to the new housing Rear Housing Group 1 Place rear housing on a block of wood stud side down and position housing seal in center hole Use Tool J 22677 fig 5 AD to seat seal in recess of rear housing Tool bottoms against housing when seal is in place 2 Assemble diaphragm plate assembly see fig 5 2D a Apply silicone lubricant to outside diameter of diaphragm plate and extension to bearing surfaces of air valve and to outer edge of valve poppet Insert air valve and push rod assembly in extension of diaphragm plate NOTICE The air valve poppet valve and push rod are serviced as an assembly a complete unit must be installed if there is damage to any of the component parts b Depress the push rod slightly and install the air valve lock Make sure the lock indexes and retains the air valve c Install the rolling diaphragm in the groove of diaphragm plate d Apply silicone lubricant to surface of r
137. 1 Place the differential case with side bearings and cups installed into position in the carrier 2 Select the smallest of the original shims as a gaging shim and place it between the bearing cup and the carrier on the ring gear side of the case 3 Install bearing caps and bearing screws finger tight Make sure bearing caps are in correct marked position 4 Mount a dial indicator on the ring gear side of the carrier with the indicator probe in contact with the back face of the ring gear 5 Position two screwdrivers between the bearing cup and the carrier on the side opposite the ring gear 6 Pull on the screwdrivers and force the differential case as far as possible toward the indicator With force still applied set the dial indicator to zero 7 Reposition the screwdrivers on the ring gear side of the case Force the ring gear into mesh with the drive pinion and observe the dial indicator Repeat this operatio several times until the same reading is obtained 8 Add the indicator reading to the gaging shim thickness to determine the correct shim dimension for installation on the ring gear side of the case For example if the gaging shim was 155 inch and the indicator reading in step 7 was 017 inch the correct shim would be 155 017 172 inch 9 Remove the gaging shim and install the correct size shim into position between the bearing cup and the carrier on the ring gear side of the case 10 To
138. 11A 3 Place forward clutch down with turbine shaft through hole in work bench 4 Remove snap ring and inspect for damage Fig 7A 112A COMPOSITION FACED PLATES STEEL PLATES DIRECT CLUTCH HOUSING Fig 7A 109A Installing Clutch Plates into Direct Clutch Housing 5 Remove backing plate from the forward clutch housing 6 Remove the clutch plates from the forward clutch housing and keep them separated from the direct clutch plates See Clutch Plate Usage Chart Fig 7A 82A 7 Inspect composition faced and steel clutch plates for signs of wear or burning 8 Inspect backing plate for scratches or damage 9 Using tools J 25018 25024 and J 23327 compress retainer and spring assembly and remove snap ring Fig 7A 113A An arbor press and tools J 25018 and J 23327 1 can be used to compress the retainer and spring assembly 10 Remove J 23327 1 J 25024 1 25018 11 Remove retainer and spring assembly from housing 12 Inspect release spring retainer for distortion 13 Inspect release springs for being collapsed 14 Remove forward clutch piston 15 Remove forward clutch outer and inner piston seals and discard Figs 7A 114A and 7A 115A 16 Do not remove the clutch apply ring from the piston unless the piston or apply ring requires replacement 200 7A 28 AUTOMATIC TRANSMISSION FORWARD TURBINE FORWARD FORWARD CLUTCH WAVED FORWARD SHAFT CLUTCH CLUTCH RETAINER amp STEEL CLUTCH SEAL HOUSIN
139. 12 Install reverse shifter shaft and detent plate into extension Locate reverse shift fork in reverse shifter shaft Use a heavy grease to hold reverse shift fork in position Be sure reverse shifter shaft O ring is placed on reverse shifter shaft after the shaft has been installed in the extension housing 13 Install tanged thrust washer on reverse idler shaft with tang of washer in notch of idler thrust face of extension 14 Place the 1st 2nd speed and 3rd 4th speed clutch sliding sleeve in neutral position Pull reverse shift shaft partially out of extension and reverse shift fork as far OVERHAUL MANUAL USE SEALER ON THIS BOLT Fig 7B 24K Extension Bolt forward in as possible Start the extension onto the mainshaft while pushing in on the shifter shaft to engage the shift fork with the reverse gear shift collar When the fork engages rotate the shifter shaft to move the reverse gear rearward permitting the extension to mate against the transmission case 15 Install reverse shifter shaft lock pin 16 Install rear extension housing to case bolts Install rear extension to rear bearing retainer bolts short bolts Torque all bolts to recommended specification NOTICE It is essential that sealer be used on the extension bolt as indicated in Fig 7B 24K 17 Position 1st 2nd speed clutch sliding sleeve into 2nd gear and 3rd 4th speed clutch sliding sleeve into neutral Position forward shift forks in sliding sleev
140. 177A a J 8092 EELER Fig 7A 17 1A Installing Pump Cover Bushing Rear _ J 8092 J 25019 4 Fig 7A 172A Removing Pump Body Bushing J 8092 J 25019 12 PUMP BODY Fig 7A 173A Installing Pump Body Bushing J 7004 1 J 25019 16 DIRECT CLUTCH HOUSING Fig 7A 174A Removing Direct Clutch Housing Bushing Front AUTOMATIC TRANSMISSION 200 7 45 4 2 J 8092 J 25019 9 DIRECT CLUTCH HOUSING Fig 7A 175A Installing Direct Clutch Housing Bushing Front J 25019 4 DIRECT CLUTCH HOUSING Fig 7A 176A Removing Direct Clutch Housing Bushing Rear 4J 8092 J 25019 6 DIRECT _ CLUTCH _ HOUSING Fig 7A 177A Installing Direct Clutch Housing Bushing Rear OVERHAUL MANUAL 200 7A 46 AUTOMATIC TRANSMISSION 22 4 25019 3 FRONT INTERNAL GEAR Fig 7A 178A Removing Front Internal Gear Bushing J 8092 J 25019 9 FRONT INTERNAL GEAR Fig 7A 179A Installing Front Internal Gear Bushing xn T d E J 7004 1 __ J 25019 14 REAR SUN GEAR S Fig 7A 180A Removing Rear Sun Gear Bushing QVERHAUL MANUAL cv M J 25019 2 REAR SUN GEAR Fig 7A 181A Installing Rear Sun Gear Bushing FRONT INTERNAL GEAR BUSHING 1 Using tool J 25019 3 with Driver Handle J 8092 remove bushing Fig 7A 178A 2 Using tool J 25019 9 with Driver Handle J 8092 drive or press new bushing into place
141. 1B Removing Governor from Case AUTOMATIC TRANSMISSION 350 7A 5 Fig 7A 12B Removing Transmission Oil Pan 8 Remove oil pan attaching screws fig 7A 12B oil pan and gasket Discard gasket 9 Remove oil pump suction screen strainer to valve body attaching screws fig 7A 13B 10 Remove oil pump screen strainer and gasket from valve body Fig 7A 13B Removing Oil Pump Suction Screen Strainer from Valve Body OVERHAUL MANUAL AUTOMATIC TRANSMISSION 350 7A 6 MANUAL CONTROL VALVE S LINK Fig 7A 14B Detent Spring and Roller Assembly REMOVAL OF VALVE BODY AND LINKAGE 1 Remove detent spring and roller assembly from valve body Remove valve body to case attaching bolts fig 7A 14B 2 Remove manual control valve link from range selector inner lever Remove detent control valve link from DETENT CONTROL VALVE WIRE Fig 7A 15B Removing Manual Control Valve Link Valve Body and Detent Actuating Lever OVERMAUL MANUAL j PLATE 4 Mt athe e Fig 7A 16B Removing Transfer Spacer Support Plate detent actuating lever fig 7A 15B Refer to valve body disassembly 3 Remove transfer plate support bolts Remove transfer support plate fig 7A 16B 4 Remove upper gasket valve body transfer spacer plate and valve body transfer spacer plate to case gasket fig 7A 17B fr VALVE BODY SPACER PLATE TO CASE GASKET Fig 7 17
142. 1D 5 SNAP RING PLIERS 21 RETAINER Figure 1D 6 Removing or Installing Retainer Ring in A 6 Clutch Drive Plate Figure 1D 7 A 6 Clutch Driven Plate and Drive Plate HOLDING FIXTURE J 9396 Figure 1D 8 Aligning A 6 Drive Plate Key 3 Install the Drive Plate Installer J 9480 1 as illustrated This Installer has a left hand thread on the body Figure 1D 9 4 Press the driven plate onto the shaft until there is approximately 3 32 space between the frictional faces of the Clutch Drive Plate and Pulley DRIVE PLATE INSTALLER J 9480 01 J 9396 HOLDING FIXTURE DRIVE PLATE INSTALLER BEARING Figure 1D 9 Installing A 6 Drive Plate NOTICE Make certain key remains in place when pressing hub on shaft A ZERO thrust race is approximately 3 32 thick and may be used to roughly gage this operation Use Clutch Hub Holder J 25030 or J 9403 hold Clutch Plate and Hub if necessary 5 Install the hub spacer and using Snap Ring Pliers J 5403 21 install the retainer ring see installed Retainer Ring in Figure 1D 10 with convex side of ring facing spacer 6 Using Thin Wall Socket J 9399 and Clutch Hub Holder J 25030 or J 9403 to install a new shaft locknut with shoulder or circular projection on the locknut facing towards retainer ring Tighten the nut to 14 26 torque Air gap between the frictional faces should now be 022 to 057 Figure 10 11 If not check for mispositioned key or shaft 7
143. 2 Inspect all differential components for excessive wear and breakage Replace parts as needed THE FOLLOWING ARE SERVICEABLE COMPONENTS FOR THIS DIFFERENTIAL e Governor assembly and latching bracket with spring e Cam Plate e Clutch disc pack with wave spring and guide clips e Pinion yoke e Pinion gears e Pinion thrust washers e Reaction blocks 4 sizes e Thrust ring e Right side shim 4 sizes e Left side guide clips Attempts to service other components will disturb critical clearances and may result in differential failure If reaction blocks or right side shim must be replaced the original pieces must be carefully measured for thicknes and replaced with a piece of the same size CAM CLUTCH SERVICE Disassembly If cam plate or clutch discs must be replaced the cam gear sub assembly must be serviced as follows Refer to Figure 4B 9H 1 Measure and record overall length of gear assembly front face of gear to back side of thrust ring include shim This dimension will be needed to reassemble unit if thrust ring is replaced DO NOT REPLACE THRUST RING UNLESS NECESSARY If ring is excessively worn or scored check bore in case for scoring If bore is scored replace entire differential 2 With gear hub end up compress disc pack and install jaws of split ring bearing removed J 22912 between the thrust ring and the top eared disc Bevel side of bearing remover should face up toward thrust ring 3 Place ca
144. 21370 9 to the flat machined area around the hole on Tool J 21370 6 d Before removing gaging tool make note of the proper band apply pin to be used during assembly of the transmission as determined by the six selective pins identified as shown in Fig 7A 17C If the transmission is in the vehicle be careful when the detent solenoid is removed as it prevents the spacer plate and gasket and check balls from dropping down 5 Remove detent solenoid attaching screws detent solenoid and gasket Fig 7A 18C Fig 7A 19C Removing Electrical Connector and O Ring Seal 400 7A 7 SERVO PISTON lt w i gt RETAINER RING i ho tp SERVO PIN ME SERVO SPRING RETAINER e p CA gt Fig 7 20 Front Servo Piston Retainer Ring and Pin SERVO PISTON SPRING 6 Withdraw electrical connector and O ring seal Fig 7A 19C 7 Remove control valve assembly spacer plate and gasket 8 Remove six 6 check balls from cored passages in transmission case Mark location of balls for aid in reassembly 9 Remove front servo piston retainer ring washer pin spring retainer and spring from transmission case Fig 7A 20C Remove Manual Linkage 1 Unthread jam nut holding detent lever to manual shaft Model CD transmision does not have parking lock mechanism 2 Remove manual shaft retaining pin from case Fig 7A 21C Fig 7A 21C Removing Manual Shaft Retaini
145. 24 Snap Ring Cover and Gasket 51 Locknut 9 Roller Bearings 25 Bearing 38 Thrust Washer 52 Output Yoke 10 Spacer 26 Speedometer Gear 37 Snap Ring 53 Bearing Retainer 11 Thrust Washer 27 Pilot Bearings 38 Thrust Washer Pin 54 Idler Gear 12 Thrust Washer Pin 28 Rear Output Shaft 39 Rear Bearing 55 Idler Gear Spacer 13 Snap Ring Front Bearing Retainer and Output 56 gier Shaft 14 Bolt and Lockwasher 29 Washer Shaft Cover 57 Locknut 15 Needle Bearings 30 Bearing Retainer 40 Front Wheel Drive 58 Washer 16 Spacer 31 Rear Wheel Orive Low Gear 59 Bearing Cone 17 Rear Output Shaft Low Gear 41 Roller Bearings 60 Bearing Cup Housing 42 Spacer Fig 7D 4R Model 205 Transfer Case Cross Section OVERHAUL MANUAL Fig 7D 5R Removing Gear Retaining Ring 8 Remove pilot rollers 15 retainer ring and washer 9 Remove oil seal retainer ball bearing speedometer gear and spacer Discard all gaskets Press out bearing as required 10 Remove oil seal from the retainer Front Output Shaft Assembly Fig 7D 2R 1 Remove lock nut wahser and yoke 2 Remove front bearing retainer attaching bolts and retainer 3 Remove front output shaft rear bearing retainer attaching bolts 4 Tap on output shaft with a soft hammer Fig 7D 3R and remove shaft gear assembly and rear bearing retainer from case Remove the sliding clutch from output high gear washer and bearing which will have remained in the case 5 Using large snap ri
146. 2872 Fig 7B 10L Removing Drive Gear Bearing 5 Install synchronizer blocker ring and 2nd speed gear onto mainshaft 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 thrust washer in slot on shaft and against 2nd speed gear bushing Then press 3rd speed gear bushing onto mainshaft using Tool J 22875 until it bottoms against thrust washer Fig 7B 18L 7 Install 3rd speed gear synchronizer blocker ring and 3rd speed gear onto mainshaft against 3rd speed gear thrust washer Fig 7B 11L Replacing Drive Gear Bearing OVERHAUL MANUAL MANUAL TRANSMISSION 7B 42 Fig 7B 12L Pilot Roller Bearing Installed 8 Index synchronizer ring key slots with synchronzier assembly keys and press 3rd and 4th synchronizer assembly onto mainshaft using Tool J 22875 and against 3rd speed gear bushing thrust face toward 3rd speed gear Fig 7B 19L Retain synchronizer assembly with snap ring 9 Install reverse driven gear with fork groove toward rear 10 Install Ist speed gear onto mainshaft and against Ist and 2nd synchronizer hub Install 1st speed gear thrust washer Fig 7B 13L Installing Bearing Retainer Oil Seal OVERMAUL MANUAL _ _ _ _ _ _ C 39 COUNTERSHAFT ASSEMBLY Disassembly Remove front countergear retaining ring and thrust washer Discard snap ring
147. 3 5WB 5 5TM Fig 7A 80B Automatic Clutch Chart 6 Lubricate with transmission fluid and install face plates and steel separator plates alternating steel and faced plates 7 Install direct clutch pressure plate and retaining ring 8 Install intermediate overrun roller clutch assembly with four 4 holes toward front of transmission FORWARD CLUTCH PISTON ASSEMBLY STEEL SEPERATOR pac Ne RING FORW ARD CLUTCH d ANA E lv INPUT SHAFT PISTON RETURN SEAT OVERHAUL MANUAL RETAINING RING FORWARD CLUTCH ASSEMBLY RETAIN INGIA RING a FORWARD CLUTCH PRESSURE PLATE Fig 7A 82B Removing Forward Clutch Retaining Ring and Pressure Plate NOTICE If roller falls out during assembly operation reinstall roller from inside to outside cage direction to avoid bending spring 9 Install intermediate clutch overrun outer race When outer race is installed it should free wheel in counterclockwise direction only 10 Install intermediate overrun clutch retainer and retainer ring as shown on Figure 7 70 FORWARD CLUTCH FIG 7A 81B Disassembly 1 Remove forward clutch retaining ring and pressure plate fig 7A 82B RETAIN e CUSHION SPRING FACED PLATES FORWARD CLUTCH PRESSURE PLATE Fig 7A 81B Forward Clutch Assembly Exploded View SEPARATOR PLATES FACED PLATES Fig 7A 83B Removing Forward Clutch Clutch Pack 2 Remove fa
148. 3 SHIFT VALVE SPRING 410 2 3 SHIFT CONTROL VALVE 11 2 3 SHIFT CONTROL VALVE SPRING 12 2 3 SHIFT CONTROL VALVE SLEEVE 13 RETAINING PIN 1 2 SHIFT VALVE RETAINING PIN PLUG RETAINING PIN 1 2 3 14 5 6 7 8 H RETAINING PIN 1 2 SHIFT CONTROt VALVE 1 2 SHIFT CONTROL VALVE SPRING 1 2 SHIFT CONTROL VALVE SLEEVE MANUAL LOW CONTROL YALVE MANUAL LOW CONTROL VALVE SPRING DETENT REGULATOR VALVE DETENT REGULATOR VALVE SPRING SEAT DETENT REGULATOR VALVE SPRING MB 2 Remove manual valve from lower left hand bore 3 From lower right hand bore remove the pressure regulator valve train retaining pin boost valve sleeve intermediate boost valve reverse and modulator boost valve pressure regulator valve spring and the pressure regulator valve 4 From the next bore remove the 2 3 shift valve train retaining pin sleeve control valve spring 2 3 shift control valve shift valve spring and the 2 3 shift valve 5 From the next bore remove the 1 2 shift valve train retaining pin sleeve shift control valve spring 1 2 shift control valve and the 1 2 shift valve 6 From the next bore remove retaining pin plug manual low control valve spring and the manual low control valve 7 From the next bore remove the retaining pin spring seat and the detent regulator valve 8 Install Tools J 22269 and J 24675 on direct clutch acc
149. 3 for information relative to parts nomenclature and location Removal and illustration of external compressor components and disassembly and assembly of internal components must be performed on a clean workbench The work area tools and parts must be kept clean at all times Parts Tray J 9402 Figure 1D 38 should be used for all A 6 internal compressor parts being removed as well as for replacement parts A 6 COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY Remove 1 Place Holding Fixture J 9396 a vise and clamp the compressor in the Holding Fixture HI PRESSURE RELIEF VALVE PROVIDES COMPRESSOR PROTECTION OIL DRAIN PLUG TORQUE TO 15 LB FT 5060 Figure 1D 1 A 6 Compressor 2 Keep clutch hub from turning with Clutch Hub Holder J 25030 or J 9403 and remove locknut from end of shaft using Thin Wall Socket J 9399 Figure 1D 4 NOTICE To avoid internal damage to the compressor DO NOT DRIVE OR POUND on the Clutch Plate and Hub assembly OR on the end of the shaft If proper tools to remove and replace clutch parts are not used it is possible to disturb the position of the axial plate keyed to the main shaft resulting in compressor damage and seal leakage due to shifting of the crankshaft 3 Thread Clutch Plate and Hub assembly Remover J 9401 into hub Hold body of Remover with a wrench and tighten center screw to remove Clutch Plate and Hub assembly Figure 1D 5 4 Remove square drive key from shaft or dri
150. 4 Start all ring gear bolts during initial assembly to maintain bolt hole adlignment Draw up all bolts evenly using a criss cross pattern to avoid cocking the gear on the case dh i d Companion Flange Differenticl Case Deflector Shim Pinion Oil Seal Gasket Pinion Front Bearing Differential Bearing Pinion Bearing Spacer C Lock Differential Carrier Pinion Shaft Lock Screw REAR AXLE DIFFERENTIAL 4B 3 Cover Thrust Washer Pinion Shaft Differential Pinion Ring Gear Shim Side Gear Pinion Rear Bearing Bearing Cap Drive Pinion Axle Shaft Fig 1B Cross Section of Differential 5 Insure that the gear is seated firmly against the case then torque the bolts to 60 ft Ibs Reassembly 1 Install thrust washers and side gears into case If original parts are being reused replace in original positions 2 Position pinions and thrust washers through loading hole in case 180 apart so they engage side gears 3 Rotate gears until the differential pinion bores and the case shaft holes are aligned 4 Install pinion shaft and lock screw It is not necessary to torque lock screw until axle shafts are installed 5 Differential may be installed in carrier now or after service is performed on the drive pinion Installation and Adjustment 1 Check condition of bearing bearing cups cup seat in carrier and carrier caps to make sure that they are free from nicks
151. 46 Reassembly eese tertie tens 4B 40 Assembly Rer Dres 4 47 Chevrolet Limited Slip sess 4B 42 Testing 22 recen etre 4B 47 Disassembly nre ert erint meets 4B 42 Eaton Positive Locking Differentials Inspection rrt n tenni rsen 4 42 1 2 Ton and 3 4 Ton 4B 48 Keassembly 5 eniin erronee erai setts 4B 42 D ppe cna dente ae EE 4B 48 Borg Warner Cone Type sese 4B 44 Disassembly ettari eret ni 4B 51 Description iere rre ses 4B 44 Inspection ed Eed 4B 51 Disassembly ninina 4B 44 Cam Clutch Service sinnene ttr 4B 51 Inspection erret e rine restore aho 4B 45 tae 4B 52 p eer deu uero eile 4B 45 OVERHAUL MANUAL Ring Gear to Case Ring Gear Bolt Shim Differential Case Clutch Pack Guide Side Bearing Clutch Disc Pinion Lock Screw Clutch Plates and Washer Side Gear REAR AXLE DIFFERENTIAL 4B 39 Pinion Shaft Preload Spring Spring Retainer i Pinion Thrust washer 9 Pinion Gear Q Fig 1D Eaton Limited Slip Exploded View EATON LIMITED SLIP FIGURE 1D Disassembly 1 Remove ring gear and side bearings following the procedures established for the conventional differential unit 2 Remove the preload spring retainer and springs by tapping on the spring ret
152. 4B 17 2 Remove cover bolts and cover as seen in figure 2E Checks and Adiustments 4B 17 and allow lubricant to drain into pan OVERHAUL MANUAL Man caps REAR AXLE DIFFERENTIAL 4B 13 1 Companion Flange 10 Straddle Bearing 19 Retainer Screw 2 Oil Deflector 11 Ring Gear 20 Bearing Cap 3 Oil Seal 12 Differential Spider 21 Case to Ring Gear Bolt 4 Bearing Retainer 13 Differential Case 22 Differential Cover 5 Shim 14 Differential Pinion 23 Bearing Cap Bolt 6 Pinion Front Bearing 15 Differential Side Gear 24 Cover Screw 7 Collapsible Spacer 16 Side Bearing 25 Axle Shaft 8 Pinion Rear Bearing 17 Side Bearing Adjusting Nut 9 Drive Pinion 18 Adjusting Nut Retainer Fig 1 5 Section of Truck Differential with 10 1 2 Ring Gear 3 Remove axle shafts as outlined in Truck Service ual NOTICE Before proceeding with following steps it is advisable to check the existing ring gear to pinion backlash as described in Step 9 of Differential Case Installation This will indicate gear or bearing wear or an error in backlash or pinion depth setting which will help in determining cause of axle noise Backlash should be recorded so that if same gears are reused then may be reinstalled at original lash to avoid changing gear tooth contact 4 Remove adjusting nut lock retainers from bearing 5 Mark bearing caps for reinstallation in the same position and remove caps 6 Loosen side beari
153. 5 Newton metre Torque Wrench J 25323 Power Steering Analyzer 0 25 inch pounds Fig 3B3 12C Overhaul 800 and 808 Gears Chart OVERHAUL MANUAL REAR AXLE DIFFERENTIAL 4B 1 SECTION 4B REAR AXLE DIFFERENTIAL CARRIER 8 1 2 AND 8 7 8 RING GEAR INDEX Differential Case ctii eerte ritieni fne 4B 1 Setting Pinion Depth 2 22 4B 5 Removal and Disassembly esse 4B 1 Installation and 4B 9 Inspection 4 1 Checks and Adjustments sse 4B 10 Side Bearing 2 4B 2 Pinion Bearing 4B 10 Ring Gear 4B 2 Side Bearing Preload 4B 10 Installation and Adjustment 4B 3 Pinion Depth and 4B 10 le WEE 4B 5 Gear Tooth Contact Pattern Check 4B 10 Removal 4B 5 Bearing 2 222212 4B 5 GENERAL INFORMATION AXLE IDENTIFICATION The rear axle codes are located as follows 10 Series The code is stamped on top of the right axle tube 3 to 5 outboard of the carrier 20 30 Series The code is stamped on the top of the right axle tube 6 to 8 outboard of the carri
154. 6 STEERING DISASSEMBLY ASSEMBLY 1 WITH PLASTIC HAMMER 1 INSTALL RING AS SHOWN IN LIGHTLY UNTIL PRESSURE VIEW PLATE IS FREE 2 REMOVE PARTS AS SHOWN 2 INSTALL PARTS AS SHOWN RING PRESSURE ROTOR VANES PLATE HOUSING THRUST PLATE Fig 3B3 4 Remove Rotating Group DISASSEMBLY ASSEMBLY 1 REMOVE PARTS AS SHOWN 1 INSTALL DRIVE SHAFT SEAL AS SHOWN IN VIEW A AND INSTALL PARTS AS SHOWN USE NEW O RINGS AND SEALS LUBRICATE O RINGS WITH POWER STEER ING FLUID BEFORE INSTALLATION Fig 3B3 5 Remove and Replace Seals OVERHAUL MANUAL ASSEMBLY L Install parts as shown DISASSEMBLY 1 Remove retaining ring and discard then remove parts Rotor RING amp U A OEA SHAFT THRUST PLATE Fig 3B3 6 Remove Thrust Plate and Rotor STEERING 3B 7 POWER STEERING GEAR 605 MODEL GENERAL DESCRIPTION This Integral Power Steering Gear has a NOTE Whenever part which forms a control valve which directs oil to either side sealing surface for an ring seal is of the rack piston The rack piston converts removed the ring seal should also be hydraulic power into mechanical force This removed and replaced with a new seal force is transmitted to the mating pitman Whenever one of the Pitman shaft or stub shaft teeth through the pitman shaft to the shaft seals are removed all adjacent seals steering linkage should be removed and replaced with new This is a small design steer
155. 64B Removing Pump to Converter Hub Lip Seal OVERHAUL MANUAL 350 7A 20 AUTOMATIC TRANSMISSION HUB LIP SEAL PUMP BODY WOOD BLOCKS Fig 7A 658 Installing Hub Lip Seal 2 Place pump body on wood blocks and pry out defective seal Coat outer diameter of new seal with a non hardening sealer and install seal using seal installer J 21359 to seat seal fully in counterbore 3 Install pump drive gear and driven gear fig 7A 66B 4 Install direct clutch drum housing to pump cover selective thrust washer over pump cover delivery sleeve Fig 7A 66B Installing Pump Drive and Driven Gears OVERHAUL MANUAL EAMAUST EXHAUST PUMP INTERMED PRESSURE d iter ATE REVERSE COOLER BY PASS VALVE COOLER OUT FROM RADIATOR COOLER IN RE VERSE TO RADIATOR OIRECT CLUTCH OUTER EXHAUST CONVERTER FEED PUMP LIP SEAL DRAIN FORWARD CLUTCH DIRECT CLUTCH EXHAUST PUMP BODY Fig 7A 67B Pump Body Oil Passages 5 Install three 3 direct clutch to pump hub hook type oil seal rings Install two 2 forward clutch to pump hub hook type oil seal rings If the 2 forward clutch to hub oil seals are teflon be sure to compress the seals slightly to set them to insure a tight fit on the hub Use care when assembling the forward clutch not to damage the seals NOTICE Check pump cover and body oil passages to make sure they are not restricted figs 7A 67B and 7 68 or damage
156. 7A 150A 9 Install servo cover retaining ring Align ring gap with an end showing in case slot Remove J 28653 Low and Reverse Clutch Housing to Case Cup Plug and Seal Fig 7 151 1 Install new cup plug and seal assembly with seal end first into hole in case 2 Using a 10mm 3 8 diameter by 150mm 6 metal rod and hammer drive the cup plug and seal assembly until it seats against the low and reverse clutch housing See Fig 7A 151A Control Valve Assembly Disassembly As each valve train is removed place the individual valve train in the order that it is removed and in a separate location relative to its position in the valve body None of the valves bushings or springs are interchangeable some coiled pins are interchangeable Remove all coiled pins by pushing through from the rough cast surface side of the control valve assebmly except the 2 pins which retain the throttle valve and throttle valve plunger 1 Remove the 4 check balls 2 Position control valve assembly as shown in Fig 7A 152A 3 Remove 1 2 accumulator piston 4 Remove manual valve from upper bore NOTICE Some of the coiled pins in the control valve assembly have pressure against them Therefore hold a shop towel over the bore while removing the pin to prevent possibly losing a bore plug spring etc 5 Remove coiled nin from upper right bore Remove 2 3 throttle valve bushing 2 3 throttle valve spring 2 3 IAU MANUAL
157. 7A 78A Removing or Installing Low and Reverse Clutch Wave Release Springs Outer Seal OVERHAUL MANUAL 200 7 A 20 AUTOMATIC TRANSMISSION LO amp REVERSE CLUTCH PISTON CLUTCH INNER SEAL LIP UP Fig 7A 79 A Removing or Installing Low and Reverse Clutch Inner Seal LO amp REVERSE J 25011 CLUTCH HOUSING LO amp REVERSE CLUTCH PISTON Fig 7A 80A Installing Low and Reverse Clutch Piston LO amp REVERSE CLUTCH HOUSING TO CASE SPACER Fig 7A 81A Proper Location of Low and Reverse Housing to Case Spacer OVERHAUL MANUAL H X u2 M M sd m Em 4 Inspect low and reverse clutch piston and clutch apply ring assembly for distortion cracks or damage The apply ring is identified by a number located on the ring See Fig 7 82 5 Inspect low and reverse clutch spring retainer for damage 6 Inspect waved spring for damage 7 Inspect low and reverse clutch housing to case spacer ring for damage Reassembly 1 Install clutch apply ring on low and reverse clutch piston 2 Install new outer and inner seals on piston with lips facing away from clutch apply ring side 3 Install seal protector J 25011 Apply transmission fluid to all clutch seals before reassembly NOTICE Flat screwdriver surface area must be smooth to prevent damagi
158. 7B 20 Cleaning and Inspection 7B 19 Extension Oil Seal or Bushing 7B 21 Transmission Case 7 19 Clutch Bearing Retainer Oil Seal 7B 21 LG e 7 19 Assembly of 2 02202 7B 21 Gears and Bushings AE 7B 20 Assembly of Transmiseton 7B 22 DISASSEMBLY OF TRANSMISSION Fig 7B 1J 1 Remove side cover attaching bolts and remove side cover assembly 2 Remove clutch gear bearing retainer bolts retainer and gasket 3 Remove clutch gear bearing to gear stem snap ring then remove clutch gear bearing by pulling outward on clutch gear until a screwdriver or other suitable tool can be inserted between bearing large snap ring and case to complete removal Fig 7B 2J The clutch gear bearing is a slip fit on the gear and into the case bore This provides clearance for removal of clutch gear and mainshaft assembly 4 Remove extension to case attaching bolts 5 Remove clutch gear mainshaft and extension assembly together through the rear case opening Fig 7B 3J 6 Using snap ring pliers expand the snap ring in the extension which retains the mainshaft rear bearing Fig 7B 4J and remove the extension 7 Using J 22246 at the front of the countershaft drive the shaft and its woodruff key out the rear of the case Tool 1 22246 will now hold the roller bearings in position within the counter gear bore Remove th
159. 8 16 bolt or J 9539 into an extension housing attaching bolt hole Fig 7A 37C b Mount a dial indicator on a 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 The selective washer controlling this end play is a steel washer having 3 lugs that is located between thrust washer and rear face of transmission case If a different washer thickness is required to bring end play within specifications it can be selected from the chart shown in Fig 7A 162C REAR END WASHER THICKNESS Identification Thickness Notches and or Numeral 074 078 None 082 086 1 Tab Side 090 094 098 102 106 110 114 118 2 Tab Side 1 Tab ODD 4 2 Tabs 5 3 Tabs OBD 22 ae 6 Fig 7A 162C Rear End Washer Selection Chart Fig 7A 163C Installing Front Band 16 Install front band with anchor hole placed over band anchor pin and apply lug facing servo hole Fig 7A 163C Install Manual Linkage a Install a new manual shaft seal into transmission case using a 3 4 diameter rod to seat seal b If removed insert actuator rod into manual detent lever from side opposite pin c Install actuator rod plunger under parking bracket over parking pawl d Install manual shaft through case and detent lever Fig 7A 164C Fig 7A 164C Installing Manual Shaft to Case AUTOMATIC TRANSMISSIONS 400 7 A 51 MANUAL SH
160. 8614 11 on flange by using two bolts with flat washers as shown in figure 12B Position J 8614 11 on flange so that the four notches are toward the flange 4 Remove pinion nut and washer 5 Thread end of J 8614 3 into small end of J 8614 2 Then with J 8614 11 installed as in step 3 insert J 8614 2 into J 8614 11 and turn it 1 8 of a turn to locked position Remove flange by turning J 8614 3 while holding J 8614 11 as shown in figure 13B REAR AXLE DIFFERENTIAL 4B 5 6 To remove the drive pinion first thread the original pinion nut half way on the pinion for thread protection 7 Place the differential cover temporarily back onto the housing using two screws This will prevent the pinion from falling to the floor during removal 8 Tap the end of the pinion nut with a large hammer and a soft drift as shown in figure 14B Care must be taken not to damage pinion bearings while removing pinion from carrier Inspect bearings and cups for damage and replace if needed 9 Remove the pinion oil seal and the front pinion bearing Remove the cover and retrieve the drive pinion from the housing Discard the pinion oil seal nut and collapsible spacer Use a new oil seal nut and spacer on reassembly Bearing Removal and Cup Replacement 1 If front pinion bearing is to be replaced drive outer race from carrier using a drift in slots provided for this purpose Tap alternately on opposite sides of the bearing cup to avoid cockin
161. 8A Rear Unit End Play Washer Chart e Remove dial indicator and clamp assembly Fig 7A 27 Do not remove J 25013 tools It may be necessary to tighten J 25013 adjusting screw on output shaft to remove snap ring 3 Using snap ring pliers remove output shaft to selective washer snap ring Fig 7A 29A REAR SELECTIVE WASHER amp IDENTIFICATION Fig 7 A 29A Removing Output Shaft to Selective Washer Snap Ring OVERHAUL MANUAL 200 7 8 AUTOMATIC TRANSMISSION FRONT CARRIER ROLLER THRUST BEARING ASSY Fig 7A 30A Removing Front Carrier and Roller Thrust Bearing THRUST BEARING ASSY Fig 7A 31A Removing Thrust Bearing Assembly and Front Sun Gear Fig 7A 32A Removing Input Drum and Rear Sun Gear OVERHAUL MANUAL 4 Front Internal Gear a Remove front internal gear rear selective washer and thrust washer b Remove rear selective washer and thrust washer from front internal gear 5 Remove front carrier assembly and the front internal gear to front carrier roller bearing assembly Fig 7A 30A The front sun gear to front carrier thrust bearing assembly may come out as the front carrier is removed 6 Remove front sun gear and front sun gear to front carrier thrust bearing assembly Fig 7A 31A This thrust bearing requires only one thrust race 7 Input drum and rear sun gear assembly a Remove input drum and rear sun gear Fig 7A 32A b Remove the 4 tanged inp
162. AFT DETENT LEVER Fig 7A 165C Installing Detent Lever and Jam Nut to Manual Shaft e Install detent jam nut on manual shaft and tighten to 18 ft Ibs Fig 7A 165C f Install retaining pin indexing with groove in manual shaft Rotate transmission to vertical position and remove J 21795 17 With converter end of transmission up carefully install direct clutch and intermediate roller assembly It will be necessary to shake and slightly twist housing to allow roller outer race to index with composition plates Housing hub will bottom on sun gear shaft Fig 7A 166C First visually line up the intermediate clutch drive lugs one above the other to help engagement of housing hub splines It also may be helpful to remove the direct clutch plates while installing housing 18 Install forward clutch hub to direct clutch housing thrust washer on forward clutch hub if not already installed Retain with petrolatum 19 Install forward clutch assembly and turbine shaft indexing direct clutch hub so end of mainshaft will bottom on end of forward clutch hub When forward clutch is Fig 7A 166C Installing Direct Clutch Assembly 400 7 A 52 AUTOMATIC TRANSMISSIONS Fig 7A 167C Installing Forward Clutch Assembly and Turbine Shaft seated it will be approximately 1 1 4 from pump face in case Fig 7A 167C 20 Install pump assembly and gasket NOTICE If turbine shaft cannot be rotated as pump is being pulled into pl
163. ANSMISSION 350 7A 33 J 23062 3 SUN GEAR ASSEMBLY Fig 7A 104B Installing Sun Gear Bushings Sun Gear Bushing With sun gear properly supported remove two 2 sun gear bushing using tool J 23062 3 and drive handle J 8092 with extension J 21465 13 Using tool J 23062 3 and drive handle J 8092 install sun gear bushing to 010 below surface at either end fig 7A 104B Reaction Carrier Bushing With reaction carrier properly supported remove bushing using tool J 23062 3 and drive handle J 8092 Using tool J 23062 3 and drive handle J 8092 install bushing flush to or 010 below inside face Direct Clutch Bushing With direct clutch drum properly supported remove bushing fig 7A 105B Using tool J 23329 and drive handle DIRECT CLUTCH DRUM Fig 7A 105B Removing Direct Clutch Drum Bushing OVERHAUL MANUAL 350 7A 34 AUTOMATIC TRANSMISSION 1 23329 Fig 7A 106B Installing Direct Clutch Drum Bushing J 8092 install direct clutch drum bushing fig 7A 106B TRANSMISSION ASSEMBLY When servicing transmission use only transmission oil or petroleum jelly as lubricants to retain bearings or races during assembly Lubricate all bearings seal rings and clutch plates prior to assembly Transmission Internal Components 1 Install low and reverse clutch piston assembly with notch in piston installed adjacent to parking pawl 2 Install seventeen 17 piston return coil springs LOW AND REVERSE
164. AUTOMATIC TRANSMISSION 200 7 1 SECTION 7A CONTENTS 200 Automatic Transmission 200 7A 1 350 Automatic Transmission 350 7A 1 400 Automatic Transmission 400 7A 1 200 AUTOMATIC TRANSMISSION INDEX Disassembly ochenta dae 1 R moval o E 7 41 Rear Gear Parts E 7 15 Low and Reverse Clutch eee 7 18 Teflon Seals e frites 1 Front Gear Parts eene 7 21 External E EE 7 2 Front Unit Parts siriene 7 24 Front 8 7 5 d and Direct Clutch 7A21 Front Gear ageet Eege SEA 7 7 eer Se bl WEE 7 A3 Rear Gear 7 9 PE ir L 7 A 35 Manual Shaft and Parking 7 10 CRDI V due P d s ek e Ae e VE EES RD Inspection and Reassembly eee 7A 11 EE Stine ipn 4 MUTA E Bushing Replacement 7 43 Special Tools eres e ete nier doe 7 48 DISASSEMBLY Removal of Converter 1 With transmission in cradle of portable jack remove J 21366 and then converter assembly by pulling straight out 2 Install Holding Fixture J 8763 02 on transmission and place into Holding Fixture J 3289 20 with manual shaft facing bench and oil pan side up Fig 7A 1A Do not over t
165. B 37 Pinion Disassembly ube 4B 35 Ring Gear and Pinion Adiustmnet 0 00000se00 4B 37 Pinion Inspection 4 4B 35 Backlash and Preload Adjustment 11 50 4B 37 Pinion Reassembly ees 4B 35 Ring Gear Thrust Pad Adjustment 4B 37 Differential Disassembly 4B 36 Installation 4B 37 Differential Inspection 2 4B 36 OVERHAUL MANUAL 4B 34 REAR AXLE DIFFERENTIAL Universal Joint Yoke Pinion Bearing Oil Seal and Retainer Oil Seal Oil Seal Gesket Front Pinion Bearing Drive Pinion Rear Pinion Bearing Ring Geer Thrust Ped Ring Geer Differentis Spider Differential Pinion Spider Gear Differentis Side Gear Differentia Cese Left Half Axle Shaft Differentia Bearing Differential Bearing Adjusting Nut Adjusting Nut Lock Differential Cese Right Half Cross Section of Truck Differential With 12 1 4 Ring Gear CASE AND DRIVE PINION Removal 1 Drain lubricant from differential remove axle shaft as outlined in Truck Service Manual See Axle Shaft Removal 2 Remove two trunnion bearing U bolts from the rear yoke and split the rear universal joint 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
166. B3 1C Overhaul 605 Gear Chart OVERHAUL MANUAL 3B 8 STEERING REMOVE AND INSTALL PITMAN SHAFT SEALS IN CAR REMOVE Clean exposed end of shaft and end of housing after removing arm Remove retaining ring Start engine and turn wheels fully to the right to force seals and washer out Turn off engine 5 Inspect housing and shaft INSTALL Install parts as shown HOUSING ASSEMBLY inspect for burrs OIL SEAL WASHER AND SIDE COVER REMOVE If pitman shaft and side cover are to be separated remove preload adjuster nut IT IS A LEFT HAND THREAD Rotate stub shaft to center gear then remove parts as shown Tap on thread end of pitman shaft with plastic hammer i i 1 3 REMOVE INSTALL PITMAN SHAFT INSTALL Install parts as shown Use new retaining ring make sure that open end of retaining ring is approx 13mm 7 from access hole Side cover must be depressed to install retaining ring SEE BELOW SIDE COVER Ci RETAINING RING DUST SEAL PRELOAD ADJ NUT Torque to 27 Newton PITMAN SHAFT GEAR EISE ES SIDE COVER O RING SEAL SIDE COVER UN PITMAN SHAFT Inspect seal surface for roughness and pitting RETAINING RING PITMAN ARM PRELOAD ADJUSTER SIDE COVER Retaining ring access hole use punch a LOCK WASHER NUT torque to 250 Newton metres 180 Ft Lbs STUB SHAFT 1 1
167. Bearing Cup Inner Pinion Bearing Cone and Roller Inner Pinion Ring and Pinion Gasket Housing Cover Screw and Washer Cover 17 18 19 21 22 23 Cover and Plug Lock Pin Pinion Shaft Differential Case Shims Differential Adjusting Cone and Roller Differential Bearing Cup Differential Bearing Cap Differential Bearing Bolt Differential Bearing Cap Bolt Ring Gear Pinion Shaft Thrust Washer Pinion Pinion Side Gear Thrust Washer Side Gear vot 3AIHG 133HAA LNOHJ3 J 22888 Fig 4C 4 Removing Side Bearing inner bearing cup Whenever baffles or oil slingers are used they become a part of the adjusting shim pack For example If a pinion is etched 3 this pinion would require 003 less shims than a pinion etched O This means by removing shims the mounting distance of the pinion is increased by 003 which is just what a 3 etching indicates Or if a pinion is etched 3 we would want to add 003 more shims than would be required if the pinions were etched O By adding 003 shims the mounting distance of the pinion was decreased 003 which is just what a 3 etching indicated If the old ring and pinion set is to be reused measure the old shim pack and build a new shim pack to this same dimension If baffle is in the axle assembly it is considered as part of the shim pack To change the pinion adjustment shims are available
168. C TRANSMISSION REACTION PARKING PAWL CARRIER GOVERNOR OW AND REVERSE OUTPUT CARRIER LOW AND REVERSE CLUTCH FORWARD CLUTCH lt T H lt Xr H az sz DE 04 E ZO lt lt 52 az eV eS x e gt o ZO gt F i az E Uv zu O lt DK ek SE uw CONVERTER ASSEMBLY Fig 7 1 350 Automatic Transmission Sectioned View OVERHAUL MANUAL ROLLER CLUTCH mg wi r J 8763 01 Fig 7A 2B Transmission in Holding Fixture AUTOMATIC TRANSMISSION 350 7A 3 Fig 7 4 Converter for Leaks TRANSMISSION DISASSEMBLY AND REASSEMBLY DISASSEMBLY 1 Install Holding Fixture J 8763 02 on transmission and place into Holding Tool base J 3289 20 with converter facing up fig 7A 2B Cleanliness is an important factor in the overhaul of the transmission Before attempting any disassembly operation the exterior of the case should be thoroughly cleaned to prevent the possibility of dirt entering the transmission internal mechanism During disassembly all parts should be thoroughly cleaned in cleaning fluid and then air dried Wiping cloths or rags should not be used to dry parts NOTICE Do not use solvents which could damage rubber seals or clutch facings RING SEAL Fig 7A 3B Removing Vacuum Modulator Assembly 2 With transmission in holding
169. C TRANSMISSION 200 7 16 i 090 6 5 32 Fig 7A 62A Positioning Steel Gear d Using J 28578 or J 6133 drive the gear to 156 mm 6 5 32 from end of output shaft to rear face of gear Figs 7A 61A 7A 62A 7 If necessary remove rear internal gear to output shaft snap ring If damaged replace with a new snap ring Fig 7A 58A Rear Internal Gear 1 Inspect rear internal gear splines teeth and bearing surface for wear cracks or damage 2 Inspect parking pawl lugs for cracks or damage 3 Install rear internal gear hub end first on output shaft as shown in Fig 7A 63A 4 Thoroughly clean air dry and inspect closely the rear internal gear to rear sun gear roller thrust bearing assembly for pitted or rough conditions 5 Install rear internal gear to rear sun gear roller thrust bearing assembly by placing the small diameter race over the output shaft Fig 7A 64A Roller Clutch and Rear Carrier Assembly Inspection 1 Remove roller clutch race Inspect race and spline for scoring or wear Fig 7A 65A REAR INTERNAL GEAR OUTPUT SHAFT Fig 7A 63A Installing Rear Internal Gear on Output Shaft OVERHAUL MANUAL THRUST BEARING ASSY INSIDE DIAMETER RACE AGAINST GEAR REAR INTERNAL GEAR OUTPUT SHAFT Fig 7A 64A Installing Thrust Bearing Assembly 2 Remove roller clutch assembly and inspect roller bearings cage and springs for damage or wear Fig 7A 65A
170. COVER o INTERMEDIATE SERVO PISTON ASSEMBLY INTERMEDIATE SERVO RETAINING RING n INTERMEDIATE SERVO COVER O RING SEAL 5 Fig 7A 14A Removing Piston and Apply Pin 7 Intermediate Servo Assembly a Using two oil pan bolts install J 28653 on case and depress cover as in Fig 7A 11A b Using small screwdriver remove intermediate servo cover retaining ring Fig 7A 12A c Remove J 28653 d Using pliers remove intermediate servo cover and discard seal rings cover seal ring may be located in case Fig 7A 13A e Remove intermediate servo piston and band apply pin assembly Fig 7A 14A 8 Check for proper intermediate band apply pin as follows a Install J 25014 2 in intermediate servo bore and retain with intermediate servo cover retaining ring aligning ring with gap at case slot Fig 7A 16A b Install pin J 25014 1 into J 25014 2 Fig 7A 16A Make sure the tapered pin end is properly located against the band apply lug Also make sure the band anchor pin is properly located in the case and band anchor lug Fig 7A 12A Removing Retaining Ring we INTERMEDIATE SS z SERVO COVER SERVO INNER OIL SEAL INTERMEDIATE SPRING RING SERVO COVER OIL BEAL SNAP OIL SEAL BAND APPLY SERVO CUSHION OUTER SERVO RETAINING PIN SELECTIVE SPRING PISTON RING SERVO INNER SERVO SPRING PISTON RETAINER Fig 7A 13A Removing Intermediate Servo Cover Fig 7A 15A Servo Components
171. DJUSTER LOWER WORM BEARING CUP LOWER WORM BEARING q LOWER BEARING RETAINER 0 DISASSEMBLE AND ASSEMBLE WORMSHAFT AND BALL NUT DISASSEMBLE ASSEMBLE Disassemble parts as 1 Assemble parts as shown shown Clean and inspect all 2 Refer to Fig for parts for excessive number of balls used BALL NUT WORMSHAFT BALL GUIDES 15 BALL GUIDE CLAMP uw os CLAMP SCREWS Pec Hi jj Jp NARROW END OF TOOTH Installing Balls Dimension A Measure land between ball grooves Fig 3B2 3 Manual Gear Overhaul Chart B OVERHAUL MANUAL 3B 4 6 ADJUST WORM BEARING PRELOAD STEERING Tighten worm bearing adjuster until it bottoms then loosen one quarter turn Carefully turn the wormshaft all the way to end of travel then turn back one half turn Tighten adjuster plug until torque wrench reads 06 to 10N m 5 to 8 Ibs A Back off preload adjuster until it stops then turn in one full turn Tighten locknut using punch against edge of slot TORQUE WRENCH With gear at center of travel check torque to turn stub shaft socket Due to tolerances some sock ets require a wrapping 7 ADJUST OVER CENTER PRELOAD B Turn adjuster in until torque to turn stub shaft is 0 5 to 12 Nm 4 to 10 in Ibs more than reading 1 Torque adjuster lock nut to 34 25 ft Ibs Prevent adjuster screw reading 41 from turning while card stock around torqueing lock nut
172. Discard the lock washers 3 Slide the pulley rim off the Rotor and Hub assembly The Pulley Rim and the Clutch Coil Figure 1D 89 are replaceable at this point FRONT SURFACE Figure 1D 89 R 4 Clutch Coil Assembly Replace 1 Assemble the Clutch Coil Pulley Rim and the Clutch Rotor and Bearing assembly as shown in Figure 1D 90 Use new special lock washers and apply sealer Loctite RC 75 Loctite 601 or equivalent to screw threads but do not lock the screws in place 2 Place the assembly on the neck of the Front Head and seat into place using Rotor and Bearing Installer J 26271 Figure 1D 88 Before fully seating the assembly on the Front Head be sure the clutch coil terminals are in the proper location in relation to the compressor and that the three protrusions on the rear of the clutch coil align with the locator holes in the Front Head PULLEY RIM Figure 1D 90 Assembling R 4 Clutch Coil Pulley Rim and Rotor and Bearing 3 Install the rotor and bearing assembly retaining ring and reassemble the Clutch Plate and Hub assembly as described in R 4 Compressor Clutch Plate and Hub Assembly Replacement procedure Check to see that the clutch plate to clutch rotor air gap is 020 040 inches Rotate the Pulley Rim and Rotor to be sure the Pulley Rim is rotating in line and adjust or replace as required 4 Tighten the pulley rim mounting screws to 100 inch pounds torque and lock the screw heads in place by b
173. E 2 LOCK NUT REAR SUCTION REED BUSHING NEEDLE BEARING Se O RING SUCTION a CROSSOVER COVER REAR CYLINDER HALF w t a _ SPACER TEFLON PISTON mr b BEARING FRONT CYLINDER HALF WR f NEEDLE BEARING SHOE d pe TEFLON RING TYPE ak TEFLON PISTON ki SHAFT U In A 8 DISCHARGE CROSSOVER TUBE DOWEL PINS b 1 THRUST RACES O RING BUSHING FRONT SUCTION REED FRONT DISCHARGE DISCHARGE CROSSOVER TUBE O RING OR BUSHING VALVE PLATE ASSEMBLY INVHHSAO YOSSAYdWOD SNINOILIQNOO HIV gegen mmm 1D 4 AIR CONDITIONING COMPRESSOR OVERHAUL FRONT SUCTION REED DISCHARGE VALVE PLATE SHAFT SEAL ASM TEFLON PISTON RING PULLEY SHAFT BALL AXIAL PLATE 4 PULLEY BEARING FER 7 DISC REAR HEAD ur P TAE NS as CLUTCH PLATE ME CH CN 3 mM AJN HUB ASSEMBLY T OIL wg SEAL SEAT GEARS 4 2 M 22721 RETAINER RING E v Ch PRESSURE 2 VALVE a A FRONT ABSORBENT HEAD SLEEVE SEAL SLEEVE OIL PICK UP TUBE THRUST FRONT CYLINDER OIL SUMP RACE HALF CLUTCH COIL REAR CYLINDER THRUST BEARING AND HOUSING HALF Figure 1D 3 A 6 Compressor Cross Section CLUTCH ASSEMBLY 4 CLUTCH PLAT THINWALL LATE SOCKET J 9399 CLUTCH HUB HOLDING TOOL J 25030 OR Figure 1D 5 Removing A 6 Clutch Plate and Hub Assembly Figure 1D 4 Removing A 6 Shaft Lock Nut AIR CONDITIONING COMPRESSOR OVERHAUL
174. EMBLY 1 Install new case extension housing to case gasket extension housing Model CL uses a seal between the extension housing and case extension FRONT END WASHER THICKNESS Thickness Number Color 060 064 0 Yellow 071 075 1 Blue 082 086 2 Red 093 097 3 104 108 4 115 119 5 126 130 Brown Green Black Purple Fig 7A 170C Front End Washer Selection Chart Fig 7A 171C Installing Extension Oil Seal Typical 2 Attach extension housing to case using attaching bolts and or studs Torque bolts to 20 25 ft Ibs 3 If necessary install a new seal as follows a All except CL Models use a non hardening sealer on outside of seal body and using Tool J 21359 drive seal in place Fig 7A 171C b Model CL use a non hardening sealer on outside of seal body and using Tool J 24057 drive seal in place Fig 7A 171C Fig 7A 172C Location of Check Balls AUTOMATIC TRANSMISSIONS 400 7A 53 SPACER PLATE TO CASE GASKET Fig 7A 173C Location of Check Balis in Vehicle Installation Installation of Check Balls Control Valve Spacer Plate and Gasket Detent Solenoid Front Servo Assembly and Electrical Connector 1 Install two control valve assembly attaching bolts with heads cut off as guide pins as shown in figure 7A 183C 2 Install six 6 check balls into ball seat pockets in transmission case Figure 7A 172C If transmission is in the vehicle inst
175. ESSOR OVERHAUL 1D 35 disassembly of the internal R 4 compressor cylinder and shaft assembly If the R 4 Compressor Internal Cylinder and Shaft Assembly is to be serviced or replaced then the oil in the R 4 compressor must be drained measured and replaced according to C C O T Refrigerant Oil Distribution in the Air Conditioning section to determine addition of proper oil quantity to new assembly A clean workbench preferably covered with a sheet of clean paper orderliness in the work area and a place for all parts being removed and replaced is of great importance as is the use of the proper clean service tools Any attempt to use make shift or inadequate equipment may result in damage and or improper compressor operation These procedures are based on the use of the proper service tools and the condition that an adequate stock of service parts is available All parts required for servicing the internal compressor are protected by a preservation process and packaged in a manner which will eliminate the necessity of cleaning washing or flushing of the parts The parts can be used in the internal assembly just as they are removed from the service package R 4 COMPRESSOR SHAFT SEAL Seal Leak Detention shaft seal should not be changed because of an oil line on the hood insulator The Seal is designed to seep some oil for lubrication purposes Only change a Shaft Seal when a leak is detected by evidence of oil sprayed in large amo
176. ETAINER VALVE ROD SPRING SILENCER RETAINER VALVE OPERATING ROD OVERHAUL MANUAL 5 8 BRAKES NORMAL LANCE NORMAL LANCE Fig 5 3B Lances in Rear Housing 17 Remove the front housing and return spring 18 Remove three nuts and washers from Spanner Wrench and separate wrench and rear housing 19 Remove Holding Fixture J 22805 from front housing 20 Work edges of front diaphragm from under lances of rear housing and remove complete vacuum assembly from rear housing using care not to damage rear housing seal Bosses on center plate must be aligned with cutouts in rear housing to remove the assembly 21 Wet the rear diaphragm retainer with denatured alcohol and remove the retainer using fingers only 22 Clamp Tool J 22839 in a vise Place the diaphragm and plate assembly on the tool with the tool seated in the hex opening in the front plate 1 2 OPEN END WRENCH J 22805 Fig 5 4B Holding and Separating Housings Using J 22805 and J 9504 in Arbor Press OVERHAUL MANUAL 23 Twist the rear diaphragm plate counterclockwise using hand leverage on the outer edge of the plate It may be necessary to use a 1 x 1 3 16 x 8 wood strip as a lever in cover slot on outside circumference of rear plate 24 After the two 2 plates have been loosened remove the plates from Tool J 22839 and place on a bench with the front plate down Unscrew the rear plate completely and carefully lift it off the fron
177. Fig 7A 93B Low and Reverse Clutch Assembly Exploded View OVERHAUL MANUAL 350 7A 30 AUTOMATIC TRANSMISSION LOW AND REVERSE OVERRUN CLUTCH RACE Fig 7 94 Overrun Clutch Inner Race 2 Remove low and reverse overrun clutch inner race from support fig 7A 94B 3 Remove low and reverse clutch roller clutch retaining ring fig 7A 95B 4 Remove low and reverse roller clutch assembly fig 7A 96B LOW amp REVERSE ROLLER CLUTCH RETAINING RING Fig 7A 95B Removing Overrun Roller Clutch Retaining Ring OVERHAUL MANUAL amp REVERSE ROLLER CLUTCH ASSEMBLY T Fig 7A 96B Removing Overrun Roller Clutch Assembly Inspection Inspect foller clutch inner and outer race for scratches and identations 2 Inspect rollers for wear and roller springs for distortion Assembly 1 Install low and reverse roller clutch assembly to inner race with ol holes toward rear of transmission 2 Install low and reverse overrun clutch outer race 3 Install low and reverse clutch to cam retaining ring Low and reverse overrun clutch inner race should free wheel in the clockwise direction only GOVERNOR ASSEMBLY All components of governor assembly with exception of driven gear are a select fit and each assembly is calibrated The governor including the driven gear is serviced as a complete assembly The driven gear can be serviced separately It is necessary
178. G Fed fmm eh bs d Cot 1 r DIRECT CLUTCH TO PUMP HUB HOOK TYPE OIL SEAL RINGS 2 TW VM qu Z DRIVEN d AUTOMATIC TRANSMISSION 350 7A 17 2 Install special tools J 22269 and J 24675 and compress spring and piston only enough to install retaining ring Align piston and oil seal ring when entering bore 3 Install the detent valve washer outer spring inner spring spring seat and spring retainer Install detent valve stop and detent valve actuating bracket Torque bolt to 52 in los Assembly detent actuating lever with retaining pin 4 Install the pressure regulator valve spring reverse and modulator boost valve intermediate boost valve boost valve sleeve and retaining pin 5 In the next bore up install 2 3 shift valve shift valve spring 2 3 shift control valve shift control 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 OIL PUMP FIG 7A 57B Disassembly 1 Place pump cover and stator shaft assembly through hole in bench INTERMEDIATE CLUTCH PISTON ASSEMBLY FORWARD CLUTCH TO PUMP HUB TEFLON OIL RINGS 2 SPRING RETAINER n
179. G PISTON SPRING PLATE BACKING RINGS ASSEMBLY ASSEMBLY ASSEMBLY THRUST FORWARD FORWARD SNAP COMPOSITION FLAT SNAP WASHER CLUTCH CLUTCH RING FACED STEEL RING DIRECT TO PISTON APPLY PLATE PLATE FORWARD SEALS RING CLUTCH Fig 7A 110A Forward Clutch Assembly Exploded View J 25024 THRUST WASHER J 23327 1 FORWARD f 1 CLUTCH W Fr 25018 ASSEMBLY FORWARD H CLUTCH TI GE L 3 Fig 7A 11 1A Removing or Installing Forward Clutch to Fig 7A 113A Removing or Installing Forward Clutch Release Direct Clutch Thrust Washer Spring Snap Ring SNAP FORWARD CLUTCH PISTON RING CLUTCH BACKING PLATE FORWARD CLUTCH ASSEMBLY CLUTCH OUTER SEAL LIP UP Fig 7A 112A Removing or Installing Snap Ring from Forward Clutch Housing Fig 7A 114A Removing or Installing Outer Piston Seal 17 Inspect the forward clutch piston and clutch apply ring assembly for cracks or damage The apply ring is identified as shown in Fig 7A 82A 18 Inspect forward clutch housing for cracks opened oil passages or other damage Fig 7A 116A 19 Check for free operation of check ball 20 Inspect forward clutch housing snap ring groove for damage or burrs 21 Inspect turbine shaft for open oil passages on both ends of shaft and journals for damage 22 Inspect cup plug for damage If cup plug is damaged or missing proceed as follows a Use 4 m No 3 easy out grind to fit and remove cup plug m
180. G PROCEDURES FOR A C SYSTEMS in the AIR CONDITIONING section 2 Remove the Clutch Plate and Hub assembly and shaft key as described in A 6 Compressor Clutch Plate and Hub Assembly Removal procedure 3 Pry out the sleeve retainer and remove the absorbent sleeve Remove the shaft seal seat retaining ring using Snap Ring Pliers J 5403 3 21 See Figure 1D 21 4 Thoroughly clean inside of compressor neck area surrounding the shaft the exposed portion of the seal seat and the shaft itself This is absolutely necessary to prevent any dirt or foreign material from getting into compressor 5 Place Seal Protector J 22974 over the end of the shaft to prevent chipping the ceramic seat Fully engage the knurled tangs of Seal Seat Remover Installer J 23128 into the recessed portion of the seal seat by turning the handle clockwise Remove the Seal Seat from the compressor with a rotary pulling motion Figure 1D 22 Discard the Seat SNAP RING PLIERS 21 J 5403 SEAL SEAT RETAINER RING FRONT HEAD Figure 10 21 Removing or Installing 6 Shaft Seal Seat Retaining Ring NOTICE DO NOT tighten the handle with a wrench or pliers however the handle must be hand tightened securely to remove the seat 6 With Seal Protector J 22974 still over the end of the shaft seat Seal Remover Installer J 9392 down over shaft end turning clockwise while pressing down to engage remover tangs with the tabs on the Seal asse
181. H RELEASE SPRING 3 Fig 7A 123C Installing Intermediate Clutch Release Springs 4 Install three 3 release springs into holes of spring guide Space equally during assembly Fig 7A 123C 5 Place spring retainer and snap ring over springs Fig 7A 124C Installing Intermediate Clutch Piston Snap Ring AUTOMATIC TRANSMISSIONS 400 7A 39 Fig 7A 125C Teflon Rings 6 Compress springs and install snap ring Fig 7 124C 7 Install four 4 oil seal rings on the center support When installing teflon oil seal rings make sure slit ends are assembled in same relation as cut Fig 7A 125C Also make sure oil seal rings are seated in ring grooves to prevent damage to rings during re assembly of mating parts over rings Retain with petrolatum 8 Air check operation of intermediate clutch piston Fig 7A 126C Fig 7A 126C Air Checking Intermediate Clutch Piston 400 7A 40 AUTOMATIC TRANSMISSIONS REACTION CARRIER SPACER RING Fig 7A 127C Inspecting Spacer Ring Inspection of Reaction Carrier Roller Clutch and Output Carrier Assembly 1 If the reaction carrier has a spacer ring in an undercut at the bottom of the roller cam ramps inspect it for damage Fig 7A 127C Fig 7A 128C Checking Pinions End Play Fig 7A 129C Checking Output Carrier Pinion End Play The reaction carrier with the undercut and spacer ring is used optionally and interchangeably with the reaction car
182. HAFT 1 Using snap ring pliers remove the 2nd and 3rd speed sliding clutch hub snap ring from mainshaft and remove clutch assembly second speed blocker ring and second speed gear from front of mainshaft See Fig 7B 7A 2 Depress speedometer retaining clip and slide or tap gear from mainshaft 3 Remove rear bearing snap ring from mainshafi groove See Fig 7B 8A 4 Support reverse gear with press plates and press on rear of mainshaft to remove reverse gear thrust washer spring washer rear bearing and snap ring from rear of mainshaft See Fig 7B 9A 5 Remove the Ist and Reverse sliding clutch hub snap ring from the mainshaft and remove the clutch assembly Ist speed blocker ring and first speed gear from rear of the mainshaft Under certain tolerance conditions it may be necessary to press the synchronizer hub and gear from the mainshaft CLEANING AND INSPECTION Transmission Case 1 Wash the transmission thoroughly inside and outside with cleaning solvent then inspect the case for cracks 2 Check the front and rear faces for burrs and if present dress them off with a fine mill file OVERHAUL MANUAL emp 2 6 56012 uoissiusue1 peedg e vi g 22 23 24 25 26 Clutch Gear Bearing Retainer Pilot Bearings Case 3rd Speed Blocker Ring 2 3 Synch Snap Ring 2 3 Synch Hub 2nd Speed Blocker Ring 2nd Speed Gear 3 455 6 7 8 9 3r 32 33 1st Speed Gear 1st Spee
183. HICKNESS Identification Thickness Notches and or Numeral 074 078 None 082 086 1 Tab Side 090 094 2 Tab Side 098 102 Fabi 4 106 110 2 Tabs Q D s 32 sz sus 5 114 118 Tabs QD Lc 6 Fig 7A 38C Rear End Washer Thickness Chart If a different washer thickness is required to bring end play within specification it can be selected from the chart shown in Fig 7A 38C 10 Remove center support to case bolt Fig 7A 39C using a 3 8 12 point thin wall deep socket Fig 7A 36C Removing Sun Gear Shaft Fig 7A 39C Removing Center Support Bolt 400 7A 12 AUTOMATIC TRANSMISSIONS COMPOSITION PLATES 8 Fig 7A 40C Removing Intermediate Backing Plate and Clutch Plates 11 Remove intermediate clutch backing plate to case snap ring 12 Remove intermediate clutch backing plate as shown in Fig 7A 40C 13 Remove intermediate clutch plates a All except CB CL and CD models Remove three 3 composition two 2 steel clutch plates and one waved steel plate b CB CL and CD models Remove three 3 composition and three 3 steel clutch plates 14 Remove center support to case retaining snap ring Fig 7A 41C Fig 7A 41C Removing Center Support to Case Retaining Snap Ring Fig 7A 42C Removing Center Support and Gear Unit from Case 15 Remove entire gear unit assembly by lifting with gear assembly installing and removing Holding Tool J
184. Halves Replace front and rear cylinders if any cylinder bore is deeply scored or damaged 16 Needle bearings may be removed if necessary by driving them out with special Thin Wall Socket J 9399 Insert socket in hub end inner side of cylinder head and drive bearing out To install needle bearing place cylinder half on Support Block J 21352 and insert bearing in end of cylinder head with bearing identification marks UP Use Needle Bearing Installer J 9432 and drive bearing into cylinder head Figure 1D 40 until Installer bottoms on the cylinder face Two different width needle bearings are used in Production compressors a 1 2 size and a 5 8 size The bearings are interchangeable Service replacement bearings are all 1 2 NEEDLE BEARING INSTALLER J 9432 NEEDLE BEARING CYLINDER HEAD SUPPORT BLOCK J 21352 Figure 1D 40 Installing A 6 Needle Bearing 17 Wash all parts to be re used with naphtha stoddard solvent kerosene or a similar solvent Air dry parts using a source of clean dry air A 6 compressor internal components may be identified by referring to Figure 1D 2 and Figure 1D 3 A 6 COMPRESSOR INTERNAL CYLINDER AND SHAFT ASSEMBLY Gaging Operation 1 Install Compressing Fixture J 9397 on Holding Fixture J 9396 in vise PLACE FRONT CYLINDER HALF in Compressing Fixture flat side down Front cylinder half has long slot extending out from shaft hole Legs of front cylinder half will be pointed
185. Holding Fixture and Base OVERHAUL MANUAL AUTOMATIC TRANSMISSION 350 7A 1 SECTION 7A 350 AUTOMATIC TRANSMISSION UNIT REPAIR OVERHAUL INDEX Transmission Disassembly and Reassembly TA 3 Low and Reverse Roller Clutch Support 7A 28 Disassembly 4 7 3 Disassembly oie tees 7A 28 Converter 4 4040 7 3 I speetlonzn Sec dco 7A 30 Converter End Clearance Check 7 4 Assembly eo son OT TER 7A 30 Removal of Extension Speedometer Driven Gear Governor Assembly ccccccsseceecsssseseeeseaeeeteretens 7A 30 Oil Pan and Screen EEN 7 4 NEE 7A 31 Removal of Valve Body and Lnkage 7 6 Ee 7A 31 Removal of Oil Pump and Internal Case Governor Driven Gear Replacement 7A 3 riter OT TERMIN 7A 9 Reassembly o ee etit 7 31 Valve ttu dee 7 16 Bushing Replacement 2 02 040042 2 7 31 Disassembly ees arae nid dde 7 16 Extension Housing Bushing sss 7 31 Inspection idt seen ee Get Eed 7 16 Output Shaft eeteeeeneees 7A 32 Reassembly EEN 7A 16 ase TE
186. ING LOCK WASHER TO SIDES OF SCREW HEAD AND DOWN OVER EDGE OF PULLEY RIM 3 MOUNTING NOTCH LOCATIONS 6198 Figure 1D 92 R 4 Pulley Rim and Inertia Ring Mounting Detail 11 Assemble the Inertia Ring onto the Pulley Rim being careful to align the Inertia Ring mounting holes with the mounting holes in the Pulley Rim If the Inertia Ring cannot be moved by hand and must be rotated for centering the mounting holes use a drift punch or blunt tool and a hammer to carefully tap at one of the large clearance notches in the inertia ring to rotate the ring into position Figure 1D 92 12 Install the special lock washers onto the 1 4 28 X 17 32 mounting screws and apply Loctite 601 or equivalent sealer to the total screw thread and the threads of the mounting holes in the rotor 13 Install the screw and washers into the rotor mounting holes and tighten finger tight When all screws are in place torque each screw to 100 in lbs torque 14 Using Rotor and Bearing assembly Installer J 26271 and Universal Handle J 8092 install the Pulley Clutch Coil Rotor and Bearing assembly onto the Front Head of the compressor Be sure to locate the clutch coil terminals in the proper position 15 Spin the Rotor and Pulley assembly to ascertain that the pulley runs in line If not the mounting screws will have to be loosened and the parts aligned 16 When all screws are torqued in place lock all mounting screws in position by flatte
187. ING RING Fig 7A 144A Intermediate Servo Exploded Intermediate Servo Piston Assembly Fig 7A 144A Inspection 1 Inspect pin and oil seal rings for damage and fit in case bore 2 Inspect inner and outer piston seal rings for damage and free fit in ring grooves Do not remove unless replacing 3 Inspect springs 4 Inspect intermediate servo cover and piston assembly for proper combination and usage See Fig 7A 145A 5 Check for proper intermediate band apply pin as follows a Install J 25014 2 in intermediate servo bore and retain with intermediate servo cover retaining ring aligning Servo Cover Inner Piston Model Identified Cast No on Cover No on Piston T1 n gt Outer Piston Identified By Cast Identified By No Of Steps on Piston OI 8632144 8632155 1 Step OX AX OT AS CS OW OR OF OZ CA PG CR CU PH 2 Steps 8632145 8632156 8632141 8632157 3 Steps BR CX PA PY PT PB 2 8630566 Wide Band 8630569 PISTON LDA NO STEP SWIDE BAND Fig 7A 145A Intermediate Servo Cover and Piston Usage Chart OVERHAUL MANUAL DIAL INDICATOR J 8001 Fig 7A 146A Intermediate Band Apply Gages ring with gap at case slot Fig 7A 146A b Install pin J 25014 1 into J 25014 2 Make sure the tapered pin end is properly located against the band apply lug Also make sure the band anchor pin is properly located in the case and b
188. INING STRAP Figure 1D 108 Releasing R 4 Shell Retaining Strap J 25008 1 HOLDING FIXTURE SHELL TO CYLINDER STEP CONTACTS COMPRESSOR SHELL 4696 Figure 10 109 Removing RA Shell Replace 1 Check the compressor cylinder assembly and interior of the compressor Shell to be sure they are free of lint dirt etc 2 Dip a new cylinder to shell O ring in clean 525 viscosity refrigerant oil and install in the rear O ring groove of the cylinder Be careful in moving the O ring across the cylinder surface to prevent damaging the O ring 3 Dip the remaining cylinder to shell O ring in the 525 oil and install it in the front O ring groove of the cylinder AIR CONDITIONING COMPRESSOR OVERHAUL 1D 41 4 Also coat inner surface of compressor Shell with the oil and swab oil onto shell to cylinder O rings Place the compressor Shell on the cylinder and rotate the retaining strap to its original location 5 Attach the Shell Intalling Fixture J 25008 2 to the Holding Fixture J 25008 1 using the long bolts and plate washers of the set Align the step projections of the Installing Fixture J 25008 2 to contact the compressor Shell evenly on both sides 6 Push the compressor shell as close to the O ring Figure 1D 110 as possible by hand and check for equal alignment of the shell around the cylinder Tighten the Fixture screws finger tight ALTERNATELY TIGHTEN SCREWS APPROX J 25008 1 HOLDING FIXTURE J 25008 2 COMPRESSO
189. IVE GEAR TANGS UP Fig 7A 71C Installing Pressure Regulator Retaining Pin and Bore Plug 7 Remove pump cover from body 8 Remove retaining pin and bore plug from pressure regulator bore Fig 7A 71C 9 Remove hook type oil rings from pump cover 10 Remove pump to forward clutch housing selective washer 11 Mark drive and driven gears for reassembly in same position and remove from the pump body See Fig 7A 72C PUMP DRIVE GEAR TANGS Fig 7A 72C Installing Pump Drive Gear PUMP COVER FOR IDENTIFICATION SQUARED OFF PRESSURE REG 8OSS Fig 7A 73C Pressure Regulator Valve Identification Inspection of Pump Body and Pump Cover NOTICE A solid type pressure r gulator valve must only be used in a pump cover with a squared off pressure regulator boss See Fig 7A 73C A pressure regulator valve with oil holes and orifice cup plug may be used to service either type pump cover 1 Inspect drive and driven gear pocket and crescent for scoring galling or other damage 2 Place pump gears in pump body and check pump body face to gear face clearance should be 0008 0035 Fig 7A 74C 3 Check face of pump body for scores or nicks 4 Check oil passages Fig 7A 75C 5 Check for damaged cover bolt attaching threads 6 Check for overall flatness of pump body face Fig 7A 74C Checking Pump Body Face to Gear Face Clearance AUTOMATIC TRANSMISSIONS 400 7 23 CONVERTER C
190. J 21351 20 Generously oil Rear Discharge Valve Plate assembly with 525 viscosity refrigerant oil around outer edge where large diameter O ring will be placed Oil the valve reeds pump gears and area where sealing surface will contact Rear Discharge Valve Plate Figure 1D 67 A 6 Front Head O Ring Installed 21 Using the 525 oil lubricate new head to shell O ring and install on rear discharge valve plate in contact with shell Figure 1D 71 AIR CONDITIONING COMPRESSOR OVERHAUL 1D 25 22 Install Suction Screen in rear head casting using care not to damage screen 23 Coat sealing surface on webs of compressor rear head casting with 525 viscosity refrigerant oil 24 Install Rear Head assembly over studs on compressor shell The two lower threaded compressor mounting holes should be in alignment with the compressor sump Make certain that suction screen does not drop out of place when lowering rear head into position Figure 1D 72 CAVITY BETWEEN GEAR TEETH 3 O CLOCK INNER GEAR OIL SUMP 6 O CLOCK OIL DRAIN PLUG 24 Figure 10 70 Positioning 6 Oil Pump Gears SHELL TO HEAD O RING CYLINDER ASSEMBLY 4955 Figure 1D 71 A 6 Shell To Front Head O Ring Installation If Rear Head assembly will not slide down over dowels in Internal Cylinder and Shaft Assembly twist Front Head assembly back and forth very slightly by hand until Rear Head drops over dowel pins 25 Install nuts o
191. J 21777 45 on the ends of arbor J 21777 1 using the step of the disc that corresponds to the bore of the carrier 6 Place the arbor and plunger assembly into the carrier being sure the side bearing discs are seated properly 7 Install the bearing caps finger tight to hold the discs from movement 8 Position dial indicator J 8001 on the mounting post of the arbor with the contact button resting on the top surface of the plunger 9 Preload the dial indicator one half revolution and tighten in this position 10 Select the button on the gage plate that corresponds to the ring gear size and rotate the plate until the plunger rests directly upon that button Fig 9B Installing Differential Shim Fig 11B Checking Ring Gear Runout OVERHAUL MANUAL 4B 8 REAR AXLE DIFFERENTIAL Fig 12B Drive Pinion Nut Removal 11 Rock the plunger rod slowly back and forth across the button until the dial indicator reads the greatest deflection At this point set the dial indicator to zero Tools will now be positioned as shown in figure 20B It is important to use a dial indicator correctly when determining pinion depth requirements Be sure to record the number indicated by the indicator needle do not record the amount of travel of the needle After zeroing the dial indicator on the highest point of deflection on the gauge plate the indicator probe is swung off the gauge plate allowing the needle to move The number which the needl
192. LL 3 13 1 2 SHIFT VALVE 29 SHIFT T V VALVE 45 CHECK BALL 2 14 1 2 THROTTLE VALVE 30 SHIFT T V SPRING 46 CHECK BALL 1 Note Sth Check 15 1 2 THROTTLE VALVE SPRING 31 RETAINING COILED PIN Ball Is In The Case 16 1 2 THROTTLE VALVE BUSHING 32 SHIFT T V BORE PLUG Fig 7A 152A Control Valve Assembly Exploded View throttle valve and 2 3 shift valve The 2 3 throttle valve spring and 2 3 throttle valve may be inside the 2 3 throttle valve bushing 6 From next bore down remove coiled pin Remove 1 2 throttle valve bushing 1 2 throttle valve spring 1 2 throttle valve and 1 2 shift valve The 1 2 throttle valve spring and the 1 2 throttle valve may be inside the 1 2 throttle valve bushing 7 From next bore down remove coiled pin and bore plug Remove reverse boost spring and reverse boost valve 8 Check the operation of the shift T V valve in the next bore down by moving the valve against the spring If it is necessary to remove the valve proceed as follows Figs 7A 153A and 7A 154A a Remove coiled pin and place valve body on shop towel with rough casting surface up b Using needle nose pliers compress the shift T V spring by pushing on the shift T V valve hold valve with small screwdriver c Place 6 3mm 1 4 rod 9 5mm 3 8 long against the end of the shift T V valve d Prying on end of the rod with a large screwdriver remove small screwdriver and remove shift T V plug shift T V spring an
193. LT Fig 7B 3B Drain Transmission 16 Using a long thin punch 1 4 inch diameter or less insert through access hole in rear case to drive out shift rail and expansion plug located in shift rail bore at front of case 17 Rotate second third shifter fork upward and out of case 18 Remove the bottom detent plug and short detent spring from case 19 Separate clutch gear from output shaft and remove output shaft assembly Fig 7 10 tilt spline end of shaft downward and lift gear end upward and out of case First and reverse sleeve and gear must pass through notch at right rear end of case 20 Remove clutch gear through top of case 21 Remove both shifter fork shafts Fig 7B 11B UPPER DETENT SPRING LONG Fig 7B 4B Location of Upper Detent Spring NOTE ALIGN ROLL PIN HOLE WHEN INSTALLING DUMMY SHAFT TOOL J 25232 COUNTERSHAFT Fig 7B 5B Removing Countershaft 22 Remove countergear with tool in place thrust washers and roll pin 23 Remove reverse idler gear and thrust washers by tapping shaft with hammer until end of idler gear shaft end with roll pin clears counterbore in rear of case and remove shaft Fig 7B 12B 24 From the bottom of the case retrieve clutch shaft roller bearing or countergear needle bearing that may have fallen into case during disassembly ALIGNMENT MARKS Fig 7B 68 Removing Front Bearing Retainer OVERHAUL MANUAL 7B 12 MANUAL TRANSMISSION 1 6654 01
194. Lockout Shift Rail Poppet Plug Gasket Spring and Ball Thrust Washer Lubricating Thrust Washer Retaining Ring Flange Lock Nut Seal Front Output Yoke Dust Shield Front Output Shaft Seal Front Output Shaft Bearing Retainer Front Output Shaft Bearing Bearing Outer Ring Bearing Retainer Gasket Front Output Shaft Front Output Shaft Rear Bearing Front Output Rear Bearing Retainer Cover Gasket Front Output Rear Bearing Retainer Drive Shaft Sprocket Drive Chain Retaining Ring Sliding Lock Clutch Leckout Shift Rail Shift Fork Retaining Pin Lockout Shift Fork Lockout Clutch Spring Spring Washer Cup Front Side Gear Front Side Gear Bearing and Spaces 123 Bearings Req d Differential Carrier Assembly 132 Bearings Req d Rear Output Shaft Roller Bearings 15 Req d Rear Output Shaft Speedometer Drive Gear Rear Output Shaft Front Roller Bearing Oil Pump 0 Ring Seal Rear Output Housing Gasket Rear Output Housing Front D Ring Seal Rear Output Housing Rear Shim Pack Bearing Retainer Rear Output Rear Bearing Rear Output Shaft Seal Rear Output Flange Rear Output Shaft Rubber Seal Washer Flange Nut Fig 7D 12S Model 203 Transfer Case Exploded View Continued OVERHAUL MANUAL TRANSFER CASES 70 15 Fig 7D 13S Removing Input Shaft to Bearing Snap Ring 14 Clean and inspect all componen
195. MISSIONS 400 7 44 Fig 7 138 Checking Converter 1 Inspect case assembly for cracks porosity or inter connected passages 2 Check for good retention of band anchor pins 3 Inspect all threaded holes for thread damage 4 On model CL inspect studs for thread damage and make sure they are tight The two 2 studs at 9 o clock and 11 o clock when viewed from the rear of case and transmission in vehicle are approximately 1 4 longer than the other four 4 studs These two longer studs are required to accommodate the parking brake actuating cable bracket 5 Inspect intermediate clutch driven plate lugs for damage or brinneling Fig 7A 139C Loosening Collet Tool J 2157 1 8 If the case assembly requires replacement remove the nameplate from the old case and re install it on the new case using the truss head nameplate attaching screw that is serviced with the case 6 Inspect snap ring grooves for damage 7 Inspect bore for governor assembly for scratches or scoring 8 Inspect modulator valve bore for scoring or damage 9 Inspect cup plug inside case for good staking and sealing 10 Inspect case bushing If necessary to replace proceed as follows Case Bushing Remove With case properly supported using tool J 21465 8 with Driver Handle J 8092 remove bushing Replace Using tool J 21465 8 adaptor ring J 21465 9 Driver Handle J 8092 and extension J 21465 13 with lube passage
196. NG COMPRESSOR STEERING REAR AXLE FRONT WHEEL DRIVE CAUTION This vehicle contains some parts dimensioned in the metric system as well as in the customary system Some fasteners are metric and are very close in dimension to familiar customary fasteners in the inch system It is important to note that during any vehicle mainte nance procedures replacement fasteners must have the same measurements and strength as those removed whether metric or customary Numbers on the heads of metric bolts and on surfaces of metric nuts indicate their strength Customary bolts use radial lines for this purpose while most customary nuts do not have strength markings Mismatched or incorrect fasteners can result in vehicle damage or malfunction or possibly personal injury There fore fasteners removed from the vehicle should be saved for re use in the same locations whenever possible Where the fasteners are not satisfactory for re use care should be taken to select a re placement that matches the original For information and assis tance see your Authorized dealer BRAKES AUTOMATIC TRANSMISSION MANUAL TRANSMISSION CLUTCH TRANSFER CASE 1979 General Motors Corporation Printed In U S A AIR CONDITIONING COMPRESSOR OVERHAUL 10 1 SECTION 1D AIR CONDITIONING COMPRESSOR OVERHAUL For Compressor REMOVAL AND INSTALLATION see Air Conditioning Section For DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES
197. O CASE INSIDE DETENT LEVER AND PIN ASSEMBLY HEX PARK ACTUATOR ASSEMBLY PARKING PAWL PARKING PAWL RETURN SPRING MANUAL DETENT ROLLER AND SPRING ASSEMBLY BOLT BRACKET TO CASE r4 H PARK BRACKET PARKING PAWL SHAFT SLOTTED SPRING PIN STEEL CUP PLUG Fig 7A 52A Manual Shaft and Parking Shaft Parts OVERHAUL MANUAL 200 7A 14 AUTOMATIC TRANSMISSION SHAF 14MM 9 16 SEAL SOCKET Fig 7 A 53A Installing Manual Shaft Seal Into Case 2 If removed install new manual shaft seal with lip facing inward into transmission case using a 13mm or 9 16 socket to seat seal Fig 7A 53A 3 Install parking pawl and return spring with tooth toward inside of case and parking pawl return spring under pawl tooth with spring ends toward inside of case Fig 7A 54A Make sure spring ends locate against case pad 4 Align parking pawl and return spring with case shaft bore 5 Install parking paw shaft tapered end first 6 Using 10mm 3 8 rod install new parking pawl shaft cup plug open end out past retaining pin hole Fig 7A 55A 7 Install parking pawl shaft retaining pin 8 While holding the parking pawl toward center of transmission install parking bracket Torque bolts to 20 0 27 0 N m 15 20 ft Ibs 9 Install parking actuator rod into inside detent lever on pin side locating lever between actuator rod tangs 10 Install parking actuator rod and inside de
198. OOLER INTAKE SEAL DRAIN BACK HOLE REVERSE MODULATOR OR INTERMEDIATE Fig 7A 75C Pump Body Oil Passages 7 Check bushing for scores or nicks If replacement is necessary proceed as follows a Using Tool J 21465 17 and driver Handle J 8092 remove bushing b From front side of pump using J 21465 17 and driver Handle J 8092 install new bushing flush to 010 below gear pocket face 8 Inspect pump attaching bolt seals for damage replace if necessary 9 Inspect pump cover face for overall flatness 10 Check for scores or chips in pressure regulator bore 11 Check that all passages are open and not interconnected Fig 7A 76C DRIVE MODULATOR OR m un gt INTERMEDIATE e N REVERSE e j tJ 2 EXHAUST F UNE __ dk BREATHER 3 CONVERTER PRESSURE REGULATOR LINE FEED HOLE COVER PUMP Fig 7A 76C Pump Cover Oil Passages 400 7A 24 AUTOMATIC TRANSMISSIONS PRESSURE REGULATOR VALVE PRESSURE REGULATOR SPACER SPRING RETAINER 59 PRESSURE REGULATOR SPRING PRESSURE BOOST VALVE PRESSURE BOOST BUSHING SNAP RING RETAINING PIN BORE PLUG PUMP COVER THRUST WASHER PUMP OIL SEAL RINGS Fig 7A 77C Pump Cover Exploded View 12 Check for scoring or damage at pump gear face 13 Inspect stator shaft for damaged splines or scored bushings If replacement of bushing is necessary proceed as follows Front a With pump cover an
199. OR CLUTCH PLATE AND HUB ROTOR AND BEARING AND COIL PULLEY RIM ARE COVERED AS MINOR BECAUSE THEY MAY BE PERFORMED WITHOUT FIRST PURGING THE SYSTEM OR REMOVING THE COMPRESSOR FROM THE VEHICLE The Compressor Shaft Seal assembly Pressure Relief Valve and Pressure Switch may also be serviced WITHOUT REMOVING THE COMPRESSOR from the vehicle but these operations are covered later in this section as Major Repair Procedures because the system MUST FIRST BE PURGED of Refrigerant 12 Illustrations used in describing these operations show the compressor removed from the vehicle only to more clearly illustrate the various operations When servicing the compressor remove only the necessary components that preliminary diagnosis indicates are in need of service Refer to the AIR CONDITIONING section Figure 1D 74 and Figure 1D 75 for information relative to parts nomenclature and location Removal and installation of external compressor components and disassembly and assembly of internal components must be performed on a clean workbench The work area tools and parts must be kept clean at all times R 4 COMPRESSOR 10 0 CU IN DISPLACEMENT Figure 1D 73 R 4 Compressor R 4 COMPESSOR CLUTCH PLATE AND HUB ASSEMBLY Remove 1 If compressor is not removed from the car loosen compressor mounting brackets disconnect the compressor drive belt and reposition the compressor for access if necessary If compressor has been removed from t
200. R CLUTCH GEAR GASKET CLUTCH GEAR BEARING RETAINER SEAL ASSEMBLY CLUTCH GEAR BEARING RETAINER CLUTCH GEAR BEARING RETAINING RING CLUTCH GEAR BEARING LOCK RING CLUTCH GEAR BEARING ASSEMBLY CLUTCH GEAR EXPANSION PLUG FILLER PLUG TRANSMISSION CASE MAGNET CASE amp 5 amp 5 28ggzZZ85 g25z 2222828 EXTENSION HOUSING TO CASE GASKET SPEEDOMETER DRIVER GEAR RETAINING CLIP TRANSMISSION REAR BEARING LOCK RING MAINSHAFT BEARING ASSEMBL Y SPEEDOMETER DRIVE GEAR EXTENSION TO CASE WASHER EXTENSION TO CASE BOLT TRANSMISSION EXTENSION VENTILATOR ASSEMBLY EXTENSION HOUSING ASSEMBLY EXTENSION HOUSING BUSHING EXTENSION HOUSING OIL SEAL ASSEMBLY COUNTERGEAR THRUST WASHER COUNTERGEAR SPACER COUNTERGEAR ROLLET BEARINGS COUNTERGEAR SHAFT COUNTERGEAR SPRING PIN COUNTERGEAR 2ND amp IRD SHIFTER FORK SHIFT FORK LOCKING SCREW 1ST ZND SHIFTER INTERLOCK SPRING SHIFTER INTERLOCK PIN IST amp REVERSE SHIFT RAIL 1ST amp REVERSE SHIFT FORK 2ND amp IRD SHIFTER INTERLOCK SPRING 2 0 amp 3RD SHIFT RAIL REVERSE IDLER GEAR THRUST WASHER REVERSE IDLER GEAR SHAFT SPRING PIN IDLER GEAR SHAFT REVERSE IDLER GEAR BUSHING REVERSE IDLER GEAR REVERSE IDLER GEAR ASSEMBLY SEAL TRANSMISSION SHIFTER TRANSMISSION SHIFTER SHAFT amp LEVER ASSEMBLY Fig 7B 2B Exploded View 3 Speed 77mm Transmission MANUAL TRANSMISSION 7B 11 DRAIN BO
201. R f SHELL INSTALLER Figure 1D 110 Installing R 4 Shell 7 Using a wrench alternately tighten each bolt approximately 1 4 turn to push the compressor Shell over the O rings and back against the shell stop flange at the rear of the compressor cylinder If one screw appears to require more force to turn than the other immediately turn the other screw to bring the screw threading sequence in step or the Shell will be cocked and made more difficult to install Normal installation does not require much force on the wrench if the screws are kept in step while turning 8 When the Shell is seated against the stops bend the shell retaining strap down into place by tapping gently with a hammer Remove the Shell Installing Fixture J 25008 2 9 Re install Clutch Rotor and Bearing Assembly Clutch Coil and Pulley Rim as an assembly with Installer J 26271 Figure 1D 88 and the Clutch Plate and Hub Assembly with Installer J 9480 01 Figure 1D 80 10 Evacuate and Charge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR A C SYSTEMS IN THE AIR CONDITIONING section R 4 COMPRESSOR DISCHARGE VALVE PLATE AND OR RETAINER Remove and Replace 1 Discharge the Refrigerant System according to the the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR C C O T A C SYSTEMS in the AIR CONDITIONING section 2 Perform Steps 1 through 9 of RA Compressor Shell
202. R BEARING RACE SMALL THRUST BEARING SPACER BEARING RETAINER RETAINER Screwdriver Pry bearing retainer atraised area Driver J 7079 2 Installer J 8524 1 Also use for seal installation after bearing is in place a Bearing with identification toward tool e PLUG Install bearing and seals gear make sure angle of thrust races are as shown DISASSEMBLE 1 Disassemble parts as shown VALVE BODY O RING VALVE BODY STUB SHAFT 7 Ve Shaft cap Mag SC lightly on wood block 8 DISASSEMBLE AND ASSEMBLE VALVE VALVE SPOOL AM ach ASSEMBLE 1 Assemble parts as shown VALVE BODY RING teflon N Pin on shaft and hole in spoo Disengage to remove mm Rotate while removing or installing 34 with power steering fluid Fig 3B3 9C Overhaul 800 and 808 Gears Chart D C Remove and install spool Lubricate spool and body D Engage stub shaft Notch must fully engage pin and cap must seat against shoulder OVERHAUL MANUAL 3B 16 STEERING DISASSEMBLE AND ASSEMBLE RACK REMOVE AND INSTALL PITMAN SHAFT PISTON SEALS AND BEARING REMOVE INSTALL Clean end of 1 Coat seal lip and washer face Disassemble parts 1 Assemble parts housing thoroughly with anhydrous calcium grease as shown as shown to prevent dirt from entering and be lean and in t
203. R CONDITIONING COMPRESSOR OVERHAUL O Ring dE EE Dischorge Crossover Tube Bushing 0922 Figure 1D 58 Service type A 6 Discharge Cross Over Tube DISCHARGE CROSSOVER IUBE FRONT CYLINDER HALF Figure 1D 59 Installing A 6 Discharge Cross over Tube Shaft Assemblies that have been disassembled in the field Also see Figure 1D 58 3 Install new dowel pins in front cylinder half if previously removed 4 Install Front Suction Reed Plate on front cylinder half Align with dowel pins suction ports oil return slot and discharge cross over tube Figure 1D 63 5 Install Front Discharge Valve Plate assembly it has a large diameter hole in the center aligning holes with dowel pins and proper openings in front suction reed plate Figure 1D 64 and Figure 1D 65 6 Coat sealing surfaces on webs of compressor front head casting with clean 525 viscosity refrigerant oil 7 Determine exact position of Front Head casting in relation to dowel pins on Internal Cylinder and Shaft Assembly Mark position of dowel pins on sides of Front Head assembly and on sides of Internal Cylinder and Shaft Assembly with a grease pencil Carefully lower Front Head casting into position Figure 1D 66 making certain that sealing area around center bore of head assembly does not contact shaft as head assembly is lowered Do not rotate head assembly to line up with dowel pins as the sealing areas would then contact the reed retainers 8 G
204. RESSURE REGULATOR SPRING PRESSURE REGULATOR GUIDE PRESSURE REGULATOR VALVE BORE PLUG RETAINER RING Fig 7A 126A Pump Assembly Exploded View clutch housing will be approximately 33 34mm 1 5 16 from the pump face in case when correctly seated See Fig 7 124 6 Remove 7 25021 Pump Assembly Fig 7A 126A Inspection 1 Remove pump to case seal ring and inspect groove for damage 2 Place pump over hole in bench with pump cover side up 3 Remove pump to direct clutch thrust washer and inspect for damage or wear Fig 7A 127A 4 Inspect 3 teflon oil ring seals for damage and free fit in grooves Do not remove unless replacing THRUST WASHER PUMP ASSEMBY Fig 7A 127 A Removing or Installing Thrust Washer from Pump OVERHAUL MANUAL 200 7A 32 AUTOMATIC TRANSMISSION PRESSURE REGULATOR 0 VALVE Fig 7A 128A Removing or Installing Pressure Regulator Valve Pressure Regulator Inspection 1 To prevent the pump from turning while removing the pressure regulator valve place a bolt or screwdriver through a hole in the pump and bench Fig 7A 128A 2 Using small screwdriver push on bore plug compressing pressure regulator spring and using snap ring pliers remove retaining ring Fig 7A 128A 3 Release valve spring tension slowly and remove valve train 4 Inspect pressure regulator valve for nicks or damage 5 Inspect spring and guide for damage or distortion 6 Inspect pres
205. Remove pinion rear bearing snap ring and press bearing from pinion using Tool J 1453 as shown in figure 2G 6 Position drive pinion in an arbor press so that the bearing is supported by two pieces of flat steel stock as shown in figure 3G Place flat stock parallel to each other and against pinion so as to pick up a large area of bearing outer race Press pinion from bearing making sure pinion is supported to prevent damage when removed from bearing Pinion Inspection 1 Wash all parts in cleaning solvent 2 Inspect pinion for scored cracked chipped or worn teeth 3 Inspect splines on pinion shaft for excessive wear 4 Inspect pinion bearing assemblies for roughness defects or excessive wear Pinion Reassembly 1 Pack the cavity between the pinion oil seal lips with a lithium base EP lubricant to provide initial lubrication and to aid in inserting pinion flange REAR AXLE DIFFERENTIAL 4B 35 quio Fig 3G Drive Pinion Front Bearing Removal 2 Press the oil seal into the reatiner Position seal lips toward the pinion bearing using Tool J 22281 as shown in figure 4G 3 Install the pinion rear bearing assembly on pinion shaft making sure that chamfered side of inner race seats against shoulder on pinion shaft Then install pinion bearing lock ring using Tool J 1364 as shown in figure 5G 4 To install pinion front bearing position the one piece double row ball bearing on pinion shaft so that extended portio
206. S tog EQUIVALENT 0160 0520 6261072 0520 0830 6261349 0830 0830 1218 6261350 3 Install twenty one 21 clutch return coil springs 4 Install spring retainer Compress spring retainer and install retaining ring using tool J 23327 1 as shown on Figure 7A 84B 5 Lubricate with trans ission fluid and install cushion spring face m plates and steel separator plates starting with the cushion spring and alternating steel and faced 6 Install forward clutch pressure plate selective fit and retaining ring Using chart on Figure 7 88 to select correct pressure plate dimension C measure distance from the top of clutch pack to the top of clutch drum dimension A Measure distance from the lower edge of the notch on the inner surface of the drum to the end of the drum dimension B Subtract B from A to get dimension C Fig 7A 88B Determining Selective Fit for Forward Clutch Pressure Plate SUN GEAR DRIVE SHELL GA SET G ASSEMBLY 2 A INPUT RING GEAR SUNGEAR LOW AND REVERSE OUTPUT RING GEAR Ke ROLLER CLUTCH REACTION AND OUTPUT SHAFT OUTPUT SUPPORT CARRIER CARRIER at 4 Trim Fig 7 A 89B Planetary Gear Train Exploded View OVERHAUL MANUAL 350 7A 28 AUTOMATIC TRANSMISSION N SUN GEAR NW RETA INING SUN GEAR DRIVE SHELL Fig 7A 90B Removing Sun Gear Drive Shell Rear Retaining Ring SUN GEAR AND SUN GEAR DRIVE SHELL FIG 7A 89B Di
207. SHAFT 5 9 Assemblies and Service Kits 0 GEAR ASSY STEERING 102 VALVE ASSY STEERING GEAR 20 PLUG SERV ASSY ADJUSTER 202 SEAL SERV KIT ADJUSTER PLUG 203 SEAL SERV KIT VALVE RING amp 204 NUT SERV KIT RACK PISTON 205 HOUSING SERV KIT STRG GEAR 206 COVER SERV KIT HSG SIDE 207 GEAR SERV KIT PITMAN SHAFT 208 THIS NUMBER NOT USED 209 SEAL SERV KIT END PLUG 210 SEAL SERV KIT HSG SIDE COVER 211 SEAL SERV KIT MASTER 212 SEAL SERV KIT RACK PISTON 213 VALVE SERV KIT CHECK 214 SEAL SERV KIT PITMAN SHAFT 215 BALL SERV RECIRCULATING 216 BEARING ASSY SERV KIT UPR THR 217 BEARING ASSY SERV KIT LWR THR e 2 STEERING GEAR EXPLODED VIEW Fig 3B3 7C Overhaul 800 and 808 Gears Chart B ELSE 9NIU33LS 3B 14 STEERING 1 REMOVE AND INSTALL PITMAN SHAFT SEALS IN CAR REMOVE Clean exposed end of pitman shaft and end of housing after removing pitman arm Remove retaining ring with snap ring pliers J 4245 Start engine and turn wheels fully to the left to force seals and washer out Turn off engine Inspect housing and shatt PITMAN SHAFT Inspect seal surface for roughness and pitting Puller J 6632 sl Remove Pitman Arm INSTALL 1 Install parts as shown HOUSING ASSEMBLY Inspect for burrs SEAL SINGLE LIP WASHER e g
208. SION FIG 7 1 1 Remove side cover attaching bolts and side cover assembly 2 Remove drive gear bearing retainer and gasket 3 Remove drive gear bearing to gear stem snap ring then remove clutch gear bearing by pulling outward on clutch gear until a screwdriver or other suitable tool can be inserted between bearing large snap ring and case to complete removal Fig 7B 2A The clutch gear bearing is a slip fit on the gear and into the case bore This provides clearance for removal of clutch gear and mainshaft assembly 4 Remove speedometer driven gear from extension 5 Remove extension to case attaching bolts 6 Remove the reverse idler shaft E ring Fig 7B 3A 7 Remove drive gear mainsahft and extension assembly together through the rear case opening Remove drive gear needle bearings and synchronizer ring from mainshaft assembly 8 Using snap ring pliers expand the snap ring in the extension which retains the mainshaft rear bearing Fig 7B 4A and remove the extension 9 Using J 22246 at the front of the countershaft drive the shaft and its woodruff key out the rear of the case Fig 7B 5A Tool J 22246 will now hold the roller bearings in position within the countergear bore Remove the gear bearings and thrust washers 10 Use a long drift or punch through the front bearing case bore and drive the reverse idler shaft and woodruff key through the rear of the case Fig 7B 6A DISASSEMBLY OF MAINS
209. SSEMBLY 1 FORWARD CLUTCH HOUSING DIRECT CLUTCH HUB SNAP RING PUMP ASSEMBLY Fig 7A 89C Installing Forward Clutch Housing to Direct Fig 7A 90C Air Checking Forward Clutch Assembly Clutch Hub Snap Ring SNAP RING INTERMEDIATE CLUTCH RETAINER INTERMEDIATE CLUTCH OUTER RACE INTERMEDIATE ROLLER CLUTCH DIRECT CLUTCH HOUSING AND 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 7A 91C Direct Clutch and Intermediate Roller Assembly SMAP RING CLUTCH RETAINER Fig 7A 92C Removing Intermediate Clutch Retainer Snap Ring 11 Install direct clutch hub and retaining snap ring Fig 7A 89C 12 Place forward clutch housing on pump delivery sleeve and air check clutch operation 7A 90C DIRECT CLUTCH AND INTERMEDIATE ROLLER DISASSEMBLY INSPECTION AND ASSEMBLY Refer to Fig 7A 79C Disassembly Fig 7A 91C 1 Remove intermediate roller assembly retainer snap ring and retainer Fig 7A 92C 2 Remove roller outer race and roller assembly 3 Turn unit over and remove backing plate to direct clutch housing snap ring Fig 7A 93C DIRECT CLUTCH BACKING PLATE DIRECT CLUTCH HOUSING Fig 7A 93C Removing Direct Clutch Backing Plate Snap Ring AUTOMATIC TRANSMISSIONS 400 7A 31 Fig 7A 94C Removing or Installing Direct Clut
210. ST Fig 7A 160A Installing 5th Check Ball OVERHAUL MANUAL 200 7 A 42 AUTOMATIC TRANSMISSION Fig 7A 161A Installing Control Valve Assembly Using Guide Pins 10 Insert 2 control valve assembly to case attaching bolts through the control valve assembly gaskets and spacer plate and install these parts aligning the manual valve with the detent lever pin Fig 7A 161A Make sure check balls 1 2 accumulator piston and manual valve do not fall out 11 Start control valve assembly to case attaching bolts except the throttle lever and bracket assembly and the oil screen attaching bolts The 2 oil screen attaching bolts are about 10mm 3 8 longer than the control valve assembly attaching bolts and they are not interchangeable n 12 Inspect inside manual detent roller and spring assembly for damage 13 Remove guide pins and replace with bolts and inside manual detent roller and spring assembly locating the tang in the control valve assembly and the roller on the inside detern lever Fig 7A 163A INTERMEDIATE LINE RND BOOST Jh INTERMEDIATE EXHAUST LO amp REV CL GOVERNOR a LO 1ST DIRECT CLUTCH wel EXHAUST 1 2 ACCUMULATOR 7 SHIFT TV 4 J ZNO RIL BOOST 14 Throttle lever and bracket assembly a Inspect throttle lever and bracket assembly for damage Fig 7A 164A b If removed install spring on top of lifter then lif
211. Seat Gasket Snap Ring Front Bearing Thrust Washer Front Wheel High Gear Front Output Shaft Needle Bearings Spacer Needle Bearing Sliding Clutch Gear Shift Fork Roll Pin Front Output Low Gear Thrust Washer Lock Pin Thrust Washer Snap Ring Rear Cover Gasket Rear Cover and Bearing Fig 7D 9R New Process Model 205 Transfer Case Exploded View Fig 70 10R Installing New Bearing Cups Idler Gear 1 Remove idler gear shaft nut 2 Remove idler shaft rear cover 3 Remove idler gear shaft using a soft hammer and tool J 23429 Fig 7D 8R 4 Roll idler gear to front output shaft hole and remove from case 5 Remove bearing cups 2 as required from idler gear CLEANING AND INSPECTION Bearings Place all bearings and rollers in cleaning solution and allow to remain long enough to loosen all accumulated lubricant Bearings should be sloshed up and Fig 7D 11R Checking Idler Gear End Play TRANSFER CASES 7D 5 FRONT OUTPUT BORE Fig 7D 12R Installing Idler Gear down and turned slowly below surface of solution to remove as much lubricant as possible Remove bearings and blow out with compressed air being careful to direct air across bearing so that bearings do not spin Shafts and Gears Clean all shafts in cleaning solution to remove all accumulations Dry with compressed air Case Cover and Bearing Cups Transfer case cover and bearing cups must be thoroughly cleaned in solution
212. Shift synchronizer sleeves to neutral positions and install cover gasket and fork assembly to case Be sure forks align with their synchronizer sleeve grooves 13 Install speedometer driven gear in extension 14 Tighten all bolts to specified torque 15 Rotate clutch gear shaft and shift transmission to free rotation in all gears MAIN DRIVE GEAR 40040 Fig 7B 17A Loading Pilot Bearings OVERHAUL MANUAL 7B 8 E ART MENS BRSHosuspRORZP Geet MANUAL TRANSMISSION Snap Ring Synchronizer Ring 2 3 Synchronizer Sleeve Synchronizer Key Spring Synchronizer Hub and Keys Synchronizer Key Spring Synchronizer Ring Second Gear Main Shaft First Gear Synchronizer Ring Synchronizer Key Spring Synchronizer Hub and Keys Synchronizer Key Spring 1 2 Synchronizer Sleeve Snap Ring Reverse Gear Thrust Washer Waved Washer Rear Bearing Snap Ring Speedometer Gear Clip Speedometer Drive Gear OVERHAUL MANUAL a 22 50 Bearing Retainer Bolts and Washers 4 Front Bearing Retainer Bearing Retainer Gasket Bearing Retainer Oil Seal Snap Ring Bearing Snap Ring Front Bearing Drive Gear Pilot Bearings Case Extension to Case Gasket Rear Bearing to Extension Retaining Ring Rear Extension Extension to Case Retaining Bolts and Washers Rear Extension Bushing Rear Seal Thrust Washer Spacer Countergear Shaft Bearings Countergear Countergear Shaft Bearings Spacer Thrust Washer Countergear Shaft
213. TAKE 7 TWOPLACES AS SHOWN FLUSH 0030 TO HOUSING D 2 optional stake V LOCATIONS M E es 1 AN DELCO MORAINE DELCO MORAINE SINGLE DIAPHRAGM POWER BRAKE VIEWED FROM BRAKE PEDAL END TANDEM POWER BRAKE VIEWED FRO BRAKE PEDAL END UNSTAKED TAB SOCKET STAKING TAB SOCKET Fig 5 13C Staking Power Brake Housing locations 180 apart fig 5 13C Do not break studs loose in rear housing or put pressure on power piston tube when locking housings 7 Push felt silencer over push rod to seat against end of power piston tube Snap ring retainer is now placed on push rod so it can hold silencer against power piston tube Plastic boot is now pushed to seat against rear housing Raised tabs on side of boot will locate in holes in center of brackets The jam nut and clevis can now be reassembled to push rod Gaging of Power Brake Unit The following gaging operation is necessary only when a major structural part such as front or rear housing power Fig 5 14C Gaging Master Cylinder Push Rod piston assembly master cylinder piston or master cylinder assembly is replaced with a new part The gage measures how far the master cylinder push rod projects from front housing This dimension must be correct to insure proper clearance in master cylinder between primary cup and compensating port Make check as follows 1 Place Tool J 22647 over piston rod in a position which will allow gage to
214. TER SNAP RINGS Fig 7B 4K Speedometer Gear and Retaining Rings OVERHAUL MANUAL REVERSE IDLER REVERSE GEAR Fig 7B bK Removing Reverse Gear and synchronizer assembly and the second gear Fig 7B 12K CLEANING AND INSPECTION Transmission Case 1 Wash the transmission thoroughly inside and outside with cleaning solvent then inspect the case for cracks 2 Check the front and rear faces for burrs and if present dress them off with a fine mill file 3 Make sure bearings are clean then lubricate with light engine oil and check them for roughness by slowly turning the race by hand Roller Bearings and Spacers All main drive gear and countergear bearing rollers should be inspected closely and replaced if they show wear Inspect countershaft and reverse idler shaft at the same time replace if necessary Replace all worn spacers Fig 7 B 6K Removing Main Drive Gear Bearing TOOL J 24658 Fig 7B 7K Removing Countergear Shaft Gears 1 Inspect all gears for excessive wear chips or cracks and replace any that are worn or damaged 2 Inspect reverse gear bushing and if worn or damaged replace the entire gear reverse gear bushing is not serviced separately 3 Check both clutch sleeves to see that they slide freely on their hubs Front and Rear Bearings 1 Wash the front and rear ball bearings thoroughly a cleaning solvent Washer Snap Ring 3rd amp 4th Speed Clu
215. TOOLS J 6456 01 Height Gauge J 1048 Gauge Plate J 1522 Pilot Bearing Driver J 23720 Clutch Pilot Tool J 1448 Pilot Bearing Puller Fig 7C 1ST Clutch Special Tools OVERHAUL MANUAL TRANSFER CASES 70 1 SECTION 7D CONTENTS Model 205 Part Time Transfer 7D 1 Model 203 Full Time Transfer 7D 8 Adapter Assemblies essent 7D 19 Bee eeleren Eeer 7D 20 Special Tools 22 ar 70 21 MODEL 205 PART TIME TRANSFER CASE INDEX Disassembly of Transfer 7D 1 Assembly of Transfer 424 24 22 7D 5 Rear Output Shaft Assembly 7D 1 Idle Gear eterne aei esee oe 7D 5 Front Output Shaft 7D 3 Shift Rail and Fork Assemblies 7D 6 Shift Rail and Fork Assemblies 70 3 Front Output Shaft 7D 6 Idler Gear 5 iF ege cepe omg paseo ets 7D 5 Rear Output Shaft Assembly 2 2 4 21 7D 7 Cleaning and 222 222 7D 5 Miscellaneous erret ttes 7D 8 DISASSEMBLY OF TRANSFER CASE FIG 7D 4R Rear Output Shaft and Yoke Assembly Fig 7D 1R 1 Loosen rear output shaft yoke nut 2 Remove rear outp
216. The pulley should now rotate freely 8 Operate the refrigeration system in the MAX A C control selector mode lever position and warm engine off fast idle speed at 2000 PRM Rapidly cycle the compressor clutch by turning the A C control selector mode lever from OFF to MAX at least 15 times at approximately one second intervals to burnish the mating parts of the clutch A 6 COMPRESSOR PULLEY AND BEARING ASSEMBLY Remove 1 Remove Clutch Plate and Hub assembly as described in A 6 Compressor Clutch Plate and Hub Assembly Removal procedure 2 Remove pulley retainer ring using Snap Ring Pliers 1 6435 26 Figure 1D 12 3 Pry out absorbent sleeve retainer and remove absorbent sleeve from compressor neck 4 Place Puller Pilot J 9395 over end of compressor shaft 1D 6 AIR CONDITIONING COMPRESSOR OVERHAUL SHAFT SEAL ASM PULLEY PULLEY BEARING SEAL SEAT RETAINER RING L7 P ABSORBENT SLEEVE CLEARANCE 022 TO 057 Figure 1D 11 Checking A 6 Air Gap NOTICE It is important that Puller Pilot J 9395 be used to prevent internal damage to compressor when removing pulley Under no circumstances should Puller be used DIRECTLY against drilled end of shaft 5 Remove Pulley and Bearing Assembly using Pulley Puller J 8433 Figure 10 13 Inspection Check the appearance of the Pulley and Bearing assembly see Figure 1D 7 The frictional surfaces of the SNAP RING PLIERS J 6435
217. Transmission Special Tools Except 4 Speed 117mm OVERHAUL MANUAL am 7B 50 MANUAL TRANSMISSION 111 2 7 8 9 10 1 234321 Snap Ring Picks 2 23432 Snap Ring Pliers 3 J 8092 Handle 4 J 23429 Intermediate Shaft Remover and Installer 5 22836 Front Output Shaft Bearing Retainer Seal Installer 6 21359 Rear Output Shaft Bearing Retainer Seal Installer 7 123431 Rear Output Shaft Housing Bearing Remover and Installer 8 17137 Adapter Seal Installer 9 192762 Intermediate Gear Bearing Cup Installer 10 122875 Rear Output Shaft Rear Bearing Installer 4 Speed 117mm Transmission Special Tools QVERHAUL MANUAL CLUTCHES 7 1 SECTION 7C CONTENTS Single Plate Diaphragm Spring Church 7 1 Single Plate Coil Spring Clutch esee 7C 3 Special ET 7C 7 SINGLE PLATE DIAPHRAGM CLUTCH INDEX Disassembly e eniin etr ere dire eid ene rus 7C 2 Inspection i ova etre d bd rb eb dav e EE 7C 2 Assembly ato restricted rea rro ret eee rep dieci Feier ed 7C 2 Pilot Bearing Replacement oce erret 7 2 BENT FINGER Flywheel Pressure Plate 8 Throwout Bearing Dowel hole Diaphragm Spring 9 Fork Pilot Bushing Cover 10 Retracting Spring Driven Disc Fig 7C 1A Bent Finger Clutch Cross Section Typical OVERHAUL MANUAL 7C 2 CLUTCHES Fig 7C 2A Retracting Spring Location Typical DISASSEMBLY FIG 7C 2A NOTICE When disassembling mark edge of pressure plate
218. Using holder J 22805 01 and Handle J 9504 01 rotate rear housing counterclockwise to unlocked position fig 5 2C Loosen housing carefully as it is spring loaded 3 Lift rear housing and power piston assembly from unit Then remove return spring 4 Remove clevis and jam nut from push rod Remove retaining ring on push rod that holds silencer in place on push rod Remove silencer OVERHAUL MANUAL 5 12 BRAKES FRONTHOUSING SEAL POWER PISTO RETURN SPRIN REAR HOUSING POWER PISTON BEARING FRONT HOUSING POWER PISTON ASSEMBLY Fig 5 1C Typical Power Brake Unit Exploded View 5 Remove seal from front housing and if defective vacuum check valve Power Piston Assembly Group Fig 5 3C NOTICE Care must be used in handling the diaphragm of power piston assembly Guard diaphragm against grease oil foreign matter and nicks or cuts J 9504 01 7 J 22805 01 Fig 5 2C Separating Power Brake Unit OVERHAUL MANUAL 1 Remove power piston assembly from rear housing 2 Remove silencer from neck of power piston tube 3 Remove lock ring from power piston by prying one end out from under large divided locking lug and then proceed to pull ring from under other two locking lugs on power piston fig 5 4C 4 Remove reaction retainer piston reaction plate three 3 reaction levers and air valve spring Also remove reaction bumper and air valve spring retainer from air valve fig 5 5C
219. VE BODY 3 Key Me Port Name 19 PLUG ADJUSTER 20 BEARING NEEDLE 21 SEAL STUB SHAFT 22 SEAL STUB SHAFT DUST 23 RING RETAINING 24 NUT ADJUSTER PLUG LOCK 25 BEARING ASSY NEEDLE PITMAN SHAFT 26 SEAL PITMAN SHAFT SINGLE LIP 27 WASHER SEAL BACK UP PITMAN SHAFT 28 SEAL PITMAN SHAFT DOUBLE LIP 29 WASHER SEAL BACK UP PITMAN SHAFT 30 RING RETAINING PITMAN SHAFT SEAL Key Peri Nome 37 SCREW ASSY LOCKWASHER amp 2 38 PLUG RACK PISTON 39 SEAL O RING RACK PISTON 40 RING RACK PISTON 41 SEAL O RING HOUSING END PLUG 42 PLUG HOUSING END 43 RING RETAINING HOUSING END PLUG 44 GEAR ASSY PITMAN SHAFT 45 SEAL ASSY GASKET 46 COVER ASSY HOUSING SIDE 47 BOLT HEX HEAD SIDE COVER 4 48 NUT LASH ADJUSTER 10 HMIAO 12 SEAL O RING VALVE BODY 3 13 RETAINER BEARING ADJUSTER 31 WASHER PITMAN SHAFT LOCK 49 SPRING CHECK VALVE 14 SPACER THRUST BEARING 32 NUT PITMAN SHAFT 50 POPPET CHECK VALVE 15 RACE UPPER THRUST BEARING SMALL 33 NUT RACK PISTON 51 CONNECTOR INVERTED FLARE 16 BEARING UPPER THRUST 34 BALL 52 CONNECTOR INVERTED FLARE 17 RACE UPPER THRUST BEARING LARGE 35 GUIDE BALL RETURN 2 53 BOLT COUPLING PINCH 18 SEAL O RING ADJUSTER 36 CLAMP BALL RETURN GUIDE 54 COUPLING STEERING
220. VER MANUAL SHAFT RK j PARKING PAWL ACTUATING ROD Fig 7A 23B Removing Manual Shaft and Inner Lever and Parking Pawl Actuator Rod from Case OVERHAUL MANUAL L3 Fig 7A 24B Removing Manual Shaft to Case Lip Seal 13 Remove parking pawl disengaging spring fig 7A 26B 14 Remove parking pawl shaft retaining plug parking pawl shaft and parking pawl fig 7A 27B if replacement is required NOTICE The parking pawl shafts retaining plug may be removed by using a bolt extractor DAN PARK LOCK LOCK BRACKET Fig 7A 25B Removing Park Lock Lock Bracket AUTOMATIC TRANSMISSION 350 7A 9 INTERMEDIATE SERVO PISTON AND SEAL WASHER ys PIN SPRING SEAT PARKING PAWL SPRING DISENGAGING SPRING Fig 7A 26B Removing Parking Pawl Disengaging Spring Fig 7A 28B Intermediate Servo Piston and Related Parts 15 Remove intermediate servo piston and seal ring REMOVAL OF OIL PUMP AND INTERNAL Remove washer spring seat and apply pin fig 7A 28B CASE COMPONENTS 1 Remove eight 8 pump attaching bolts with washer type seals fig 7A 29B PUMP ASSEMBLY PARKING PAWL SHAFT RETAINING PLUG Fig 7A 27B Parking Pawl Shaft Retaining Plug Parking Pawl Fig 7A 29B Removing Pump Attaching Bolts Shaftand Parking Pawl OVERHAUL MANUAL 350 7A 10 AUTOMATIC TRANSMISSION SLIDE HAMMERS TIGHTEN JAM NUTSIE Fig 7A 30B Removing Pump from Case 2 Install two 2 threade
221. Wrench J 9504 and rotate the rear housing clockwise to separate the two housings If the rear housing cannot be readily loosened tap the rear housing lightly with plastic hammer 10 Remove Tool J 9504 from the rear housing CAUTION Care must be exercised not to damage or loosen studs in the rear housing Also take care that no pressure is brought to bear on plastic diaphragm plate tension 11 Lift the rear housing assembly from the unit Rear Housing Group 1 Remove the air filter element from location within the diaphragm plate extension CAUTION To prevent chipping of the plastic diaphragm plate exercise extreme caution when removing the air filter retainer Use a small screwdriver or other suitable tool and pry at several peripheral locations until the retainer is freed 2 Separate the diaphragm plate assembly from the rear housing and lay the rear housing aside 3 Disassemble diaphragm plate assembly fig 5 2D a Remove rolling diaphragm from the groove in the diaphragm plate hub CAUTION Care should be used in handling the diaphragm of the diaphragm plate assembly The diaphragm should be protected from grease oil foreign matter and from nicks scratches and gouges b Hold the diaphragm plate so that the push rod is in its normal 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 diaphrag
222. Y WEIGHT 2 THRUST CAP PRIMARY WEIGHT 2 Fig 7A 57C Governor Exploded serviced as a complete assembly However the driven gear can also be serviced separately It is necessary to disassemble governor assembly in order to replace driven gear Disassembly may also be necessary due to foreign material causing improper operation In such cases proceed as follows Disassembly 1 Cut off one end of each governor weight pin and remove pins governor thrust cap governor weights and springs Governor weights are interchangeable from side to side and need not be identified Fig 7A 57C 2 Remove governor valve from governor sleeve Be careful not to damage valve 3 Perform following inspections and replace governor driven gear if necessary Inspection 1 Wash all parts in cleaning solvent air dry and blow out all passages 2 Inspect governor sleeve for nicks burrs scoring or galling 3 Check governor sleeve for free operation in bore of transmission case 4 Inspect governor valve for nicks burrs scoring or galling 5 Check governor valve for free operation in bore of governor sleeve 6 Inspect governor driven gear for nicks burrs or damage 7 Check governor driven gear for looseness on governor sleeve 8 Inspect governor weight springs for distortion or damage 9 Check governor weights for free operation in their retainers Fig 7A 58C Checking Valve Opening With Weights Outward
223. a SEAL DOUBLE LIP ma WASHER 25 RETAINING RING 7 lt PITMAN ARM LOCK WASHER 6 NUT Torque to 250 Newton Metres 180 Ft Lbs Installer 46219 J Install Seals 1 Remove parts 1 3 REMOVE AND INSTALL HOUSING END PLUG REMOVE INSTALL Install parts as shown Open end of retaining ring to be approx 25 mm 1 inch from access hole as shown Retaining ring access hole Use Punch HOUSING ASSEMBLY HOUSING END PLUG RING SEAL HOUSING END PLUG RETAINING RING 2 REMOVE AND INSTALL PITMAN SHAFT AND SIDE COVER REMOVE If pitman shaft and 1 side cover are to be separated remove preload adjuster nut 4 REMOVE AND INSTALL RACK PISTON REMOVE 1 Remove parts asshown 1 INSTALL Install parts as shown INSTALL If removed install gasket seal by bending tabs around When installing rack cover edges care should be taken not to cut teflon seal rack piston seal compressor J 7576 or J 8947 may be used to compress seal Rotate stub shaft to center gear then remove parts as shown Install parts as shown SIDE COVER BOLTS Torque to 60 Newton Metres 40 Ft Lbs ADJUSTER NUT SIDE COVER GASKET SEAL 1 PITMAN SHAFT Insert ball retainer J 21552 Hold tool tightly against worm while turning stub shaft counter clockwise The rack piston will be forced onto the tool Remove the rack piston and ball re
224. ace forward or direct clutch housing have not been properly installed to index with all clutch plates This condition must be corrected before pump is pulled fully into place 21 Install all but one pump attaching bolts and seals Torque to 18 ft Ibs See Figure 7A 169C for location of omitted bolt 22 If necessary to install a new front seal use a non hardening sealer on outside of seal body and using Tool J 21359 drive seal in place Fig 7A 168C Fig 7A 168C Installing Pump Seal INDICATOR J 8001 Fig 7A 169C Checking Front Unit End Play 23 Check front unit end play as follows Fig 7A 169C a Install a 3 8 16 threaded bolt or a Slide Hammer Bolt J 9539 into bolt hole in pump b Mount a dial indicator on rod and index indicator to register with end of turbine shaft c Push turbine shaft rearward d Push output shaft forward e Set dial indicator to zero f Pull turbine shaft forward Read resulting travel or end play which should be 003 024 Selective washer controlling this end play is located between pump cover and forward clutch housing If more or less washer thickness is required to bring end play within specifications select proper washer from the chart in Fig 7A 170C An oil soaked washer may tend to discolor It will be necessary to measure washer for its actual thickness 24 Install remaining front pump attaching bolt and seal Torque 18 ft lbs CASE EXTENSION ASS
225. aching two halves of case together OVEAHAUL MANUAL 6 Separate plain half of differential case from flanged half 7 Remove five plates and discs from side gear ring A series of clutch plates and dished Belleville friction plates on each side of differential side gears transmits drive from differential case to axle shafts Carefully observe the order in which the plates are used since they must be replaced in the same order Refer to figure 22D 8 Remove side gear ring and side gear 9 Remove two cross shafts and pinion gears 10 Remove side gear side gear ring and five plates and discs from the opposite side Observe the order in which the plates are used Inspection 1 Inspect cross shafts and pinions for scoring wear pitting etc If the center lands of either cross shaft show signs of wear examine ends of axle shafts to determine if the axle shaft is rubbing against cross shaft This rubbing condition may cause a whine or howl that is similar to a pinion bearing noise at 40 to 50 MPH This condition can 4 Friction Plate Tabbed Belleville 5 Friction Disc Toothed Belleville Differential Case Bolt Differential Case Plain Half Differential Case Flanged REAR AXLE DIFFERENTIAL 4B 47 Friction Plate Tabbed Side Gear Ring Flat Side Gear Friction Disc Toothed Pinion Gears Flat Cross Shafts Fig 22D Power Lok Differential be corrected by grinding 1 32 off the end of the axl
226. ack for setting preload add or remove an equal amount as was added or removed from the inner shim pack 5 Install outer cup in carrier bore using installer J 7818 with Drive Handle J 8092 6 Press rear pinion bearing onto pinion shaft using installer J 24433 7 Install drive pinion and bearing into the differential carrier 8 Install preload shims and front pinion bearing Do not install oil seal at this time 9 Install flange and holding bar J 8614 11 as shown in Drive Pinion Removal 10 Install washer and nut onto pinion shaft Torque nut to 250 165 ft 11 Remove holding bar and with an inch pound torque wrench measure rotating torque Rotating torque should be 10 to 20 in 165 with original bearings or 20 to 40 in Ib with new bearings Torque reading to start shaft turning must be disregarded 12 If torque requirements preload are not to specifications adjust shim pack as necessary a To increase preload decrease the thicknes of preload shims b To decrease preload increase the thickness of preload shims 13 When bearing preload meets specifications remove nut washer and flange from pinion shaft 14 Install new pinion oil seal into housing as shown in figure 11F using J 24384 15 Install flange washer and nut Using holder bar J 8614 11 torque nut to 250 lbs ft OVERHAUL MANUAL Fig 11F Installing Pinion Oil Seal DIFFERENTIAL CASE Installation and Adjustment
227. aft OVERHAUL MANUAL 78 46 MANUAL TRANSMISSION J 22873 Fig 78 21L Installing Counter Gear Snap Ring Fig 7B 22L Installing Clutch Countergear Fig 7B 24L Countergear Front Support Tool OVERHAUL MANUAL MANUAL TRANSMISSION 7B 47 J 23070 Fig 7B 26L Installing Mainshaft Rear Bearing Lock Nut 4 Wheel Drive only Fig 7B 25L Installing Countergear Rear Bearing OVFRHAUL MANUAL E 7B 48 MANUAL TRANSMISSION SPECIFICATIONS THREE SPEED 76mm THREE SPEED 77mm Clutch Gear Retainer to Case Bolts Clutch Gear Retainer to Case Bolts Side Cover to Case Bolts 15 ft Ibs Top Cover to Case Bolts Extension to Case Bolts 45 ft lbs Extension to Case Bolts Shift Lever to Shifter Shaft Bolts 25 ft Ibs Shift Lever to Shifter Shaft Bolts Lubrication Filler Plug 13 ft Ibs Lubrication Filler Plug Transmission Case to Clutch Housing Bolts 75 ft Ibs Transmission Case to Clutch Housing Bolts Crossmember to Frame Nuts 25 ft Ibs Crossmember to Frame Nuts Crossmember to Mount Bolts 40 ft Ibs Crossmember to Mount Bolts 2 3 Cross Over Shaft Bracket Retaining Nut 18 ft lbs 2 3 Cross Over Shaft Bracket Retaining Nut 1 Rev Swivel Attaching Bolt 1 Rev Swivel Attaching Bolt Mount to Transmission Bolt Mount to Transmission Bolt FOUR SPEED 76mm Clutch Gear Retainer to C
228. ainer Fig 7A 114C and three 3 5 Remove intermediate clutch piston Fig 7A 117C clutch release springs Fig 7A 115C 6 Remove inner and outer piston seal Do not remove three 3 screws retaining roller clutch inner race to center support SPRING RETAINERS INTERMEDIATE CLUTCH SPRING GUIDE Fig 7A 114C Removing Spring Retainer Fig 7A 116C Removing Intermediate Clutch Spring Guide AUTOMATIC TRANSMISSIONS 400 7A 37 INTERMEDIATE CLUTCH PISTON Inspection Fig 7A 118C 1 Inspect roller clutch inner race for scratches or indentations Be sure lubrication hole is open Be sure constant bleed plug orifice approx 020 dia is open Fig 7 47 2 Inspect bushing for scoring wear or galling If replacement is necessary proceed as follows a Using Tool J 21465 6 with Driver Handle J 8092 remove bushing b From front side of center support align elongated slot in the bushing with drilled hole in the oil delivery sleeve closest to the piston Using Tool J 21465 6 and Driver Handle J 8092 drive bushing squarely into the bore until the bushing is flush to 010 below top of oil delivery sleeve 3 Check oil ring grooves and oil rings for damage 4 Air check oil passages to be sure they are not inter CENTER SUPPORT connected amp RACE ASSEMBLY 5 Inspect piston sealing surfaces for scratches Fig 7A 117C Removing Intermediate Clutch Piston 6 Inspect piston seal grooves for nicks or other
229. ainer through the observation hole in the case See figure 2D Drive the spring retainer from the case sufficienly to allow insertion of a 1 4 inch bolt in each of the two front springs Secure each bolt with a nut as in figure 3D 4 After installing the retaining bolts continue to drive spring retainer from the case until enough of the retainer is exposed to permit installation of bar stock and C clamp as shown in figure 5D Center the bar stock over the axle shaft hole in the spring retainer then compress C clamp sufficiently to permit withdrawal of spring pack 5 Position spring pack in vise and remove 1 4 inch bolts Alternately relieve C clamp pressure and vise pressure until spring compression is relieved See figure 6D 6 For Truck Models roll out the differential pinions and thrust washers For Passenger models pinion gears can be removed by rotating them in one direction only Using figure 7D as a reference rotate differential case clockwise to remove the first gear then rotate case counter clockwise to remove the second gear To remove second gear it may OVERHAUL MANUAL 4 40 REAR AXLE DIFFERENTIAL Fig 2D Removing Preload Spring Pack Typical be necessary to assist pinion gear upon its seat by prying on gear through observation holes on case Mark pinions and side gears for reassembly in original position 7 Remove side gear clutch pack shims and guides from case Tap the assembly from the case
230. al Gear and Thrust Washer 1 Inspect forward clutch hub for worn splines and for lubrication holes 2 Inspect internal gear for cracks or damage THRUST BEARING ASSY INSIDE DIAMETER RACE AGAINST CARRIER FRONT CARRIER Fig 7A 91A Installing Thrust Bearing Assembly Onto Front Carrier Fig 7A 92A Installing Output Shaft to Selective Washer Snap Ring AUTOMATIC TRANSMISSION 200 7 23 3 Inspect gear teeth for excessive wear or damage 4 Inspect bushing for damage or scoring 5 Inspect thrust washer front internal gear to selective washer for scoring or damage 6 Install thrust washer on front internal gear and retain with petrolatum Fig 7A 92A 7 Install front internal gear and thrust washer Rear Selective Thrust Washer 1 Inspect selective washer for scoring or damage Fig 7 92 The rear selective thrust washer must be installed with the identification number toward the front of the transmission 2 Install rear selective washer 3 Inspect output shaft to selective thrust washer snap ring for damage or distortion It may be necessary to move output shaft upward by turning the adjusting screw on J 25013 5 to install output shaft to selective washer snap ring 4 Install snap ring on output shaft Fig 7A 92A NOTICE Make sure snap ring is fully seated in output shaft groove or damage may occur Check Rear Unit End Play 1 Loosen J 25013 5 adjusting screw on output shaft and push outp
231. al carrier using spreader as shown in Figure 4C 1 2 Install differential bearing cups in their correct locations then install differential case into carrier 3 Install differential bearing caps in the correct location as indicated by marks made at disassembly Install cap screws finger tight Rotate differential assembly and rap on case with a soft faced hammer 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 Backlash must be held to 004 to 009 and must not vary more than 002 between positions checked 6 Whenever backlash is not within limits differential bearing shim pack should be corrected to bring backlash within limits 7 Check gear tooth contact as described in Gear Tooth Contact Pattern Check 8 After a successful pattern check install housing cover using a new gasket 9 Install axle shafts and install axle assembly into vehicle See Service Manual 10 Fill with recommended lubricant lower vehicle to floor and road test vehicle GEAR TOOTH CONTACT PATTERN CHECK Prior to final assembly of the differential a Gear Tooth Contact Pattern Check is necessary to verify the correct relationship between ring gear and drive pinion Gear sets which are not positioned properly may be noisy or have short life or both With a pattern check the most desirable
232. al clearances and could result in differential complaints OVERHAUL MANUAL 4B 50 REAR AXLE DIFFERENTIAL DIFFERENTIAL DIAGNOSIS Complaint Possible Cause Does not lock A Little or no spring A preload on the latching bracket B Flyweights on governor B assembly stuck closed C Broken Drive teeth on governor and or cam gear assembly D Broken clutch plates D in cam gear assembly Locks in turns A Governor assembly A tight in case B Broken or weak B governor flyweight spring C Flyweight in governor C assembly stuck open D Broken cam plate and or D governor drive teeth Noisy Correction Replace governor assembly and latching bracket Replace governor assembly and latching bracket Replace cam plate governor assembly and latching bracket Replace clutch plates and wave spring Free up governor assembly Replace governor assembly and latching bracket Replace governor assembly and latching bracket Replace cam plate governor assembly and latching bracket NOTE addition to normal axle noise see section on standard differential the locking differential exhibits some clutch noise upon engagement and disengagement A Broken clutch plates A B Broken reaction block B Broken differential C gears Reaction blocks must be replaced with blocks of identical thickness Fig 4B 3H Diagnosis Chart OVERHAUL MANUAL Replace clutch plates and wave
233. al tag secured by one of the attaching bolts Remove cover and gasket The tag shows the number of teeth on pinion and drive gear 3 Remove differential side bearing caps making sure they are marked for reassembly in the same position 4 Position Spreader Tool J 24385 so the two dowels on tool fit into recesses in carrier install two hold down bolts and install a dial indicator at one end of opening in carrier to indicate width of opening 5 Expand spreader tool to spread carrier a maximum of 020 NOTICE Do not attemtp to remove differential without using the spreader tool Do not expand carrier Fig 4C 1 Spreading Case With J 24385 OVERHAUL MANUAL 4C 2 WHEEL DRIVE more than 020 in or it may be damaged and take a permanent set 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 Relieve pressure on spreader tool and remove tool Oil Seal Replacement The axle shaft inner oil seals are located just outboard of the differential bearings item 28 Fig 4C 2 They can be replaced only after the differential is removed from the carrier using tool J 28648 Disassembly 1 Remove bearing cups from differential case and identify for reassembly 2 Remove bearing cones from case using puller J 22888 and correct plug fig 4C 4 and remove shims from case Identify all parts so they may b
234. all a blocking ring with clutching teeth downward over the synchronizing surface of the second speed gear All three blocker rings used in this transmission are identical 3 Install the second and third synchronizer assembly with the fork slot downward press it onto splines on the mainshaft until it bottoms Both synchronizer assemblies used in this transmission are identical If sleeve Fig 7B 11A Removing or Installing Rear Extension Bushing MANUAL TRANSMISSION 7B 5 M M 9 00 J 21426 Fig 7B 12A Installing Rear Extension Seal becomes removed from 2 3 hub notches on hub O D face forward end of mainshaft Be sure the notches of the blocker ring align with the keys of the synchronizer assembly 4 Install snap ring retaining synchronizer hub to mainshaft Both synchronizer snap rings are identical Turn the rear of the mainshaft upward Install the following components on the mainshaft 5 Install the first speed gear with clutching teeth upward the front face of the gear will butt against the flange on the mainshaft 6 Install a blocker ring with clutching teeth downward over synchronizing surface of the first speed gear 7 Install the first and reverse synchronizer assembly with fork slot downward push it onto splines on the mainshaft SCREWDRIVER Fig 7B 13A Removing Drive Gear Bearing Retainer Seal OVERHAUL MANUAL 7B 6 MANUAL TRANSMISSION 8 Install synchronizer hu
235. all check balls into ball seat pockets on spacer plate Fig 7A 173C 3 Install control valve spacer plate to case gasket gasket with extension for detent solenoid and a C near front servo location Fig 7A 174C SPACER PLATE GASKET Fig 7A 174C Installing Control Valve Assembly Spacer Plate and Gasket AUTOMATIC TRANSMISSIONS 400 7 54 Fig 7A 175C Installing Detent Solenoid and Gasket 4 Install control valve spacer plate and control valve to spacer plate gasket gasket identified with a a VB near front servo 5 Install detent solenoid gasket 6 Install detent solenoid assembly with connector facing outer edge of case Fig 7A 175C Do not tighten bolts at this time 7 Install front servo spring and spring retainer into transmission 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 1s 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 Figure 7A 176C 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 SERVO PISTON RETAINER RING SERVO PIN M SERVO SPRING RETAINER SERVO PISTON SPRING p 41 Fig 7A 176C Installing Fr
236. aller segments tight enough to the Installer Guide J 24608 2 to properly install the Teflon ring on the piston 6 Lubricate the piston ring area with 525 viscosity refrigerant oil and rotate the Piston and Ring Assembly into the Ring Sizer J 24608 6 at a slight angle Figure 1D 53 Rotate the piston while pushing inward until the piston is inserted against the center stop of the Ring Sizer J 23608 6 NOTICE DO NOT push the Piston and Ring Assembly into the Ring Sizer J 24608 6 without proper positioning and rotating as described above as the ends of the needle bearings of the Ring Sizer may damage the end of the piston 7 Rotate the Piston and Ring Assembly in the Ring Sizer J 24608 6 several COMPLETE turns until the Assembly rotates relatively free in the Ring Sizer Figure 1D 53 8 Remove the Piston and Ring Assembly wipe the end of the piston and ring area with a clean cloth and then push the Piston and Ring Assembly into the Ring Gage J 24608 1 Figure 1D 54 The piston should go through the Ring Gage with a 6 Ib force or less without lubrication If not repeat Steps 6 and 7 9 Repeat the procedure for the opposite end of the piston Figure 1D 55 NOTICE DO NOT lay the piston down on a dirty surface where dirt or metal chips might come into contact and become imbedded in the Teflon ring surface 10 Lubricate BOTH ENDS of the piston with 525 viscosity refrigerant oil before inserting the piston into the cylinder
237. an be used in the internal assembly just as they are removed from the service package Piston shoe discs and shaft thrust races will be identified by number on the parts themselves for reference to determine their size and dimension see Figure 1D 38 A 6 COMPRESSOR SHAFT SEAL SEAL LEAK DETECTION A shaft seal should not be changed because of an oil line on the hood insulator The Seal is designed to seep some oil for lubrication purposes Only change a Shaft Seal when a leak is detected by evidence of oil sprayed in large amounts and then only after actual refrigerant leakage is determined by test Should an A 6 compressor shaft seal ever have to be replaced because it was determined to be the cause of excessive signs of oil leakage in the A C system then the oil in the A 6 compressor must be drained measured and replaced according to C C O T Refrigerant Oil Distribution in the Air Conditioning section to determine oil loss The accumulator in this A 6 system must then also be removed oil drained measured etc according to same section SPECIFICATION PARTS CARBON MATERIAL LARGE CHAMFER ON INSIDE OIAMTER CERAMIC MATERIAL WITH POLISHED FACE O RINGS NEOPRENE THUS CAPABLE OF GIVING HEAT RESISTANCE AND LIFE EXPECTANCY Figure 1D 20 Specification A 6 and R 4 Compressor Shaft Seal Kit Remove 1 Discharge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGIN
238. and Blocker Ring Reverse Gear Assembly Fig 7B 16J Clutch Gear and Mainshaft Details Fig 7B 17J Installing Rear Bearing 7B 23 OVERHAUL TWN eH papojdx3 uorssiusue1 peedg p rgi g4 Bearing Retainer Gasket Retainer to Case Oil Seal Snap Ring Bearing to Shaft Snap Ring Bearing to Case Drive Gear Bearing Drive Gear Mainshaft Pilot Bearings 4th Speed Blocker Ring Case Filler Plug Reverse Idler Gear Reverse Idler Shaft Woodruff Key Thrust Washer Front Gear Needle Retainer Washer Needle Bearings Countergear Needle Retainer Washer Thrust Washer Rear Gear Countershaft Woodruff Key Synchronizer Sleeve Snap Ring Hub to Shaft Key Retainer 3 4 Synchronizer Hub Clutch Keys Key Retainer 3rd Speed Blocker Ring 3rd Speed Gear Needle Bearings Second Speed Gear 2nd Speed Blocker Ring Mainshaft 1st Speed Blocker Ring First Speed Gear Thrust Washer Wave Washer Rear Bearing Snap Ring Bearing to Shaft Speedo Drive Gear and Clip Gasket Extension to Case Snap Ring Extension to Rear Bearing Extension Vent Bushing Oil Seat 1 2 Synchronizer Sleeve and Reverse Gear Key Retainer 1 2 Synchronizer Hub Clutch Keys Key Retainer Snap Ring Hub to Shaft 3 4 Shift Fork Detent Spring 3 4 Detent Cam 1 2 Detent Cam 3 4 Shifter Shaft Gasket Cover to Case Cover TCS Switch and Gasket Lipseal Detent Cam Retain
239. and anchor lug c Install dial J 8001 and position dial indicator point on top of J 25014 2 zero post and set dial indicator to zero INTERMEDIATE BAND APPLY PIN SELECTION CHART DIAL INDICATOR TRAVEL APPLY PIN IDENTIFICATION 0 72mm 0 029 1 Ring 722mm 1 44mm 029 057 2 Rings 1 44mm 2 16mm 057 086 3 Rings 2 16mm 2 88mm 086 114 Wide Band Fig 7A 147A Intermediate Band Apply Pin Chart Fig 7A 148A Removing Intermediate Servo Piston from Apply Pin AUTOMATIC TRANSMISSION 200 7A 37 d Align stepped side of pin J 25014 1 with torquing arm of J 25014 2 Arm must stop against step of pin J 25014 1 If band selection pin does not register between the high and low limits look for possible problem with the intermediate band direct clutch housing or case Make sure J 25014 2 gauge plate is pulled backwards and seated squarely against the retaining ring e Apply 12 N m 100 156 of torque to hex nut on side of gauge Slide dial indicator over gauge pin J 25014 1 Fig 7A 146A Read dial indicator and see Fig 7A 147A for proper size Dial indicator travel is reversed making the indicator readings backwards On an indicator that ranges from 0 100 a 5mm 020 travel will read 2mm 080 a 1 5mm 060 travel will read 1mm 040 The identification ring is located on the band end of the pin f Remove retaining ring and band apply pin gauges If new app
240. and assemble the 4th speed blocker ring onto the clutch gear clutching surface with its clutching teeth toward the gear Fig 7B 20J 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 CAUTION Be sure the notches in the blocker ring align with the keys in the 3 4 synchronizer assembly 7 Place extension to case gasket at rear of case holding in place with grease and from the rear of the case assemble the clutch gear mainshaft and extension to case as an assembly 8 Install extension to case retaining bolts Using seal cement on bottom bolt only 9 Install front bearing outer snap ring to bearing and position bearing over stem of drive gear and into front case bore 10 Install snap ring to drive gear stem and drive gear bearing retainer and gasket to case The retainer oil return hole should be at the bottom 11 Shift synchronizer sleeves to neutral positions and install cover gasket and fork assembly to case Be sure forks align with their synchronizer sleeve grooves 12 Tighten all bolts to specified torque MANUAL TRANSMISSION XH LIE 15 14 Drive Gear Bearing First Speed Gear Drive Gear Thrust Washer Mainshaft Pilot Spring Washer Bearings Rear Bearing 3 4 Synchronizer Speedo Drive Gear Asser uly Mainshaft Third Speed Gear Snap Ring Second Speed Gear Synchronizing 1 2 Synchronizer
241. and or O Rings Removal procedure 3 Remove valve plate retainer ring using Internal Snap Ring Pliers J 4245 23 Figure 1D 111 Remove Compressor Discharge Valve Plate Figure 1D 112 for valve plate replacement and or piston inspection Repeat this operation for additional valve plates and retainer rings If all four valve plates and retainers are to be removed remove two sets and then rotate compressor and Holding Fixture J 25008 1 in vise for access to the remaining two valve plates and retainers VALVE PLATE RETAINER RING Figure 1D 111 Replacing R 4 Valve Plate Retainer 4 Install Discharge Valve Plates and or Retainers as shown in Figures 10 111 and 1D 112 Reposition compressor and Holding Fixture in vise as necessary for access 1D 42 AIR CONDITIONING COMPRESSOR OVERHAUL 5 Re install compressor Shell as described in R 4 Compressor Shell and or O Rings Replacement procedures 6 Evacuate and Charge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR A C SYSTEMS the AIR CONDITIONING section PISTON AND REED ASSY Figure 1D 112 Replacing R 4 Discharge Valve Plate R 4 COMPRESSOR CYLINDER AND SHAFT ASSEMBLY Remove 1 Discharge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR A C SYSTEMS in the AIR CONDITIONING section 2 Remove the Clutch Plate and Hub assembly
242. and snap ring grooves for wear or damage 2 Inspect lubrication passages for being plugged or damaged 3 Inspect splines for damage 4 Inspect governor drive gear for rough or damaged teeth 5 Inspect speedometer drive gear for rough or damaged teeth and also the clip for damage 6 If necessary to replace speedometer drive gear proceed as follows For nylon gear a Depress speedometer drive gear clip b Remove gear and clip tapping gear lightly with plastic hammer Make sure speedometer drive gear is located so speedometer driven gear will mesh with it c Place speedometer drive gear clip with the tanged end in the correct hole in the output shaft Fig 7A 59A d Align the slot of the speedometer drive gear with the clip and install the gear For steel gear models PA CO CR CS CY a Remove steel gear using J 21427 01 and suitable puller such as J 8433 Fig 7A 60A b Position front end of shaft on a block of wood to prevent damaging the front end c Position gear larger chamfered inside diameter first over rear end of output shaft AUTOMATIC TRANSMISSION 200 7 15 SPEEDOMETER DRIVE GEAR CLIP SPEEDOMETER SNAP RING DRIVE GEAR OUTPUT SHAFT Fig 7A 59A Installing Speedometer Drive Gear and Clip SPEEDOMETER DRIVE GEAR J 21427 01 Fig 7A 60A Removing Steel Gear J 28578 SPEEDOMETER DRIVE GEAR Fig 7A 61A Installing Steel Gear OVERHAUL MANUAL AUTOMATI
243. and springs and thrust cap on governor sleeve 3 Align pin holes in thrust cap governor weight assemblies 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 5 Check governor valve for free movement in governor sleeve BUSHING REPLACEMENT Extension Housing Bushing Remove extension housing bushing from housing using tool J 21424 9 with drive handle J 8092 Install extension OVERHAUL MANUAL 350 7A 32 AUTOMATIC TRANSMISSION J 21424 9 EXTENSION HOUSING Fig 7A 98B Installing Extension Housing Bushing housing bushing in housing flush to 010 below seal counter bore surface using tool J 21424 9 with drive handle J 8092 fig 7A 98B Output Shaft Bushing With output shaft properly supported remove bushing using remover J 9534 01 and slide hammer J 7004 fig 7A 99B Using tool J 23062 7 install bushing until tool bottoms on output shaft Case Bushing With case properly supported drive out bushing from rear of case using tool J 23062 1 and drive handle J 8092 OUTPUT RING GEAR OUTPUT SHAFT J 9 534 J 2619 4 ADAPTER SLIDE HAMMER Fig 7A 99B Removing Output Shaft Bushing OVERHAUL MANUAL J 21465 15 J 2619 4 SLIDE HAMMER A PUMP COVER AND STATOR Fig 7A 100B Removing Stator Shaft Front Bushing Using tool J 23062 1 and drive handle J 8092 with extension 7 21465
244. ange of the diaphragm Apply a thin coat of silicone lubricant to the I D of the secondary diaphragm Fig 5 6A Installing Divider OVEAHAUL MANUAL Fig 5 7A Installing Primary Support Plate and Diaphragm Assembly 17 With assembly Tool J 28458 mounted on the power piston place the secondary diaphragm and support plate assembly over the power piston see Figure 5 5A and push down until it bottoms on power piston 18 Hold the housing divider so that the formed over flange that holds the primary diaphragm of the divider faces down Place the power piston bearing in the I D of the divider so that the extended lip of the bearing faces up 19 Lubricate the I D of the power piston bearing with silicone lubricant TOOL J 28458 Fig 5 8A Installing Diaphragm Retainer REMOVING STAKE FROM TAB SOCKET 0 128 STAKE TWO PLACES AS SHOWN FLUSH 79 030 TO HOUSING 0 0 Q ovrionat stare LOCATIONS DELCO MORAINE DELCO MORAINE SINGLE DIAPHRAGM POWER BRAKE TANDEM POWER BRAKE VIEWED FRON BRAKE PEDAL END VIEWED FRON BRAKE PEDAL END UNSTAKED TAB SOCKET TAB SOCKET Fig 5 9A Staking Power Brake Housings 20 With Tool J 28458 still positioned on the power piston hold the housing divider so that formed over flange of the divider faces up Press the divider down over the tool and onto the power piston tube where it will rest against the secondary diaphragm fig 5 6A 21 Assemble the
245. angs crack or break during this operation it will be necessary to replace that half of the housing 5 Remove Tool J 9504 from the rear shell 6 Install air silencers over push rod end and then install push rod boot Install boot retainer 7 Clevis Type Push Rod Install locknut and push rod clevis 8 Install mounting bracket to the rear shell if so equipped CAUTION See Caution on Page 1 of this section 9 Remove power cylinder from vise and remove Holding Fixture J 22805 10 Apply silicone lubricant sparingly to the piston rod keeping lubricant away from rounded end of rod Guide piston rod into center bore of the diaphragm plate until it is fully seated against reaction disc 11 Install front housing seal Press seal into front housing until seal is bottomed in recess of housing Fig 5 5D Gaging Piston Rod Gaging 1 Place the power head assembly in a padded vise front housing up Do not clamp tight 2 Remove the front housing seal to assure that no vacuum is in the power head while gaging 3 Insert the master cylinder piston rod flat end first into the piston rod retainer 4 Press down on the master cylinder piston rod with approximately a 40 50 pound load to be sure it is properly seated 5 Place Gage J 22647 over the piston rod in a position which will allow the gage to be slipped to the left or right without contacting the studs fig 5 5D 6 The center section of the gage has
246. ant oil and assemble onto O Ring Installer J 21508 see Figure 1D 96 2 Insert the O Ring Installer J 21508 completely down into the compressor neck until the Installer bottoms Lower the moveable slide of the O Ring Installer to release the O Ring into the seal seat O ring lower groove The compressor neck top groove is for the shaft seal retainer ring Rotate the Installer to seat the O ring and remove the Installer See Figure 1D 24 Figure 1D 96 Installing R 4 O Ring On Car 3 Coat the O Ring and seal face of the new Seal assembly with clean 525 viscosity refrigerant oil Carefully mount the Seal assembly to Seal Installer J 9392 by engaging the tabs of the seal with the tangs of the Installer Figure 10 97 4 Place Seal Protector J 22974 over end of compressor shaft and carefully slide the new Seal assembly onto the shaft Gently twist the Installer J 9392 CLOCK WISE while pushing the Seal assembly down the shaft until the Seal assembly engages the flats on the shaft and is seated in place Disengage the Installer by pressing downward and twisting counterclockwise 5 Attach the ceramic Seal Seat to the Seal Seat Remover and Installer J 23128 and dip the ceramic Seat in clean 525 viscosity oil refrigerant to coat the seal face and outer surface Carefully install the Seat over the compressor shaft and J 22974 Seal Protector and push the Seat into place with a rotary motion Figure 1D 98 Take care not to dislodg
247. anual shaft seal using screwdriver Fig 7A 44A PIN MANUAL SHAFT TO CASE INSIDE DETENT LEVER AND PIN ASSEMBLY HEX PARK ACTUATOR ASSEMBLY PARKING PAWL PARKING PAWL MANUAL DETENT ROLLER AND SPRING ASSEMBLY BOLT BRACKET TO CASE PARK BRACKET PARKING PAWL SHAFT A AG RETURN SPRING ee SLOTTED SPRING PIN STEEL CUP PLUG Fig 7A 41A Manuel Shaft and Parking Shaft Parts OVERHAUL MANUAL RETAINING IDENTIFICATION GROOVE PIN GROOVE Fig 7A 43A Removing Manual Shaft from Case 25 oo ge MANUAL SHAFT SEAL Fig 7A 44A Removing Manual Shaft Seal From Case Fig 7A A5A Removing Parking Pawl Bracket Bolt AUTOMATIC TRANSMISSION 200 7 11 e Remove parking lock bracket Fig 7A 45A f Remove parking pawl shaft retaining pin Fig 7A 46A g Using 6 3mm No 4 easy out remove parking pawl cup plug and discard Fig 7A 47A Grind approximately 20mm 3 4 from end of 6 3mm No 4 easy out to remove cup plug h Using 4mm No 3 easy out remove parking pawl shaft Fig 7A 48A i Remove parking pawl and return spring INSPECTION AND REASSEMBLY Inspection of Case Assembly 1 Inspect case assembly for damage cracks porosity or interconnected oil passages If case is porous refer to porosity repair RETAINING PIN Fig 7A 46A Removing Parking Pawl Shaft Pin PARKING PAWL CUP PLUG
248. aring a To increase backlash loosen the left adjusting nut and tighten the right adjusting nut an equal amount b To decrease backlash loosen the right adjusting nut and tighten the left adjusting nut an equal amount REAR AXLE DIFFERENTIAL 48 19 LOW FLANK CONTACT INCREASE PINION SHIM TO MOVE PINION AWAY FROM RING GEAR TOE CONTACT INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT DECREASE PINION SHIM TO MOVE PINION TOWARD THE RING GEAR C 10 Fig 18E Gear Teeth Contact Pattern Check DANA DIFFERENTIALS 10 1 2 RING GEAR INDEX Differntial Case Removal and Disassembly 4B 20 Drive Pinion Removal and Disassembly ss 4B 21 Differential Case Reassembly ANEREN 4B 22 Shim Requirements Gaging Procedures ess 4 22 Drive Pinion Assembly and 0 4B 23 Differential Case Installation and Adjustment 4B 24 Checks and Adjustments ENEE 4B 25 OVERHAUL MANUAL 4B 20 REAR AXLE DIFFERENTIAL Pinion Nut Companion Flange Oil Seal Oil Slinger Pinion Front Bearing Front Bearing Cup Preload Shim Pack Pinion Depth Shim Pack Rear Bearing Cup Pinon Rear Bearing Washer Drive Pinion Ring Gear Washer Differential Case Ring Gear Bolt Washer Differential Side Bearing A Gasket Side Bearing Cup Co
249. arts as shown HOUSING ASSEMBLY Inspect for burrs NEEDLE BEARING Remove only if it needs replacing edge of bearing against tool and flush with bottom of counterbore install with lettered Remove and install bearing not necessary unless bearing 15 to be replaced 11 REMOVE AND INSTALL CONNECTORS REMOVE 1 Remove parts as shown NOTICE Some models will not use these connectors INSTALL 1 Install parts as shown Remover No 4 Screw Extractor INVERTED FLARE CONNECTORS C HOUSING ASSEMBLY Fig 3B3 4C Overhaul 605 Gear Chart D 12 ADJUST THRUST BEARING PRELOAD B Measure 13mm 2 coun terclockwise and mark housing only A Tighten adjuster plug until it bottoms use 17mm hex driver Torque to approx 40 Newton metres 30 Ft Mark housing and adjuster in line D Tighten lock nut Use punch in notch C Turn adjuster back until mark lines up with second mark on housing STEERING 3B 11 13 ADJUST CENTER PRELOAD A Back off preload adjuster Turn adjuster in until LEFT HAND THREAD until it stops then turn 0 6 to 1 2 Newton metres 6 to 10 in it in one full turn With gear at center of travel check torque to turn stub shaft reading 1 Torque adjuster lock nut to 27 Newton metres 20 Ft Ibs from turning while torqueing lock nut i
250. as shown in figure 7F 9 Install bearing on opposite side in the same manner Be sure to support differential case on pilot plug J 8107 3 SHIM REQUIREMENTS GAGING PROCEDURES Side Bearing Shims 1 With the pinion removed from the carrier place the bearing cups over the side bearings and install the differential case into the carrier 2 Place the shim which was originally installed on the ring gear side into its original position 3 Install the bearing caps lightly in their marked positions Tighten the caps just enough to keep the bearings in place 4 Mount a dial indicator on the carrier with the tip of the indicator on the back face of the ring gear 5 Position two screwdrivers between the bearing shim and carrier on the ring gear side of the case Pull on the screwdrivers and force the differential case as far as possible away from the dial indicator 6 With force still applied set the indicator dial to zero being sure the probe is still in contact with the ring Fig 8F Screwdrivers Against Case gear 7 Reposition the screwdrivers to the opposite side of the differential case as shown in figure 8F 8 Pull on the screwdrivers and force the differential case back toward the dial indicator Repeat several times until the same indicator reading is obtained 9 To the dial indicator reading add the thickness of the shim Record the result as this figure will be used during determination of side bearing
251. ase Bolts Side Cover to Case Bolts Lubrication Filler Plug Transmission Case to Clutch Housing Bolts Crossmember to Frame Nuts FOUR SPEED 83mm Clutch Gear Retainer to Case Bolts Side Cover to Case Bolts Extension to Case Bolts Shift Lever to Shifter Shaft Bolts Lubrication Filler Plug Transmission Case to Clutch Ho sing Bolts Crossmember to Mount and Mount to Extension Bolts Rear Bearing Beie to Jae Bolts Extension to Rear Bearing Retainer Bolts Short Retainer to Case Bolt Transmission Drain Plug FOUR SPEED 117mm Clutch Gear Bearing Retainer to Case Bolts Cover to Case Bolts Extension and Retainer to Case Bolts Upper Lower Lubrication Filler Plug Shift Lever to Shifter Shaft Nut Mount To Transmission Bolts OVERHAUL MANUAL MANUAL TRANSMISSION 7B 49 SPECIAL TOOLS 10 1 J 1126 Transmission Guide Pins 7 2 18059 Retainer Snap Ring Pliers 3 J 22246 J 22379 Countergear Loading Tool 8 4 J 5778 Extension Bushing Remover and Installer 9 5 J 5154 Extension Seal Installer 10 6 J 5814 01 Speedometer Drive Gear Remover 11 and Adapter J 5814 15 12 13 J 1453 01 Speedometer Drive Gear Press Plates and Press Plate Holder J 358 1 41 2228 Rear Bearing Press Plates J 933 Main Drive Gear Wrench J 5590 Clutch Gear Bearing Installer J 9772 Clutch Gear Bearing Installer J 23096 Clutch Gear Retainer Seal Installer J 5752 Transmission Holding Fixture Manual
252. ase Components 3 Install two 3 8 16 threaded slide hammer bolts J Removal 9539 with weights J 6585 01 into bolt holes in pump body 1 If necessary to replace pry front seal from pump and remove pump assembly from case Fig 7A 32C See Fig 7A 31C illustration for location of threaded holes 2 Remove pump attaching bolts 4 Remove and discard pump to case seal and gasket 5 Remove forward clutch assembly and turbine shaft from transmission Fig 7A 33C 6 Remove forward clutch hub to direct clutch housing thrust washer if it did not come out with forward clutch housing assembly 7 Remove direct clutch assembly Fig 7A 34C Fig 7A 32C Removing Pump Assembly Fig 7A 34C Removing Direct Clutch Assembly Fig 7A 35C Removing Front Band 8 Remove front band assembly Fig 7A 35C 9 Remove sun gear shaft Fig 7A 36C Check Rear End Play as Follows Fig 7A 37C a Install J 9539 or a 3 8 16 threaded bolt into extension housing attaching bolt hole Fig 7A 37C b Mount a dial indicator on bolt 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 that is located between output shaft thrust washer and rear face of transmission case AUTOMATIC TRANSMISSIONS 400 7A 11 DIAL INDICATOR Fig 7A 37C Checking Rear Unit End Play REAR END WASHER T
253. ase will suddenly fall free when it is pried past a certain point therefore make sure case is properly supported to prevent damage The bearing caps may be loosely installed as shown in Figure 2B to prevent case from falling 6 Place left and right bearing cups with bearing caps so that they may be reinstalled in original positions Place shims with appropriate cups Inspection 1 Clean all parts in cleaning solvent inspect all bearing cups races and rollers for scoring chipping or evidence of excessive wear 2 Inspect axle shaft and side gear splines for evidence of excessive wear 3 Inspect hypoid ring gear and pinion teeth for possible scoring cracking or chipping 4 Inspect differential case pinions side gears thrust washers and pinion shaft for cracks scoring spalling or excessive wear OVERHAUL MANUAL 4B 2 REAR AXLE DIFFERENTIAL TRUCK REAR AXLE IDENTIFICATION All rear axles used in Chevrolets are stamped with a prefix code designating the axle ratio and vehicle identification build date axle source and shift code RAA EXAMPLE 001 G 1 Axle amp Vehicle Code See Chart Below Day Code Jan 1 001 603560 1 EXAMPLE Shift Code 1st Shift Source Code Buffalo Gear amp Axle GM of Canada Warren EX wA DANA P N MONTH DAY CODE CODE MODEL SHIFT CODE PRODUCTION YEAR LINE CODE The Dana Part number and build date are stamped on the rear surface
254. ated in step 5 which will give the proper bearing preload and backlash and install side bearing Installation 1 Spread differential carrier using spreader as shown in figure 15F 2 Install differential bearing outer races in their correct location then install differential case into carrier 3 Install differential bearing caps in the correct location as indicated by marks made at disassembly Install cap screws finger tight Rotate differential assembly and rap on case with a soft faced hammer to ensoure 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 Backlash must be held to 004 to 009 and must not vary more than 002 between positions checked 6 Whenever backlash is not within limits differential bearing shim pack should be corrected to bring backlash within limits REAR AXLE DIFFERENTIAL 4B 31 Old Pinion New Pinion Marking Marking 0 008 0 007 0 006 0 007 0 006 0 005 0 006 0 005 0 005 0 004 4 0 004 0 003 0 003 0 002 TT 000s 0007 one z000 000s one 0007 wow Fig 21F Dana Pinion Code Chart 0 002 4 0 001 7 Check gear tooth contact as descr
255. b Install new cup plug to 1 0mm 039 below surface Reassembly 1 Install clutch apply ring on piston 2 Install new outer and inner seals on piston with lips facing away from clutch apply ring side Figs 7A 114A and 7 115 CLUTCH INNER LIP UP FORWARD CLUTCH PISTON Fig 7A 115A Removing or Installing Inner Piston Seal EXHAUST CHECK BALL FORWARD CLUTCH HOUSING FORWARD CLUTCH FEED HOLE Fig 7A 116A Forward Clutch Housing AUTOMATIC TRANSMISSION 200 7 29 NOTICE Use care when installing forward clutch piston past large forward clutch snap ring groove Groove could cut outer seal on piston 3 Lubricate seals and install forward clutch piston Fig 7A 117A To make the piston easier to install insert tool between the inner seal and shaft rotate tool around the shaft to compress the lip of the seal while pushing down slightly on the piston Use the same procedure between the outer seal and the housing Refer to Figs 7A 117A and 7A 118A 4 Install retainer and spring assembly NOTICE Retainer could locate in snap ring groove and forcing retainer to compress springs could damage retainer plate 5 Using J 23327 1 J 25024 and J 25018 adaptor compress retainer past the snap ring groove and install snap ring Fig 7A 113A An arbor press and J 23327 1 and J 25018 can be used to compress the retainer and spring assembly 7 FORWARD CLUTCH PISTON FORWARD CLUTCH
256. b to mainshaft snap ring Be sure the notches of the blocker ring align with the keys of the synchronizer assembly 9 Install reverse gear with clutching teeth downward 10 Install reverse gear thrust washer steel 11 Install reverse gear spring washer 12 Install rear ball bearing with snap ring slot downward press onto mainshaft 13 Install rear bearing to mainshaft snap ring 14 Install speedometer drive gear and retaining clip ASSEMBLY OF TRANSMISSION FIG 7B 18A 1 Using Tool J 22246 load a row of roller bearings 27 and a bearing thrust washer at each end of the countergear Use heavy grease to hold them in place Fig 7B 16A Fig 7B 14A Installing Clutch Gear Bearing Retainer Seal aa L 1 10 II Drive Gear Drive Gear Bearing 3rd Speed Blocker Ring Mainshaft Pilot Bearings 14 Snap Ring 2 3 Synchronizer Assembly 2nd Speed blocker Ring 2nd Speed Gear Shoulder Part of Main Shaft Ist Speed Gear 1st Speed Blocker Ring Ist Speed Synchronizer Assembly Snap Ring Reverse Gear Fig 7B 15A Clutch Gear and Mainshaft Assembly Reverse Gear Thrust Washer Spring Washer Rear Bearing Snap Ring Speedo Drive Gear and Clip Mainshatt MANUAL TRANSMISSION 7B 7 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 Be sure coun
257. before proceeding with assembly On the button end of each pinion there is etched a plus number a minus number or a zero 0 number which indicates the best running position for each particular gear set This dimension is contolled by the shimming behind the Nut Washer Pinion Flange Outer Bearing Shims Drive Pinion Inner Bearing Shims Lock Pin Differential Side Gear Thrust Washer Axle Shaft 14 13 14 15 16 17 19 FRONT WHEEL DRIVE 4 3 2120 19 18 17 16 Differential Bearing Cone 20 Differential Case Differential Bearing Cup 21 Differential Bearing Adjusting Bearing Cap Shims Differential Bearing Adjusting 22 Differentia Bearing Cap Shims 23 Differential Bearing Cone Differential Pinion 24 Differential Bearing Cup Thrust Washer 25 Cover Bolt Cover 26 Gasket Pinion Cross Shaft 27 Axle Shaft Ring Gear 28 Oil Seal Fig 4C 2 Front Axle Differential Assembly 29 30 31 32 33 34 35 36 37 Thrust Washer Ring Gear Bolt Oil Slinger Differential Carrier Inner Bearing Cone Inner Bearing Cup Outer Bearing Cup Outer Bearing Cone Oil Slinger Oil Seal OVERHAUL MANUAL 8IA pepojdxa3 jenue19giQ O y Du Nut Washer Companion Flange Pinion Oil Seal Gasket Outer Pinion Oil Slinger and 8 Cone and Roller Outer Pinion Bearing Shims Outer Pinion Bearing Inner Pinion Oil Slinger 11 12 13 Shims Inner Pinion
258. bly out of carrier 5 Remove front internal gear ring from output carrier assembly 6 Remove sun gear Fig 7A 49C 7 Remove reaction carrier to output carrier thrust washer 8 Turn assembly over and place main shaft through hole in work bench Fig 7A A9C Removing Sun Gear SNAP RING Fig 7A 50C Removing Output Shaft to Carrier Snap Ring 9 Remove ring from output shaft of models that use an ring 10 Remove output shaft to output carrier snap ring Fig 7A 50C 11 Remove output shaft 12 Remove output shaft to rear internal gear thrust bearing and two 2 races 13 Remove rear internal gear and mainshaft Fig 7A 51C Do not drop bearings REAR INTERNAL GEAR g 7A 51C Removing Rear Internal Gear and Mainshaft F SNAP RING MAIN SHAFT Fig 7A 52C Removing Rear Internal Gear to Main Shaft Snap Ring 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 mainshaft Fig 7A 52C NYLON SPEEDOMETER DRIVE GEAR NYLON SPEEDOMETER DRIVE GEAR CLIP Fig 7A 53C Removing Nylon Speedometer Drive Gear AUTOMATIC TRANSMISSIONS 400 7A 15 SPEEDOMETER DRIVE GEAR CLIP Fig 7A 54C Installing Speedometer Drive Gear Clip Speedometer Drive Gear Replacement If removal and installation or replacement of the speedometer drive gear is necessary proceed as follows Nylon Spe
259. bolts with clean engine oil and install 10 Pull ring gear onto case by alternately tightening bolts around case When all bolts are snug tighten bolts evenly and alternately across diameter to 120 ft lbs torque Do not use hammer to force ring gear on case TT SPRING BLOCK Fig 4B 19D Spring and Spring Block OVERHAUL MANUAL 48 46 REAR AXLE DIFFERENTIAL CLUTCH CONE SIDE GEAR Fig 4B 20D Case Cone Installation TIGHTEN BOLTS ONE TURN AT A TIME THEN TORQUE TO 30 FT LBS Fig 4B 21D Bolt Torque Sequence 11 Install unit into axle carrier following instructions given for Standard Differential POWER LOK DIFFERENTIAL The Power Lok differential shown in figure 22D is a unit which is installed as optional equipment in place of the standard differential The locking differential permits the major driving force to be transmitted to the wheel with better traction This means that the vehicle can be operated on ice snow sand or under other adverse conditions with a minimum amount of slippage through one wheel Disassembly 1 Remove differential bearing cups and tag for reassembly reference 2 Remove differential bearing cones using Puller Tool J 22888 3 Tag each bearing cone and shim for reassembly reference as they should be replaced in their original locations 4 Scribe mark on both halves of differential so they can be reassembled in their original locations 5 Remove eight bolts att
260. bs 11 Install manual shaft to case spacer clip Intermediate Servo Piston Valve Body Oil Pan and Gasket l Install intermediate servo piston apply pin spring and spring seat 2 Install intermediate servo piston and metal oil seal ring 3 Install four 4 check balls into proper transmission case pockets fig 7A 18B OVERHAUL MANUAL 4 Install oil pump pressure screen and governor feed Screen 5 Install valve body transfer plate and gasket assembly 6 Install valve body to transfer plate gasket 7 Install valve body Connect manual control valve link to range selector inner lever Torque bolts in random sequence to 130 inch pounds 8 Install spacer support plate torque bolts to 130 in Ibs 9 Connect detent control valve wire to detent valve actuating lever then attach lever to valve body 10 Install detent roller and spring assembly to valve body 11 Align lube holes in strainer with those in valve body and install strainer assembly gasket and strainer 12 Install oil pan using a new gasket Tighten bolts to 130 inch pounds in succession until bolts maintain torque specification NOTICE If a new oil pan is being installed transfer production code number is on right side of old pan to new pan On JA and JH models production code number is on governor cover Governor and Vacuum Modulator l Install governor assembly cover and seal and retainer wire 2 Install vacuum modulator valve
261. burrs and foreign material 2 Lubricate bearings with axle lubricant position cups on proper bearing then install differential assembly in carrier and support the assembly to prevent it from falling 3 Install strap J 22779 6 on left bearing by tightening bearing bolts alternately and evenly to snug fit 4 With the ring gear tight against the pinion gear 000 to 001 backlash insert gaging Tool J 22779 between the left bearing cup and carrier housing as shown in figure 6B 5 While oscillating tool turn adjusting nut clockwise until a noticeable drag is produced OVERHAUL MANUAL 4B 4 REAR AXLE DIFFERENTIAL Fig 2B Differential Case Removal 6 Tighten lock bolt on side of tool 7 Between the right bearing and carrier install Service Spacer A 170 Service Shim B and Feeler Gage C Thickness of Feeler Gage must be sufficient to produce a slight drag when moved between carrier and Service Shim 8 Now measure the above dimensions as shown in figure 7B a Using a micrometer as in figure 8B measure the thickness of J 22779 in a minimum of three places and average these readings Record the result b Add together the dimensions of the Service Shim Service Spacer and Feeler Gage Record the result 9 Use the sample procedure in figure 7B to determine the proper thickness for each shim pack NOTICE Production preloading of the differential bearings is accomplished by the use of cast iron preload
262. by pressing in on plug install retaining pin and remove screwdriver 8 In lower right hand bore install 3 2 valve 9 Install 3 2 spring spacer bore plug hole out and retaining pin 10 In next bore up install the 2 3 shift valve open end out into the bore and install 3 2 intermediate spring 11 Install 2 3 modulator valve into bushing and install both parts into valve body bore 12 Install 2 3 valve spring and retaining pin Model CZ does not use a 2 3 shift valve spring 13 In next bore up install 1 2 valve stem end out 14 Install parts as follows AUTOMATIC TRANSMISSIONS 400 7A 21 Titus 25 26 MODELS CG CF amp CA Manual Valve 1 2 Detent Valve Bore Plug 2 3 Modulator Retaining Pin Bore Plug Detent Valve Detent Regulator Valve Spacer Detent Regulator Valve Spring 1 2 Shift Valve 2 2 Modulator Valve 2 Regulator Valve pring 1 2 Mod Valve Spring 1 2 Regulator Valve 1 2 Modulator Bushing Retaining Pin Retaining Pin 1 1 S 1 2 Accumulator Valve 1 2 Primary Accumulator Spring 2 3 Shift Valve 3 2 Intermediate Spring 2 3 Modulator Valve 2 3 Shift Valve Bushing Retaining Pin 3 2 Valve Spacer 3 2 Spring Bore Plug Retaining Pin 1 2 Accumulator Valve Sec Spring Spring LATER DESIGN Fig 7A 67C Control Valve Assembly Exploded View a Models CG CJ and CP Install the 1 2 valve spring and
263. by turning the handle clockwise Remove the Seal Seat from the compressor with a rotary pulling motion Figure 1B 93 Discard the Seat NOTICE DO NOT tighten the handle with a wrench or pliers however the handle must be hand tightened securely to remove the Seat Figure 1D 93 Removing R 4 Ceramic Seal Seat On Car 7 With Seal Protector J 22974 still over the end of the shaft set Seal Remover Installer J 9392 down onto shaft end turning clockwise while pressing down to engage Remover tangs with the tabs on the Seal assembly Then lift the Shaft Seal assembly out see Figure 1B 94 Discard the Seal Figure 1D 94 Removing R 4 Seal On Car 8 Remove and discard the seal seat O ring from the compressor neck using O Ring Remover 9553 Figure 1D 95 9 Recheck the shaft and inside of the compressor neck for dirt or neck foreign material and be sure these areas are perfectly clean before installing new parts Inspection Seals should not be re used Always use a new specification service seal kit on rebuild see Figure 10 20 Be extremely careful that the face of the Seal to be installed is not scratched or damaged in any way Make sure that the 10 36 AIR CONDITIONING COMPRESSOR OVERHAUL Figure 10 95 Removing RA O Ring On Car Seal Seat and Seal are free of lint and dirt that could damage the seal surface or prevent sealing Replace On Car 1 Coat the new seal seat O ring in clean 525 viscosity refriger
264. ce plates steel separator plates and cushion spring fig 7A 83B 3 Using tool J 23327 compress piston return seat and remove retaining ring fig 7A 84B 4 Remove piston return seat and twenty one 21 clutch return springs On JA and JH models return springs are attached to return seat J 23327 1 Fig 7A 84B Compressing Forward Clutch Piston Return Seat AUTOMATIC TRANSMISSION 350 7 25 CLUTCH PISTON INNER SEAL Fig 7A 85B Removing Forward Clutch Piston Inner and Outer Seals 5 Remove forward clutch piston assembly 6 Remove the forward clutch inner and outer piston seals fig 7A 85B Inspection 1 Inspect drive and driven clutch plates for signs of burning scoring or wear 2 Inspect twenty one 21 springs for collapsed coils or signs of distortion 3 Inspect piston for cracks OVERHAUL MANUAL 350 7A 26 AUTOMATIC TRANSMISSION 020 PIANO WIRE CRIMPED INTO COPPER TUBING FORWARD CLUTCH HOUSING FORWARD CLUTCH BALL CHECK EXHAUST FORWARD CLUTCH DRUM Fig 7A 86B Forward Clutch Exhaust Check Ball Installing Piston 4 Inspect clutch housing for wear scoring open oil passages and free operation of exhaust check ball fig 7A 86B 5 Inspect input shaft Input shaft and clutch housing are serviced separately 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 cra
265. cess for feeler gage 14 Install top plate on Compressing Fixture J 9397 Tighten nuts to 15 Ib ft 20 torque using a 0 25 Ib ft 0 60 torque wrench Gaging Procedure Steps 15 thru 18 The gaging operations which follow have been worked out on a simple basis to establish and provide necessary running tolerances Two gaging procedures are necessary The first is made to choose the proper size shoe discs to provide at each piston a 0016 to 0024 total preload between the seats and the axial plate at the tightest place through the 360 degree rotation of the axial plate The bronze shoe discs are provided in 0005 variations including a basic ZERO shoe The second performed at the rear shaft thrust race and bearing stack up is designed to obtain 0025 to 0030 preload between the hub surfaces of the axial plate and the front and rear hubs of the cylinder A total AIR CONDITIONING COMPRESSOR OVERHAUL 1D 17 Figure 1D 44 Assembling A 6 Cylinder Halves of 14 steel thrust races including a basic ZERO race are provided in increments of 0005 thickness to provide the required fit Feeler and Tension Gage Set J 9564 01 or J 9661 01 may be used for gaging proper shoe disc size Feeler Gage Set J 9564 01 or Dial Indicator Set J 8001 may be used to determine proper thrust race size PROPER SELECTION OF THRUST RACES AND BALL SEATS IS OF EXTREME IMPORTANCE 15 Measure clearance between REAR BALL of No
266. ch Snap Ring 4 Remove direct clutch backing plate composition plates steel clutch plates 5 Using clutch compressor Tool J 4670 and J 21664 compress spring retainer in arbor press and remove snap ring Fig 7A 94C 6 Remove retainer and fourteen 14 piston release springs Keep springs separate from forward clutch release springs 7 Remove direct clutch piston Fig 7A 95C 8 Remove outer seal from piston 9 Remove inner seal from piston 10 Remove center piston seal from direct clutch housing Inspection 1 Inspect roller assembly for popped or loose rollers 2 Inspect inner cam and outer race for scratches or wear DIRECT CLUTCH PISTON ASSEMBLY HOUSING Fig 7A 95C Removing Direct Clutch Piston Assembly aG 400 7A 32 AUTOMATIC TRANSMISSIONS 3 Inspect clutch housing for cracks wear proper opening of oil passages or wear on clutch plate drive lugs 4 Inspect composition faces and steel clutch plates for sign of wear or burning 5 Inspect backing plate for scratches or other damage 6 Inspect clutch piston for cracks 7 Inspect fourteen 14 release springs for collapsed coils or signs of distortion The 14 direct clutch release springs are not serviced If one or more of these springs require replacement discard all of them and instal the 16 service direct clutch release springs 8 Inspect housing for free operation of check ball Assembly The forward and direct clutch pistons ha
267. ch assembly clutch plate end up over hole in bench Align direct clutch composition faced clutch plate teeth one above the other to make the forward clutch assembly easier to install 2 Install forward clutch assembly into direct clutch Hold direct clutch housing and rotate forward clutch back and forth until the forward clutch is seated Fig 7A 121A When the forward clutch is seated it will be approximately 15 8mm 5 8 from the tang end of the direct clutch housing to the end of the forward clutch drum Fig 7A 122A 3 Grasp direct and forward clutch assemblies to prevent their separation and position on bench with the turbine shaft up 4 Install J 25021 as shown in Fig 7A 123A 5 Install direct and forward clutch assemblies using J 25021 and rotate into position Fig 7A 123A The direct FORWARD CLUTCH HOUSING DIRECT CLUTCH HOUSING Fig 7A 121A Installing Forward Clutch Assembly FORWARD CLUTCH HOUSING b 15 8 mm 5 8 DIRECT CLUTCH HOUSING v9 Fig 7A 122A Forward Clutch Properly Seated in Direct Clutch Fig 7A 123A Installing Direct and Forward Clutch Assemblies 34 mm 1 5 16 Fig 7A 124A Direct and Forward Clutch Assemblies Properly Installed INTERMEDIATE BAND E Fig 7A 125A Installing Intermediate Band Assembly AUTOMATIC TRANSMISSION 200 7A 31 PUMP BODY PUMP COVER THRUST WASHER PUMP OIL SEAL RINGS P
268. ck ring is seated under lug with raised divider Be sure both ends of lock ring are securely under large lug Rear Housing Group Assembly 1 Place a new power piston bearing center of rear housing so flange on center hole of housing fits into groove of power piston bearing The large flange on power piston bearing will be on stud side of housing 2 Coat inside of power piston bearing with Delco Power Brake Lube or equivalent Final Assembly 1 Place air silencer over holes on tube of power piston Wipe tube of power piston with Delco Power Brake Lube or equivalent 2 Assemble power piston to rear housing 3 Wipe tube of reaction retainer with Delco Power Brake Lube or equivalent and lay assembly aside 4 Place front housing in a vise Place power piston return spring over the insert in the front housing Lubricate the I D of the support plate seal with power brake lube or equivalent 5 Lightly lubricate beaded edge of the diaphragm with Power Brake Lube or equivalent Hold rear housing and power piston assembly over front housing with master cylinder push rod down Position rear housing so that when rotated into locked position scribe marks on the housings will be in line 6 Using Holder J 22805 01 and Wrench J 9504 01 lock housings together Stake housing interlocks at 2 new OVERHAUL MANUAL 5 18 BRAKES REMOVING STAKE FROM TAB SOCKET 2202 LOCATIONS _ AE e A 1 ES EY O LIR S
269. cks or distortion e On models with a teflon seal at the end of the input shaft proceed as follows e Inspect the input shaft teflon seal ring for damage See Figure 7A 87B If the seal is cut or otherwise damaged it must be replaced Some scoring and or scuffing of the shaft is normal Remove seal with a sharp pointed knife by inserting under the seal and cutting making sure not to damage the seal land area Install new seal using J 22974 and J 9392 01 Position J 22974 with large open end on top of input shaft chamfer Slide teflon seal partially down tool taper by hand Position J 9392 01 or 9 16 box end wrench OVERHAUL MANUAL Fig 7A 87B Input Shaft Teflon Seal Replacement over end of J 22974 and slowly push teflon seal down taper and onto shaft and groove Do not leave seal on untapered or middle of tool as this will stretch the seal excessively After the seal is on the shaft it must be sized Dip end of input shaft in automatic transmission fluid to lubricate seal and shaft and slowly insert seal and shaft into output shaft three times before final assembly of transmission Check that seal has not been cut and is free in the groove Reassembly 1 Install new forward clutch inner piston seal and outer piston seal 2 Install the forward clutch pistons assembly with the aid of a feeler gage or a piece of 020 piano wire crimped into copper tubing fig 7A 86B AUTOMATIC TRANSMISSION 350 7A 27 USE WHEN DIM I
270. crews just enough to hold the bearing cups in place 2 Install dial indicator on carrier with indicator button contacting back of ring gear as in figure 19F 3 Place two screwdrivers between bearing cup and housing on ring gear side of case and pry ring gear into mesh with pinion gear as far as it will go Rock ring gear to allow bearings to seat and gears to mesh With force still applied set indicator to 0 4 Reposition screw drivers on opposite side of ring gear and pry ring gear as far as it will go Now take an indicator reading Repeat until the same reading is obtained every time This reading will be the necessary amount of shims between the differential case and differential bearing on the ring side gear Remove differential bearing from the ring side and assemble proper amount of shims Reassemble bearing 5 Remove the differential bearing from the opposite side of ring gear To determine the amount of shims needed here use the following method a Subtract the size of shim pack just installed on ring gear side of case from the reading obtained and recoreded in step 10 of Differential Case Reassembly b To this figure add an additional 015 shims to compensate for preload and backlash Example If reading in step 10 of Differential Case Reassembly was 085 and the shims installed on ring gear side of case was 055 the correct amount of shim will be 085 055 015 045 6 Install shims as indic
271. ct speedometer drive gear Inspection of Rear Internal Gear 1 Inspect gear teeth for damage or wear 2 Inspect splines for damage 3 Inspect gear for cracks Inspection of Sun Gear 1 Inspect gear teeth for damage or wear 2 Inspect splines for damage 3 Be sure oil lubrication hole is open 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 With sun gear shaft properly supported using Tool J 21465 15 with slide hammer and Adapter J 2619 remove bushing AUTOMATIC TRANSMISSIONS 400 7 41 PINION PIN BRONZE WASHER STEEL WASHER HEADED END PLANET PINION NEEDLE BEARINGS STEEL WASHER BRONZE WASHER Fig 7A 131C Planet Pinion Assembly Exploded View Replace Using Tool J 21465 5 with Driver Handle J 8092 press or drive replacement bushing into place until tool bottoms INSPECTION OF MAIN SHAFT 1 Inspect shaft for cracks or distortion 2 Inspect splines for damage 3 Inspect ground bushing journals for damage 4 Inspect snap ring groove for damage 5 Make sure that lubrication holes are open NOTICE If replacement of mainshaft is required make sure that the orifice cup plug in the service mainshaft is removed INSPECTION OF FRONT AND REAR BANDS SUPPORT TO CASE SPACER 1 Inspect lining for cracks flaking b
272. cylinder AIR CONDITIONING COMPRESSOR OVERHAUL 1D 21 PISTON AND RING ASSEMBLY J 24608 6 RING SIZING TOOL Figure 1D 53 Turning A 6 Piston and Ring Assembly Into Ring Sizing Tool D J 24608 1 PISTON RING GAGE Figure 10 54 Gaging 6 Piston Ring Size TEFLON RING 0919 Figure 1D 55 A 6 Teflon Piston Ring Installed in Piston 9 Generously lubricate all moving parts with clean 525 viscosity refrigerant oil and check for free rotation of the parts 10 Replace the Suction Cross Over Cover Figure 1D 61 Compress the cover as shown to start it into the slot and then press or carefully tap it in until flush on both ends SELECTED REAR THRUST RACE SELECTED REAR SHOE DISC THRUST BEARING ZERO THRUST RACES LIFT SHAFT UPWARD AND HOLD THE THRUST RACES AND BEARING AGAINST HUB E H ZERO FRONT SHOE DISC THRUST BEARING 0920 Figure 1D 56 Installing 1st A 6 Piston Assembly Into Front REAR THRUST RACES BEARING FRONT THRUST RACES AND BEARINGS 0921 Figure 1D 57 Installing 2nd A 6 Piston A 6 COMPRESSOR INTERNAL CYLINDER AND SHAFT ASSEMBLY Re Install 1 Place Internal Cylinder and Shaft Assembly on Internal Assembly Support Block J 21352 with rear end of shaft in Support Block hole 2 Now install new O ring and bushing in front end of discharge cross over tube Figure 1D 62 The O ring and bushing are service parts only for Internal Cylinder and 1D 22 AI
273. cylinder and position the strap high enough to clear the cylinder as the Shell is removed Figure 1D 108 6 Remove Compressor Holding Fixture J 25008 1 and reverse Holding Fixture with step block protrusions engaging the compressor Shell Install the medium length bolts through the Holding Fixture and thread them fingertight on both sides into the compressor cylinder until the step of the fixture protrusions contact the compressor Shell Figure 1D 109 With compressor at room temperature check to be sure the step protrusions do not overlap the cylinder but will pass both sides 7 Using a wrench alternately tighten each bolt approximately 1 4 turn to push the Shell free of the O rings on the cylinder If one screw appears to require more force to turn than the other immediately turn the other screw to bring the screw threading sequence in step or the Shell will be cocked and made more difficult to remove Normal removal does not require much force on the wrench if the screws are kept in step while turning The Shell can be removed by hand as soon as the Shell is free of the shell to cylinder O rings Do not turn the screws any further than necessary to release the Shell 8 Remove the compressor Shell and remove the Holding Fixture J 25008 1 from the compressor Reverse the Holding Fixture to again hold the compressor by the opposite side using the short length screws 9 Remove and discard both cylinder to Shell O rings RETA
274. d shim s in the differential case 7 Position pinion gears and thrust washers on side gears Install pinion shaft through case and gears 8 Install dial indicator in case so that contact button rests against pinion gear as shown in figure 10D 9 Compress clutch pack using a screwdriver as shown in figure 11D Move the pinion gear to obtain tooth Fig 6D Removing Preload Springs from Pack Fig 7D Removing Differential Pinion Gears clearance 10 Tooth clearance should be 001 to 008 If required change shims to obtain proper tooth clearance 11 Remove side gear assembly and repeat tooth clearance procedure for other side gear on opposite side of case 12 Remove pinion shaft gears and thrust washers 13 Install remaining side gear clutch pack assembly and shims in case 14 Install pinion gears and thrust washers Installation of pinion gears can be performed by reversing the pinion gear removal procedure 15 For all except Corvette assemble springs in spring retainer 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 See figure 11D 16 Position spring pack between side gears and remove bar stock and C clamp 17 On Corvette install Tool J 22311 to compress clutch pack secure pack with 1 4 bolts as shown in figure 12D Partially install pack then remove bolts and complete pack installation Remove tool REAR AXLE
275. d using a plastic hammer to overcome friction of O ring seal between front head and compressor shell 17 Wipe excess oil from sealing surfaces on front head casting webs and examine sealing surface If any surface damage is observed the head should be replaced 18 Remove Front Discharge Valve Plate assembly and Front Suction Reed Plate Examine reeds and seats Replace necessary parts 19 Remove Suction Cross Over Cover by prying with screwdriver between cylinder casting and cover Figure 1D 34 20 Examine Internal Cylinder and Shaft Assembly for any obvious damage If Internal Assembly has sustained major damage due to loss of refrigerant or oil it may be necessary to use the Service Internal Cylinder and Shaft Assembly rather than replace individual parts 1D 14 AIR CONDITIONING COMPRESSOR OVERHAUL SUCTION CYLINDER ASSEMBLY Figure 1D 34 Removing 6 Suction Cross Over Cover A 6 COMPRESSOR INTERNAL CYLINDER AND SHAFT ASSEMBLY Disassembly Use Parts Tray J 9402 Figure 1D 38 to retain compressor parts during disassembly 1 Remove Internal Cylinder and Shaft Assembly from compressor as described in A 6 Compressor Internal Mechanism Cylinder and Shaft Assembly Removal procedure 2 Identify by pencil mark or some other suitable means each piston numbering them as 1 2 and 3 Figure 10 35 SUPPORT BLOCK J 21352 Figure 1D 35 Numbering A 6 Piston and Cylinder Bores Number the piston bores in the
276. d Blocker Ring 1st Speed Synch Hub 1st Speed Synch Snap Ring Reverse Gear Reverse Gear Thrust and Spring Washers 10 11 12 13 14 36 37 38 Snap Ring Bearing to Mainshaft Extension Vent Speedometer Drive Gear and Clip Mainshaft Rear Oil Seal Retainer Oil Seal Snap Ring Bearing to Gear 15 16 17 39 Clutch Gear Bearing Snap Ring Bearing to Case Thrust Washer Front Thrust Washer Rear Snap Ring Bearing to Extension Rear Bearing Countergear Roller Bearings Magnet 2 3 Synch Sleeve Countergear Counter Shaft Reverse Idler Shaft 1st Speed Synch Sleeve E Ring Reverse Idler Gear Woodruff Keys cad NOISSINSNVH I IVANY MANUAL TRANSMISSION 7B 3 Fig 7B 2A Removing Clutch Gear Bearing Retaining Ring 3 Check bearing bores in case and if damaged replace case Front and Rear Bearings 1 Wash the front and rear ball bearings thoroughly in a cleaning solvent 2 Blow out bearings with compressed air NOTICE Do not allow the bearings to spin turn them slowly by hand Spinning bearings may damage the race and balls 3 Make sure bearings are clean then lubricate with light engine oil and check them for roughness by slowly turning the race by hand Bearing Rollers clutch gear and counter gear bearing rollers should be inspected closely and replaced if they show wear Inspect counter shaft and reverse idler shaft at the same time replace if necessary Replace all w
277. d discard the front head O ring seal 3 Remove the two thrust washers and one belleville washer from the compressor shaft Note the assembled position of the washers 4 Install a new thrust washer on the compressor shaft with the thrust washer tang pointing up Figure 1D 105 5 Install the new belleville washer on the shaft with the high center of the washer up 6 Install the remaining thrust washer on the shaft with the tang pointing down Figure 1D 105 7 Lubricate the three washers with clean 525 viscosity refrigerant oil and assemble the Front Head and new O ring onto the compressor as described in R 4 Compressor Front Head Replacement procedure R 4 COMPRESSOR MAIN BEARING Remove 1 Discharge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR C CO T A C SYSTEMS in the AIR CONDITIONING section 2 Remove the Front Head assembly as described in RA Compressor Front Head Removal procedure Discard front head O ring 3 Place the Front Head assembly on two blocks as shown in Figure 1D 106 and use Main Bearing Remover J 24896 to drive the Main Bearing out of the Front Head Replace 1 Place the Front Head with neck end down on a flat solid surface 2 Align the new Main Bearing and the Bearing Installer J 24895 squarely with the bearing bore of the Front THRUST WASHERS J 24896 d BEARING REMOVER y sa Figure 1D 106 Removing R 4 Ma
278. d positions around the gear Variation in readings should not exceed 001 Position the dial indicator so that indicator button is perpendicular to tooth angle and in line with gear rotation 14 If variation in backlash readings exceeds 002 measure ring gear and case runout as shown in figure 11B Gear runout should not exceed 003 should runout exceed this limit check ring gear and case for deformation and or foreign matter between case and gear 15 If gear lash is not within limits correct by decreasing shim thickness on one side and increasing thickness of other shim the same amount Total shim thickness must be maintained at all times to maintain proper preload 16 Backlash changes approximately 002 for each 003 change in shim dimensions If backlash exceeds 008 increase the shim thickness on the ring gear side while decreasing the shim thickness on the opposite side an equal amount If backlash is less than 005 decrease the shim thickness on the ring gear side while increasing the shim thickness on the opposite side an equal amount DRIVE PINION Removal 1 Remove differential as previously outlined 2 Check torque required to rotate drive pinion as described under Drive Pinion Installation and Adjustment If there is no preload reading check for looseness of pinion assembly by shaking push pull the companion flange Looseness indicates the need for bearing replacement 3 Install Holder J
279. d shift T V valve e Discard shift T V plug and remove 6 3mm 1 4 rod from shift T V bore 9 From next bore down remove outer coiled pin MANUAL 200 7A 40 AUTOMATIC TRANSMISSION Fig 7A 155A Removing Inner Coiled Retaining Pin Remove the throttle valve plunger bushing throttle valve spring and on models BR and CX remove the detent pin Using a 1 5mm 1 16 allen wrench with ground sides to fit inside the pin remove the inner coiled pin Fig 7A 155A Remove the throttle valve 10 From upper left bore remove coiled intermediate boost spring and intermediate boost valve 11 From next bore down remove coiled pin low overrun clutch spring and low overrun clutch valve 12 From next bore down remove coiled pin direct clutch exhaust spring and direct clutch exhaust valve 13 From next bore down remove coiled pin valve bore plug 1 2 accumulator valve and 1 2 accumulator valve spring Inspection 1 Wash control valve body valves springs and other parts in clean solvent and air dry 2 Inspect 1 2 accumulator piston for damage 3 Inspect 1 2 accumulator piston seal for damage and free fitting groove Do not remove seal unless replacing 4 Inspect valve for scoring cracks and free movement in their bores 5 Inspect bushings for cracks or scored bores 6 Inspect valve body for cracks damage or scored bores 7 Inspect springs for distortion or collapsed coils 8 Insp
280. d slide hammers J 7004 into threaded holes in pump body and remove pump assembly from case fig 7A 30B Discard pump gasket 3 Remove intermediate clutch cushion spring fig 7A 31B INTERMEDIATE CLUTCH CUSHION SPRING Fig 7A 31B Removing Intermediate Clutch Cushion Spring OVERHAUL MANUAL CH INTERMEDIATE CLUT STEEL PLATES Fig 7A 32B Removing Intermediate Clutch Plates 4 Remove intermediate clutch drive plates and steel reaction plates fig 7A 32B 5 Remove intermediate clutch pressure plate fig 7A 33B e Ir INTERMEDIATE CLUTCH PRESSURE PLATE Be Fig 7A 33B Removing Intermediate Clutch Pressure Plate lt S AUTOMATIC TRANSMISSION 350 7 11 e KK e FRONT INPUT RING 4 BAND S GEAR THRUST WASHER Fig 7A 34B Removing Intermediate Overrun Brake Band Fig 7A 36B Removing Input Ring Gear Front Thrust Washer 6 Remove intermediate overrun brake band fig 7A 8 Remove input ring gear front thrust washer fig 7A 34B 36B Washer has 3 tangs 7 Pull outward on the input shaft to remove the direct 9 Remove input ring gear to output shaft snap ring and forward clutch assemblies from case fig 7A 35B fig 7A 37B INPUT RING em DNS A FORWARD AND DIRECT CLUTCH ASSEMBLIES Fig 7A 35B Removing Direct and Forward Clutch Fig 7A 37B Removing Input Ring Gear to Output Shaft Snap Assemblies Ring
281. d stator shaft properly supported using Tool J 21465 15 with slide hammer tool J 2619 and adapter Tool J 2619 4 remove bushing b Using Tool J 21465 3 with Driver Handle J 8092 press or drive replacement bushing into place until tool bottoms Rear c With pump and stator shaft properly supported using Tool J 21465 15 with slide hammer Tool J 2619 and adapter tool J 2619 4 remove bushing d Using Tool J 21465 2 with Driver Handle J 8092 pressor drive replacement bushing into place until tool bottoms 14 Inspect oil ring grooves for damage or wear 15 Inspect selective washer thrust face for wear or damage 16 Inspect pressure regulator and boost valve for free operation in their respective bores 17 Inspect pump cover for open 1 8 breather hole Fig 7A 76C Assembly 1 Install drive and driven pump gears with alignment marks up into pump body Fig 7A 72C drive gear tangs up 2 Protect stator shaft and install pump cover in vise 3 Install spacer s if used retainer and spring into pressure regulator bore Fig 7A 77C 4 Install pressure regulator valve from opposite end of bore stem end first AUTOMATIC TRANSMISSIONS 400 7A 25 _ PUMP COVER 5 Install boost valve into bushing stem end out and install both parts into pump cover by compressing bushing against spring 6 Install retaining snap ring 7 Install pressure regulator valve bore plug and retaining pin into opposite end of
282. diameter than on JB8 Remove the pilot portion of Tool J 24551 8 Lubricate the piston and Piston Installing Tool with clean power steering fluid Hold the large end of the tool against the piston fig 5 13 and slide the tool and piston into the piston bore and through the piston seal Remove piston installing tool 9 If removed install return hose fitting with new O ring 10 If accumulator valve was removed install new seat into the valve bore The seat can be forced to the bottom by installing the two function valve fig 5 8E NOTICE Make certain the check valve seat is cup side up when in bore 11 If removed insert new dump valve over the two function valve making certain that the dump valve plunger is held in place until installation is complete 12 Insert spool valve spring and spool valve assembly into bore in housing Extend power piston lever to accept sleeve on spool valve then slide lever pins into slot in sleeve 13 Position a NEW figure eight seal in the groove in the housing cover Then join the booster housing and cover and secure with five screws Tighten the screws to 20 ft Ibs CAUTION See Caution on Page 1 of this section 14 Install output rod spring and new spring retainer 15 Secure new baffle and spring retainer using Piston Installing Tool or 7 8 socket as shown in Figure 5 14E 16 Using clean power steering fluid lubricate accumulator seal Install seal and accumulator in hous
283. differential case 2 Position differential pinions and new thrust washers in differential case Align pinions with holes in differential case 3 Install pinion shaft in differential case Align hole in shaft with hole in case then install lock pin Peen hole to prevent pin dropping out of case 4 Position ring gear to case then install cap screws Tighten cap screws evenly and alternately to specifications 5 With an arbor press press differential side bearings onto case using Tool J 21051 Do not install shims at this time Fig 19F Checking Runout REAR AXLE DIFFERENTIAL 4B 29 6 Place differential case in carrier and install bearing caps Care should be taken to install caps in original position Use mark placed on caps and carrier at removal Tighten caps just enough to keep bearing caps in place 7 Install dial indicator on carrier with indicator button contacting back of ring gear as in figure 19F Rotate differential case and check for runout If runout is greater than 002 the assembly should be removed and the ring gear removed from the case Again install differential case and check runout at differential case flange 8 Should runout of case flange be greater than 002 the defect is probably due to bearings or differential case and should be corrected before proceeding further 9 Position two screwdrivers between bearing cup and carrier on opposite side of ring gear away from dial indicator side P
284. dometer drive gear using a heat lamp or suitable heat method 3 Align slot in speedometer drive gear with retaining clip and install 4 Install extension housing to case square cut O ring seal 5 Attach extension housing to case using attaching bolts Torque to 25 ft 165 6 If necessary install a new extension housing seal using seal installer J 5154 or 1 21426 fig 7A 110B Manual Linkage 1 If necessary install a new manual shaft to case lip seal using 3 4 diameter rod seat seal in case 2 Install parking pawl tooth toward the inside of case into case 3 Install parking pawl shaft into case and through parking pawl 4 Install parking pawl shaft retainer plug Drive into case using a 3 8 dia rod until retainer plug is 130 to 170 below face of case then stake in three places Fig 7A 110B Installing Extension Housing Seal OVERHAUL MANUAL 350 7A 36 AUTOMATIC TRANSMISSION Fig 7A 111B Park Lock Bracket Special Boit Identification 5 nstall parking pawl disengaging spring square end hooked on pawl 6 Install park lock bracket torque bolts to 29 ft Ib fig 7A 111B using 290 M Bolts 6 marks on head 7 Install range selector inner lever to parking pawl actuator rod 8 Install actuating rod under the park lock bracket and parking pawl 9 Install manual shaft through case and range selector inner lever 10 Install retaining nut on manual shaft Torque to 30 ft I
285. e Fig 7A 11C Clean governor screen in clean solvent and air dry 4 Remove governor pipes from control valve assembly 5 Disconnect solenoid lead wire from connector terminal Fig 7A 12C Removal of Rear Servo Valve Body Spacer Gasket and Front Servo Remove rear servo cover attaching screws servo cover and gasket Discard gasket Fig 7A 13C 2 Remove rear servo assembly from case Fig 7A 14C 3 Remove rear servo accumulator spring 4 Make band apply pin selection check to determine possible cause of malfunction Fig 7A 15C GOVERNOR SCREEN ASSY GOVERNOR FEED PIPE HOLE Fig 7A 11C Removing Governor Screen Assembly AUTOMATIC TRANSMISSIONS 400 7A 5 Fig 7A 13C Removing Rear Servo Cover Attaching Bolts REAR SERVO ASSEMBLY Fig 7A 14C Removing Rear Servo Assembly 400 7A 6 AUTOMATIC TRANSMISSIONS TORQUE Fig 7A 15C Checking Rear Band Apply Pin Except Models CD and CL Rear Band Apply Pin Selection All Models Except CD and CL a Attach band apply pin selection Gage J 21370 5 and J 21370 6 to transmission case with attaching screws checking to make certain the gage pin does not bind in servo pin hole Fig 7A 15C 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 indentification in the form of one two or three rin
286. e assembly if there is any occasion to doubt cleanliness such as parts dropped or left exposed for eight hours or longer CAUTION If there is any suspicion of contamination or evidence of corrosion completely flush the vehicle hydraulic brake system Failure to clean the hydraulic brake system can result in early repetition of trouble Use of gasoline kerosene anti freeze alcohol or any other cleaner with even a trace of mineral oil will damage rubber parts Inspecting Rubber Parts Wipe fluid from the rubber parts and carefully inspect each rubber part for cuts nicks or other damage These parts are the key to the control of fluid or air flow if the unit is in for overhaul or if there is any question as to the serviceability of rubber parts REPLACE them Inspecting Metal Parts BADLY DAMAGED ITEMS OR THOSE WHICH WOULD TAKE EXTENSIVE WORK OR TIME TO REPAIR SHOULD BE REPLACED In case of doubt install new parts Do not rely on the brake unit being overhauled at an early or proper interval New parts will provide more satisfactory service even if the brake unit is allowed to go beyond the desired overhaul period Assembly Figs 5 1D and 5 2D 1 Be careful during the rebuild procedure that no grease or mineral oil comes in contact with the rubber parts of the power brake unit 2 Lubricate power head parts as outlined below with silicone lubricant provided in the service repair kit Front Housing Group
287. e drive pinion Install a new collapsible spacer into position 6 Press front bearing onto drive pinion 7 Lubricate the oil seal lips with a lithium base extreme pressure lubricant and install the seal in the retainer bore Use J 24434 with driver handle J 8092 Press the seal into the bore until it seats against internal shoulder 8 Install pinion flange and oil deflector onto the splines then install lock washer and new pinion nut 9 Clamp the pinion flange into a vise Install J 8614 11 as in figure 8E Tighten the nut to achieve proper bearing preload a Proper preload is attained when rotational torque required to rotate the pinion is 25 35 in lbs for new bearings or 5 15 in lbs for used bearings b Tighten pinion nut to approximately 350 ft lbs then take a torque reading as shown in figure 15E using J 5853 c Continue tightening pinion nut in small increments until proper preload is attained Fig 9E Removing Flange OVERHAUL MANUAL Fig 11E Removing Pinion Rear Bearing REAR AXLE DIFFERENTIAL 4B 17 Fig 12E Removing Straddle Bearing NOTICE Over tightening of pinion nut may collapse spacer too much requiring its replacement Installation and Adjustment 1 Examine the head of the drive pinion for a pinion depth code number 2 Compare the depth code number with the number on the original pinion Use the following chart to select the proper shim for preliminary setting of pinion dep
288. e front end of the sleeve Pulley Puller Pilot J 9395 see Figure ID 13 may be used to install the retainer Press and tap with a mallet setting the retainer and sleeve into place retainer should be recessed approximately 1 32 from the face of the compressor neck See Figure 10 24 11 Reinstall the Clutch Plate and Hub assembly as described in A 6 Compressor Clutch Plate and Hub Assembly Replacement procedure Some compressor shaft seal leaks may be the result of mispositioning of the axial plate on the compressor shaft The mispositioning of the axial plate may be caused by improper procedures used during pulley and driven plate removal pounding collisions or dropping the compressor If the axial plate is mispositioned the carbon face of the shaft seal assembly may not contact the seal seat and the rear thrust races and bearing may be damaged To check for proper positioning of the axial plate on the shaft remove the clutch driven plate and measure the distance between the front head extension and the flat shoulder on the shaft as shown in Figure 1D 24 To measure this distance use a wire gage the clearance should be between 026 and 075 If the shaft has been pushed back in the axial plate measurement greater than 075 disassemble the compressor and replace the shaft and axial plate assembly rear thrust races and thrust bearing If there also appears to be too much or insufficient air gap between the drive and driv
289. e gear and bearings Fig 7B 5J OVERHAUL MANUA TWANWW 3 WHW3AO 1296 55012 uoissiusuei1 peeds p r g Bu Drive Gear Bearing Retainer Pilot Bearings Case 4th Speed Blocker Ring 4 3 Snych Snap Ring 4 3 Synch Hub 3rd Speed Blocker Ring 3rd Speed Gear 2nd Speed Gear 5 678 9 2nd Speed Blocker Ring 1 2 Speed Synch Hub 1 2 Speed Synch Snap Ring 1st Speed Blocker Ring First Gear Reverse Gear Thrust and Spring Washers Snap Ring Bearing to Mainshaft 10 11 12 1314 15 16 17 Extension Vent Speedometer Drive Gear and Clip Mainshaft Rear Oil Seal Retainer Oil Seal Snap Ring Bearing to Gear Drive Gear Bearing Snap Ring Bearing to Case Thrust Washer Front Thrust Washer Rear Snap Ring Bearing to Extension Rear Bearing Countergear Roller Bearings Anti Lash Plate Assembly Magnet 4 3 Snych Sleeve Countergear Assembly Counter Shaft Reverse Idler Shaft 1 2 Speed Synch Sleeve and Reverse Gear Reverse Idler Gear Sliding Clutch Key Woodruff Key NOISSIINSNVHL PULL MAIN DRIVE GEAR FORWARD Fig 7B 2J Removing Clutch Gear Bearing 8 Remove reverse idler gear stop ring Use a long drift or punch through the front bearing case bore and drive the reverse idler shaft and woodruff key through the rear of the case Fig 7B 6J DISASSEMBLY OF MAINSHAFT 1 Using snap ring pliers remove the 3rd and 4th speed sliding clutch hub
290. e 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 See figure 25B Test 1 Wipe oil out of carrier and carefully clean each tooth of ring gear 2 Use gear marking compound and apply this mixture sparingly to all ring gear teeth using a medium stiff brush When properly used the area of pinion tooth contact will be visible when hand load is applied OVERHAUL MANUAL ZERO THE INDICATOR WITH THE PROBE ON THE HIGH POINT OF THE GAUGING SURFACE SWING THE PROBE OFF THE GAUGE PLATE _ THE INDICATOR NEEDLE WILL MOVE TOWARD THE PROPER NUMBER WHICH INDICATES THE REQUIRED SHIM FOR A NOMINAL PINION A THIS NUMBER IS THE CORRECT SHIM THICKNESS FOR A NOMINAL PINION Fig 21B Use of Dial Indicator 3 Tighten bearing cap bolts to 55 Ib ft 4 Expand brake shoes until a torque of 20 30 Ib ft is required to turn the pinion A test made without loading the gears will not give a satisfactory pattern Turn companion flange with wrench so that ring gear rotates one full revolution then reverse rotation so that ring gear rotates one revolution in opposite direction Excessive turning of ring gear is not recommended 5 Observe pattern on ring gear teeth and compare with Figure 26B Fig 22B Installing Rear Bearing Adjustments Affec
291. e old seal in place OVERHAUL MANUAL Fig 7D 17S Removing Rear Output Bearing Retaining Ring REAR OUTPUT SHAFT HOUSING FRONT Disassembly 1 Remove ring from rear output shaft housing front and discard 2 To remove roller bearings from housing insert a long drift through rear opening and drive bearing from housing Fig 7D 18S Remove and discard rubber seal Assembly 1 Position rubber seal in bearing bore Use grease to hold in place Position roller bearing in bore and press into place until bearing bottoms out in housing 2 Position new ring on housing Fig 7D 18S Removing Rear Output Shaft Front Bearing Fig 7D 19S Installing Rear Output Shaft Seal Front Output Shaft Bearing Retainer Seal Replacement Fig 70 205 1 or drive out existing seal from retainer bore 2 Clean and inspect retainer 3 Apply sealer to outer diameter of new seal 4 Position seal to retainer bore and using Tool J 22836 or equivalent install seal in retainer PRESS SEAL IN RETAINER BORE TO THIS DIMENSION 130 D SCH WORD OUTSIDE s MOLDED IN RUBBER 25 FRONT m d SHAFT FRONT BEARING RETAINER SEAL Lip FRONT OUTPUT SHAFT F BEARING RETAINER ZZ Fig 7D 20S Installing Front Output Bearing Retainer Seal TRANSFER CASES 70 17 Fig 7D 21S Positioning Range Box for Assembly Front Output Shaft Rear Bearing Replacement 1 Remove rea
292. e points toward is the correct shim thickness required for a nominal pinion See figure 21B 12 Repeat the rocking action of the plunger several times to verify the setting 13 Once the zero reading is obtained swing the plunger until it is removed from the gaging plate button The dial indicator will now read the required pinion shim thickness for a nominal pinion Record this figure 14 Check the rear face of the drive pinion being installed for a pinion code number This number indicates the necessary alteration of the pinion shim thickness as Fig 13B Drive Pinion Flange Removal OVERHAUL MANUAL Fig 14B Removing Drive Pinion determined in step 13 a If the pinion is stamped with a plus number add that many thousandths to the indicator reading For example if indicator reading is 019 and pinion is marked 4 2 the correct depth shim for installation will be 019 002 021 inch b If the pinion has no plus 4 or minus use the indicator reading as the correct shim thickness c If the pinion is stamped with a minus number subtract that many thousandths from the indicator reading For example if the indicator reading is 031 and pinion is marked 3 the correct depth shim for installation will be 031 003 028 inch 15 Remove bearing caps and depth gaging tools from carrier 16 Position the shim selected in step 14 on the pinion shaft against pinion head 17 Lubricat
293. e push rod assembly so that the floating control valve bottoms on the tube section of the power piston 5 Place lip of retainer on the O D of Tool J 23175 fig 5 3A Manually press the retainer until seated in the power piston tube fig 5 4A 6 Install filter element over the push rod eye and press into the power piston tube 7 Using snap ring pliers place the snap ring into the groove in the air valve 8 Install the rubber reaction bumper on the end of the air valve Fig 5 3A Installing Air Valve Push Rod Retainer 9 Install air valve spring on end of air valve 10 Install reaction body with large I D hole up 11 Install reaction body retainer 12 Install reaction piston into reaction body large diameter up 13 Apply a light film of silicone lubricant to the O D of the rubber reaction disc 14 Place the rubber reaction disc in the cavity of the reaction body Fig 5 AA Seating Air Valve Push Rod Retainer Using J 23175 OVERHAUL MANUAL 5 4 BRAKES Fig 5 5A Installing Secondary Diaphragm and Support Plate Assembly 15 Place the power piston on bench with the push rod up Install assembly cone J 28458 over push rod end of piston fig 5 5A 16 Assemble secondary diaphragm to secondary support plate Press the raised flange on the I D of the diaphragm through the center hole of the support plate Be sure that the edge of the support plate center hole fits into the groove in the raised fl
294. e reassembled in their original location 3 Drive the pinion shaft lock pin out of case 4 Remove ring gear bolts from case and separate ring gear from case 5 Remove pinion shaft pinions side gears and thrust washers from case DRIVE PINION Removal 1 Using Holding Bar J 8614 1 attached to pinion shaft flange remove self locking nut and washer from pinion shaft 2 Install Tool J 8614 2 and 3 into holding bar as shown in Figure 4C 5 and remove flange from drive pinion Remove drive pinion from carrier 3 With 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 4 Should inspection indicate necessity pinion earing cups can be removed from b carrier using a long drift and hammer Remove shims and oil slinger which are located behind the inner bearing cup Tag shims for reassembly 5 Remove inner pinion cone and roller using Tool J 22912 installed as shown in Figure 4C 6 and press pinion from bearing Inspection 1 Clean all gears and bearings in cleaning solvent and inspect all bearing cups races and rollers for scoring chipping or evidence of excessive wear On pinion bearing rollers inspect large end of rollers for wear This is where wear is most evident on tapered roller bearings NOTICE The pinion bearings are of the tapered type and the natural wear pattern is a frosted condition w
295. e shaft 2 Inspect clutch discs and plates for wear cracked or distorted condition 3 Inspect side gear rings side gears and differential cases for worn cracked or distorted condition that would render these parts unfit for further services Assembly During assembly operations all parts should be kept clean and free of dirt or other foreign material As each part is assembled in its proper position it is necessary that it be lightly coated with the correct lubricant 1 Place tabbed Belleville friction plate 4 in flanged differential case being extremely careful that convex bulged side is toward the side gear See figure 22D 2 Assemble remaining plates and discs to splines of side gear ring being sure they are assembled in the same order of removal The convex bulged side of the Belleveille friction disc 5 should be toward the side gear and it should nest into the Belleville friction plate 4 3 Place assembled side gear ring with plates and discs in flanged half of differential case 4 Install side gear and cross shafts with pinions 5 In the order listed install the following 1 side gear 2 side gear ring 3 flat plate with tabs 4 flat disc with teeth 5 flat plate with tabs 6 Belleville disc with convex bulged side up or toward side gear 7 Belleville plate with convex bulged side up or side toward gear 6 Position plain half of differential case over previously assembled par
296. e the rear pinion bearing with liberal amounts of hypoid lubricant and install rear bearing Use J 8609 01 for the 8 1 2 ring gear or J 5590 for the 8 7 8 ring gear as shown in figure 22B Fig 15B Removing Drive Pinion Rear Bearing Fig 16B Installing Pinion Rear Bearing Cup Installation and Adjustment 1 Lubricate the front bearing with liberal amounts of hypoid lubricant and place into outer cup 2 For 8 7 8 ring gear position seal in bore and place gage plate J 22804 2 over seal and against flange Gage plate insures proper seating of seal in carrier bore See figure 23B Use J 23911 to press seal into bore until gage plate is flush with the carrier shoulder and seal flange Turn gage plate 180 seal must be square in carrier to seal propberly For 8 1 2 ring gear place a new seal into position in carrier bore Tap lightly with a protective plate and a hammer until seal flange seats against carrier 3 Coat lips of pinion oil seal and seal surface of pinion flange with hypoid lubricant 4 Install a new pinion bearing spacer onto drive pinion 5 Place drive pinion into position and mount a suitable thick washer or sheet metal plate over the pinion stem Install the original pinion nut and tighten sufficiently to draw pinion through the front bearing far enough to leave threads exposed when the companion flange is placed into position Remove the washer and install the companion flange using J 8614 11 Fig
297. e the seat O ring However be sure Seal Seat makes a good seal with O ring Remove Installer J 23128 and Seal Protector J 22974 6 Install the new seal seat retainer ring with its flat side against the Seal Seat using Snap Ring Pliers J 5403 3 21 See Figure 1D 21 Use the sleeve from Seal Seat Remover Installer J 23128 to press in on the seal seat retainer ring so that it snaps into its groove Figure 10 98 Installing RA Ceramic Seal Seat On Car 7 For Leak Test pressurize SUCTION SIDE low pressure side of compressor on vehicle with Refrigerant 12 vapor to equalize pressure to the drum pressure Temporarily install the shaft nut and with compressor in horizontal position rotate the compressor shaft in normal direction of rotation several times by hand Leak test the Seal Correct any leak found Remove discard and later replace the shaft nut 8 Remove any excess oil resulting from installing the new seal parts from the shaft and inside the compressor neck 9 Install the Clutch Plate and Hub assembly as described in R 4 Compressor Clutch Plate and Hub Assembly Replacement procedure AIR CONDITIONING COMPRESSOR OVERHAUL 1D 37 10 Re install compressor belt and tighten bracketry 11 Evacuate and Charge the Refrigerant System according to the DISCHARGING ADDING EVACUATING AND CHARGING PROCEDURES FOR A C SYSTEMS the AIR CONDITIONING section R 4 COMPRESSOR SHAFT SEAL REPLACEMENT
298. eaction disc and position disc in center bore of diaphragm plate Use piston rod to seat disc in bore Make sure disc is fully seated before removing piston rod NOTICE If reaction disc is not fully seated it will result in an erroneous push rod height adjustment 3 Apply silicone lubricant to LD of rear housing seal and diaphragm bead contact surface of rear housing Install diaphragm plate assembly in rear housing 4 Place air filter element over push rod and into diaphragm plate extension Install filter retainer OVERHAUL MANUAL 5 22 BRAKES Final Assembly l Attach base of Holding Fixture J 22805 to front housing with nuts and washers and draw down tight to eliminate bending or damage to studs Clamp base in bench vise with power section up fig 5 1A CAUTION Be sure to align tool so that the check valve in the front housing is not damaged 2 Place Spanner Wrench J 9504 over studs on rear housing and attach with nuts and washers Draw nuts down tight to eliminate bending or damaging of studs 3 Place diaphragm plate return spring in front housing and position rear housing assembly on front housing small end of spring downward Position rear housing so that when housings are locked scribe marks on front and rear housings will be in alignment 4 Press down on Spanner Wrench J 9504 and rotate the rear housing counterclockwise to assemble the two housings CAUTION Bend lances in on the rear housing If the t
299. ear and thrust washer 2 Remove snap ring in front of 3rd 4th synchronizer assembly 3 Remove reverse driven gear 4 Press behind second speed gear to remove 3rd 4th synchronizer assembly 3rd speed gear and 2nd speed gear along with 3rd speed gear bushing and thrust washer Fig 7B 15L 5 Remove 2nd speed synchronizer ring 6 Supporting 2nd speed synchronizer hub at front face press mainshaft through removing Ist speed gear bushing OIL SLINGER and 2nd speed synchronizer hub 7 Split 2nd speed gear bushing with chisel and remove bushing from shaft Exercise care not to damage mainshaft Inspection 1 Wash all parts in cleaning solvent 2 Inspect mainshaft for scoring or excessive wear at thrust surfaces or splines 3 Inspect clutch hub and clutch sleeve for excessive wear and make sure sleeve slides freely on clutch hub Also check fit of clutch hub on mainshaft splines Third and fourth speed slutch 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 thrust surfaces for excessive scoring and inspect third speed gear mainshaft bushing for excessive wear Third speed gear must be a running fit on mainshaft bushing and mainshaft bushing should be press fit on shaft 5 Check second speed thrust washer for excessive scoring 6 Inspect 2nd speed gear for excessive wear at thrust surface Check synchronizer springs for lo
300. earing assembly on blocks as shown in Figure 1D 84 Drive the bearing out of the rotor hub with Rotor Bearing Remover J 25029 It is not necessary to remove the staking at the rear of the rotor hub to remove the bearing see Figure 1D 85 Replace 1 Place the Rotor and Hub assembly face down on a clean flat and firm surface PULLEY RIM PULLEY RIM SCREW AND LOCKWASHER 6 LOCATIONS Figure 1D 82 Installing R 4 Rotor and Bearing Puller Guide 2 Align the new bearing squarely with the hub bore and using Pulley and Bearing Installer J 9481 with Universal Handle J 8092 drive the bearing fully into the hub Figure 1D 86 The Installer will apply force to the outer race of the bearing 3 Using a center punch with a 45 angle point stake 0 45 055 deep the bearing in three places 120 apart as shown in Figure 10 85 but do not stake too deeply to avoid distorting the outer race of the bearing ROTOR AND 4 REPLACE BEARING ASSEMBLY ON CAR J 25031 2 ROTOR AND BEARING PULLER J 25031 1 GUIDE Figure 1D 83 Removing R 4 Clutch Rotor Assembly J8092 DRIVER HANDLE J25029 ROTOR BEARING REMOVER Figure 1D 84 R 4 Clutch Rotor Bearing Removal NOTICE Rotor and Bearing assembly removal and installation may be completed on the car without Discharging the A C system A Position the Rotor and Bearing assembly on the front head B With Rotor and Bearing Installer J
301. ecessary to add lubricant use only lubricant No 1052271 or equivalent SERVICE PROCEDURES Rear axle service procedures are the same for the limited slip as for the conventional differential except for servicing the case assembly If the case clutch cone side gears or pinion gears are damaged it is necessary to replace case assembly CAUTION Never raise one wheel and run the engine with the transmission in gear The driving force to the wheel on the floor will cause the vehicle to move Do not use on the vehicle type wheel balancers on the rear wheels unless both wheels are off the floor Differential Case Disassemble 1 Before disassembling differential case inspect differential side bearings for visible damage of rollers and outer races 2 Place one outer race onto its matched inner race and roller assembly and turn slowly applying hand load 3 If bearing outer race turns smoothly and no visible damage is found bearing can be reused 4 Repeat above operation with other race and matched bearing and check for smoothness Both side bearings and their outer races are matched parts If either bearing is to be replaced its matching outer race must also be replaced 5 Inspect fit of inner races on case hubs by prying against shoulders at puller recesses Bearing inner races must be tight on case hubs If either bearing is loose on case entire case must be replaced 6 If bearing inspection indicates that bearing
302. ect bore plugs for damage Reassembly Install all flared coiled pins zinc coated with the flared end out and from the machined face of the control valve assembly Install the two 2 tapered coiled pins black finish that retain the throttle valve and throttle valve bushing with the tapered end first Coiled pins do not fit flush on rough casting face Make sure that all coiled pins are flush at the machined face 1 Position control valve body as shown in Fig 7A 152A 2 Install into lower left bore 1 2 accumulator spring DVERHAUL MANUAL 1 2 accumulator valve smaller stem end out Install bore plug hole out and coiled pin 3 In next bore up install direct clutch exhaust valve longer stem end out direct clutch exhaust spring and coiled pin 4 In next bore up install low overrun clutch valve longer stem end out low overrun clutch spring and coiled pin 5 In next bore up install intermediate boost valve longer stem end out intermediate boost spring and coiled pin 6 In lower right bore install throttle valve smaller outside diameter land first making sure valve is seated at the bottom of the bore Install inner coiled pin between the lands of this valve Fig 7 155 Install the detent pin on models BR and CX only into the shift T V spring and install these 2 parts into the bore Install the throttle valve plunger stem end first into the throttle valve plunger bushing and install these 2 pa
303. ed reed valves 12 Examine reeds for damage and replace if necessary 13 Using Oil Pick Up Tube Remove J 5139 Figure 1D 33 remove Oil Pick Up Tube Remove O ring from oil inlet AIR CONDITIONING COMPRESSOR OVERHAUL 1D 13 SEALING SURFACES SHELL TO HEAD OT RING OIL PUMP ROTORS REAR DISCHARGE VALVE PLATE ASSEMBLY Figure 1D 31 Removing 6 Rear Discharge Valve Plate 14 Loosen compressor from Holding Fixture J 9396 place Internal Cylinder and Shaft Assembly Support Block J 21352 over oil pump end of shaft and while holding Support Block in position with one hand lift compressor from Holding Fixture with other hand Invert compressor shaft will now be facing upward and position on bench with Internal Assembly Support Block resting on bench 15 Lift Front Head and Compressor Shell Assembly up leaving Internal Cylinder and Shaft Assembly resting on Internal Assembly Support Block OIL PICK UP TUBE REMOVER J 5139 Figure 1D 33 Removing 6 Oil Pick Up Tube NOTICE To prevent damage to shaft DO NOT TAP ON END OF COMPRESSOR SHAFT to remove Internal Cylinder and Shaft Assembly If Internal Assembly will not slide out of compressor shell tap on Front Head with a plastic hammer 16 Rest compressor shell on its side and push Front Head assembly through Compressor Sheel being careful not to damage sealing areas on inner side of front head Discard O ring It may be necessary to tap on outside of front hea
304. edometer Drive Gear 1 Depress clip and slide speedometer drive gear off output shaft Fig 7A 53C 2 To install place clip square end toward flange of shaft into hole in output shaft Fig 7A 54C Align slot in speedometer drive gear with clip and install gear The nylon speedometer drive gear is installed at the factory only ALL service replacement speedometer drive gears are STEEL When replacing the nylon speedometer drive gear with a steel gear discard the retaining clip and refer to Step 2 of steel speedometer drive gear installation Models CA CF and CG do not have a speedometer drive gear Steel Speedometer Drive Gear 1 Install speedometer drive gear remover Tool J 21427 01 and J 9539 bolts with J 8105 or suitable puller on 400 7A 16 AUTOMATIC TRANSMISSIONS Fig 7A 55C Removing Steel Speedometer Drive Gear output shaft and remove speedometer drive gear fig 7A 55C 2 Install new steel speedometer drive gear and drive to location 5 21 32 below end of output shaft for all models Fig 7A 56C GOVERNOR ASSEMBLY All components of governor assembly with exception of driven gear are a select fit and each assembly is calibrated The governor including the driven gear is INSTALLER SPEEDOMETER DRIVE GEAR Fig 7A 56C Installing Steel Speedometer Drive Gear GEAR RETAINING PIN S 2 48 AMA H SLEEVE AND CARRIER ASSEMBLY SPRINGS 2 SECONDAR
305. en Assembly of Adapter 1 Position sleeve to adapter bore and tap into place using a suitable piece of pipe NOTICE Assemble drive sleeve with oil groove facing transmission side Lubricate sleeve spline with transmission oil before assembly 2 Coat O D of seal with sealing compound and install seal using Tool J 23504 and Handle J 8092 in a similar manner as shown in Fig 7D 2T WITH E a WITH MANUAL 4 SPEED ADAPTERS USED WITH AUTOMATIC TRANSMISSIONS Adapters used with automatic transmissions do not require service since there are no internal components such as seals sleeves or bearings Fig 7D 2T Installing Adapter Seal WITH Q WITH MANUAL 3 SPEED Fig 7D 1T Adapter Assemblies Used With Manual Transmissions OVERHAUL MANUAL LE 7D 20 TRANSFER CASES SPECIFICATIONS Nut Shift Lever to Shifter 34 48 Nut Knob Asm to Shift Lever 14 20 26 40 Bolt Shifter Asm to Transfer Case 46 54 120 140 Nut Shift Arms to Case 14 20 14 20 Screw Shift Lever Boot Retainer 2 2 3 2 2 2 3 2 Bolt Adapter to Transmission 48 60 26 34 Bolt Adapter to Transfer Case 46 54 27 41 Filler Plug 41 48 41 48 Bolts P T O Cover 20 24 20 24 Nut Skid Plate to Crossmember 55 70 55 70 Bolt Support Strut Rod Transmission End 40 54 Transfer Case End 150 200 Model 205 Part Time 203 Full Time K10 30 Manual Trans K10 30 Automatic Trans 1 00 to 1 1 0
306. en plates dislocation of the shaft should be suspected If the carbon seal is not seating against the seal seat it will not be possible to completely Evacuate the System as outlined under DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR C CO T A C SYSTEMS in the AIR CONDITIONING section 12 Add Oil Evacuate and Charge System see DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR SYSTEMS in the AIR CONDITIONING section A 6 COMPRESSOR PRESSURE RELIEF VALVE OR PRESSURE SWITCH When necessary to replace the Pressure Relief Valve or Pressure Switch if so located located in the compressor rear head casting Figure 1D 26 and Figures 1D 27 and 28 the valve switch assembly should be removed after PURGING THE SYSTEM OF REFRIGERANT A new valve switch and coated with 525 viscosity refrigerant oil should be installed see DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR C C O T A C SYSTEMS the AIR CONDITIONING section A 6 COMPRESSOR INTERNAL MECHANISM CYLINDER AND SHAFT ASSEMBLY Service operations to the 6 compressor Rear Head or Internal Mechanism Cylinder and Shaft of the compressor should be performed with the system PURGED OF REFERIGERANT according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR C C O T A C SYSTEMS in the AIR CONDITIONING section The compressor must also be removed from the vehicle to insure tha
307. ending lock washers Figure 1D 88 R 4 COMPRESSOR INERTIA RING INSTALLATION R 4 compressors will be built with one of three conditions 1 No Inertia Ring installed no installation is required unless directed by a diagnostic procedure If a ring is to be added use Procedure I 2 A bolted on Inertia Ring is installed replace using Procedure I All new screws washers and Loctite 601 or equivalent must be used 3 welded on Inertia Ring is installed replace using Procedure II Procedure 1 Loosen the compressor drive belt and rotate the compressor pulley as required to locate one screw and lock washer mounted through a mounting hole of the Pulley Rim Figure 1D 91 rather than a mounting notch screw location DO NOT remove the drive belt unless necessary NOTICE For identification purposes washers locked over the edge of the Pulley Rim at the mounting hole locations will not usually dimple down in the center like the indentation of the lockover at a mounting notch screw location 2 Remove the three mounting screws and lockwashers at the pulley rim mounting hole locations The pulley rim mounting holes are located 120 apart radially around the AIR CONDITIONING COMPRESSOR OVERHAUL 1D 33 rim or every other mounting screw location Do not remove the screws in the mounting notches 3 Temporarily make a trial fit of the Inertia Ring to the Pulley Rim If any portion of the sheer edge of
308. enerously lubricate new O ring and angled groove at lower edge of front head casting with 525 viscosity refrigerant oil and install new O ring into groove Figure 1D 67 PISTONS IN STAIR STEP POSITION REAR THRUST RACES AND BEARING FRONT CYLINDER HALF COMPRESSING FIXTURE Figure 1D 61 Installing 6 Suction Cross over Cover 9 Coat inside machined surfaces of compressor shell with 525 viscosity refrigerant oil and position shell on Internal Cylinder and Shaft Assembly resting on O ring seal 10 Using flat side of a small screwdriver gently position O ring in around circumference of Internal Cylinder and Shaft Assembly until Compressor Shell slides down over Internal Cylinder and Shaft Assembly As shell slides down line up oil sump with oil intake tube hole Figure 1D 68 AIR CONDITIONING COMPRESSOR OVERHAUL 1D 23 BUSHING Figure 1D 62 Installing O Ring On A 6 Discharge Cross Over Tube DISCHARGE CROSSOVER TUBE OIL RETURN SLOT e DOWEL PINS d DOWEL PINS NE ON 5062 FRONT SUCTION SUPPORT BLOCK REED PLATE J 21352 Figure 1D 63 Installing A 6 Front Suction Reed 11 Holding Support Block J 21352 with one hand invert Internal Cylinder and Shaft Assembly and place back into Holding Fixture J 9396 with front end of shaft now facing downward Remove Support Block 12 Install new dowel pins in rear cylinder half if previously removed 13 Install new O ring i
309. ensions differential side gears and case cannot be serviced separately any side gear or case damage is found the entire differential must be replaced Fig 4B 7H 3 4 Ton Unit Internal clearances are such that shims reaction blocks and thrust ring should not be replaced unnecessarily even if slight wear indications are present If shims reaction blocks or thrust ring must be replaced due to damage correct measurement and replacement procedures must be followed Failure to do so may disturb critical clearances and could result in differential complaints Fig 4B 8H 3 4 Ton Assembly REAR AXLE DIFFERENTIAL 4B 53 Disassembly 1 Remove ring gear and side bearings following procedures established for the standard differential 2 Remove 3 screws on front face of ring gear flange 3 Set unit on right side case half and gently pry apart at yoke hole locations Fig 4B 7H 4 Remove left side case half To prevent side gear from falling out hold thumb against inside of gear hub while separating case halves 5 Inspect components for damage If the governor assembly and latching bracket are the only items to be replaced remove and proceed to Step 7 of reassembly procedure Pry under pinion yoke and remove and proceed with detailed inspection if further damage is observed inspection 1 Clean all parts with solvent Inspect all bearings for chipping or evidence of excessive wear Replace parts as needed
310. enter of reaction body by pushing down on the end of the reaction piston with a small blunt punch 9 Remove air valve spring 10 Remove the rubber reaction bumper on the end of the air valve 11 Using Truarc No 2 pliers J 4880 or equivalent remove the retaining ring from the air valve 12 Remove the air filter from the tubular section of the power piston 13 Remove the air valve push rod assembly from the push rod end of the power piston The following removal methods are recommended a Place the power piston in an arbor press and press the air valve push rod assembly out of the bottom of the power piston tube with a rod not exceeding 1 2 in diameter b An alternate method would be the use of a heavy round shanked screwdriver Insert screwdriver on both sides of the push rod and pull the air valve push rod assembly BRAKES 5 3 straight out A considerable force will be required 14 Removal of the air valve push rod assembly will disassembly the control valve retainer 15 Remove the O ring from the air valve 16 Air valve push rod assemblies with a formed eye on the end of the push rod will be serviced using a complete assembly since the floating control valve cannot be removed over the eye end of the push rod Cleaning After disassembly immerse all metal parts denatured alcohol Plastic parts as well as the rubber power diaphragms should be cleaned in denatured alcohol or clean brake fluid Care
311. ential failure Slight polishing or scuffing on discs and shims is normal 10 Remove disc pack from side gear and carefully lower disc pack assembly into left side case half Make sure car guide clips are in their proper position 11 Install side gear in left side case half Rotate gear to engage spline with splines on discs 12 Being careful not to dislodge side gear assembly hold thumb on inside of side gear spline lower the left hand case assembly onto the right hand case Index left hand case so holes in housing will line up for the governor assembly and latching bracket shafts 13 Turn entire unit over and install three 3 screws 14 Lock an axle shaft in a vise in a vertical position Install differential assembly on axle shaft engaging the spline of the axle with a side gear Rotate unit slowly A short shaft held in pinion yoke hole will aid in rotating The unit should turn smoothly without binding or locking up REAR AXLE DIFFERENTIAL 4 55 NOTICE Differential will lock if turned rapidly 50 rpm or greater 15 Install ring gear and side bearings using the procedure outlined for conventional differentials 16 Place differential unit in carrier and adjust ring gear to pinion backlash and gear tooth pattern as outlined in the conventional differential section NOTICE Use standards differential lubricant DO NOT use lubricants specifically designed for limited slip differentials OVERHAUL MANUAL 4B
312. er Dana Axles Dana rear axles used in Light Duty Trucks will be stamped with the Dana part number and production code indicating the month day year shift and production line on which the axles were assembled DIFFERENTIAL CASE Removal and Disassembly NOTICE Before proceeding with following steps it is advisable to check the existing ring gear to pinion backlash described under Checks Adjustments This will indicate gear or bearing wear or an error in backlash or pinion depth setting which will help in determining cause of axle noise Backlash should be recorded so that if same gears are reused they may be reinstalled at original lash to avoid changing gear tooth contact 1 Remove screw that retains differential pinion shaft and remove pinion shaft 2 Remove rear axle shafts as outlined in the Service Manual 3 Roll out the differential pinions and thrust washers then remove side gears and thrust washers Mark pinions and side gears so that they can be reassembled in original position 4 Mark the bearing caps and housing for reassembly in same position Loosen bearing cap bolts Tap surface of bearing caps to loosen NOTICE Do not attempt to pry caps off as this may damage machined face of caps 5 Using a pry bar as shown in figure 2B pry differential case out of carrier Exercise caution in prying on carrier so that gasket sealing surface is not damaged If the bearings are preloaded the c
313. er 1 2 Shift Fork O Ring 1 2 Shift Shaft Spring Ball O Ring Reverse Shifter Shaft and Fork peace NOISSINSNVYL Fig 7B 19J Loading Countergear Bearing MANUAL TRANSMISSION 7B 25 MAIN DRIVE GEAR Fig 7B 20J Loading Mainshaft Bearings 4 SPEED 83MM TRANSMISSION INDEX Disassembly of Transmission sese 7B 25 Extension Oil Seal and or Bushing Replacement 7B 29 Disassembly of Mainshaft sss 7B 28 Drive Gear Bearing Retainer 7B 30 Cleaning and Inspection 7B 28 Reverse Shifter Shaft and or Seal Replacement 7B 30 Transmission Case 7B 28 Reverse Idler Shaft Replacement ccc 7B 31 Bearing Rollers and 7B 28 Transmission Side Cover EAR 7 52 GOALS E 7 29 Assembly of Countergear 22222222024 7 32 Front and Rear Bearngs 7 29 Checking Countergear End 7 32 LE 7B 29 Assembly of Manshaft A 7B 32 Clutch Keys and Springs Replacement 7B 29 Assembly of Transmiseion 7 33 DISASSEMBLY OF TRANSMISSION Sectional and exploded view of the transmission are provided in Figures 7 and 7B 2K to assist in the disassembly of the transmission 1 Thoroughly clean the exterior of the transmission assembly 2 Shift transmission into second gear remove drain plug from lower right of
314. ernal gear parking pawl lugs to pass by parking pawl tooth 10 Using J 25013 5 adjusting screw Fig 7A 73A and looking through parking pawl case slot adjust the height of the rear internal gear parking pawl lugs to align flush with the parking pawl tooth AUTOMATIC TRANSMISSION 200 7 17 ROLLER CLUTCH RACE ROLLER CLUTCH REAR CARRIER Fig 7A 65A Roller Clutch and Rear Carrier Exploded REAR CARRIER Te ENERGIZING FEELER EMEN ROLLER SPRING Fig 7A 68A Installing Roller Into Cage ROLLER CLUTCH REAR CARRIER Fig 7A 67A Installing Thrust Washer Into Rear Carrier Fig 7A 69A Installing Roller Clutch into Rear Carrier OVERHAUL MANUAL 200 7 18 TRANSMISSION NOTICE Make sure speedometer drive gear is visible through speedometer gear bore If drive gear is not visible it may be located on wrong journal of shaft LOW AND REVERSE CLUTCH Inspection Inspect low and reverse clutch composition faced and steel clutch plates for signs of wear or burning Low and Reverse Clutch Housing Assembly Fig 7A 75A ROLLER CLUTCH REAR CARRIER Disassembly RACE 1 Compress low and reverse clutch spring retainer remove snap ring and retainer and inspect for damage Fig 7A 70A Installing Roller Clutch R 8 5 9 Ee distortion Fig 7A 76A THRUST WASHER J 25013 5 J 25013 1 REAR CARRIER ASSEMBLY Fig 7A 7 1A Installing Thrust Washer Fig 7A 73A Installi
315. es 18 Position 1st 2nd speed gear shifter shaft and detent plate into 2nd gear position and using a sealer install cover gasket and side cover assembly to transmission 19 Check operation of transmission MANUAL TRANSMISSION 78 35 4 SPEED 117MM TRANSMISSION INDEX Disassembly of Transmission eee 7B 35 Drive Gear Bearing Retainer Oil Seal 7 39 Subassembly Operations 0 4 7 35 eiie nets 7 40 Transmission Cover 7 35 Disassembly 5 enter reed seed ecu ete 7B 40 Disassembly ade dete e a este ti eve rye eat 7 35 Inspection sis tete 7 40 Assembly ge DES 7 35 Assembly EE 7 41 Drive Gear 2 deiade enr qe 7B 38 Countershaft covered re eos 7B 42 RE UE 7B 38 Disassembly nieren orioa a i a i ai 7B 42 Inspection 5 eee pe em ARAA 7 38 Assembly 7B 42 Assembly ss as terree eee tides 7B 39 Assembly of Transmission eene 7B 42 DISASSEMBLY OF TRANSMISSION Refer to Figures 7B 1L and 7B 2L 1 Mount transmission in suitable holding fixture and remove cap screws attaching transmission cover assembly to transmission case If required insert two 5 16 x 18 screws in cover flange threaded holes and turn evenly to raise cover dowel pins from case Move reverse shifter fork so that reverse idler
316. etent Plate Third and Fourth Speed Gear Shifter Shaft and Detent Plate Poppet Spring Interlock Pin Interlock Sleeve Detent Balls Transmission Side Cover Third and Fourth Speed Shifter Lever First and Second Speed Shifter Lever T C S Switch and Gasket Lever Attaching Nuts OVERHAUL MANUAL 7B 28 MANUAL TRANSMISSION REVERSE SHIFTER SHAFT PIN Fig 7B 3K Removing Reverse Shifter Shaft Lock Pin 13 Shift first second and third fourth clutch sliding sleeves forward to permit adequate clearance for mainshaft removal Remove mainshaft and rear bearing retainer assembly from the transmission case 14 Remove front reverse idler gear and thrust washer from case Gear teeth face toward front of transmission 15 Using a dummy shaft J 24658 drive countergear shaft out of countergear Fig 7B 7K and remove countergear and tanged thrust washers from case Check bottom of case for pilot bearings or other loose components DISASSEMBLY OF MAINSHAFT Fig 7B 8K 1 Using snap ring pliers remove 3 4 clutch assembly retaining ring at front of mainshaft Fig 7B 9K Slide washer synchronizer and clutch assembly synchronizer ring 3rd speed gear from mainshaft 2 Spread rear bearing retainer snap ring Fig 7B 10K and slide retainer from mainshaft 3 Remove rear bearing to mainshaft snap ring Fig 7B 11K 4 Support mainshaft under 2nd gear and press mainshaft from rear bearing Ist gear and sleeve 1 2 clutch SPEEDOME
317. event loosing the roller bearings 123 which may fall out of clutch assembly if it is pulled off the input shaft 17 Pull up on shift rail and disconnect rail from link 18 Remove lift input shaft assembly from range box At this point the transfer case is completely disassembled into its subassemblies Each of these subassemblies should then be disassembled for cleaning and inspection CLEANING AND INSPECTION BEARINGS Place all bearings and rollers in cleaning solution and allow to remain long enough to loosen all accumulated lubricant Bearings should be sloshed up and down and turned slowly below surface of solution to remove as much lubricant as possible Remove bearings and blow dry with compressed air being careful to direct air across bearing so that bearings do not spin SHAFTS AND GEARS Clean all shafts and gears in cleaning solution to remove all accumulations Dry with compressed air CASE COVER AND HOUSINGS Transfer case cover and housings must be thoroughly cleaned in solution to remove all accumulation of lubricant and dirt Remove all trace of gaskets from surfaces where used INSPECTION Carefully inspect all bearings and rollers fro evidence of chipping cracks or worn spots that would render bearing unfit for further service Bearings are non adjustable and if worn or damaged must be replaced with new parts Inspect shaft splines drive chain and gears If any indication of failure such as chipped teeth or
318. fixture remove torque converter assembly 3 Remove vacuum modulator assembly attaching bolt and retainer 4 Remove vacuum modulator assembly O ring seal and modulator valve from case fig 7A 3B Discard O ring Inspection of Converter 1 Check converter for leaks as follows fig 7A 4B a Install Tool J 21369 and tighten b Apply 80 psi air pressure to tool c Submerge in water and check for leaks 2 Check converter hub surfaces for signs of scoring or wear J 21371 8 Fig 7A BB Installing J 2157 1 8 OVERHAUL MANUAL 350 7A 4 AUTOMATIC TRANSMISSION J 21371 3 m Fig 7A 6B Checking Converter End Clearance Converter End Clearance Check Figs 7 5 7 6 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 ft lbs fig 7 5 3 Install Tool J 21371 3 and tighten hex nut to 3 ft Ibs fig 7A 6B 4 Install Dial Indicator J 8001 and set it at zero while its plunger rests on the cap nut of Tool J 21371 8 5 Loosen hex nut while holding cap nut stationary With the hex nut loosened and holding Tool J 21371 3 firmly against the converter hub the reading obtained on the dial indicator will be the converter end clearance End clearance should be less than 050 If the end clearance is 050 or greater the converter must be replaced EXTENSION HOUSING LIP SEAL Fig 7A 7B
319. front cylinder half in like manner so that pistons can be replaced in their original locations 3 Separate cylinder halves using a wood block and mallet Figure 1D 36 Make certain that discharge cross over tube does not contact axial plate when separating cylinder halves a new Service Discharge Cross Over Tube will be installed later see Step 5 of Internal Cylinder and Shaft Assembly procedure Figure 1D 36 Separating 6 Cylinder Halves NOTICE UNDER NO CIRCUMSTANCE SHOULD SHAFT BE STRUCK AT EITHER END in an effort to separate upper and lower cylinder halves because the shaft and the axial plate could be damaged 4 Carefully remove the rear half of the cylinder from the pistons and set the front cylinder half with the piston shaft and axial plate in Compressing Fixture J 9397 5 Pull up on compressor shaft and remove piston previously identified as No 1 with balls and shoe discs from axial plate a Inspect the Teflon piston rings for nicks cuts or metal particles imbedded in exposed ring surface and replace the piston rings as required if either condition exists See A 6 Teflon Piston Ring Replacement procedure 6 Remove and discard the piston shoe discs 7 Remove and examine piston balls and if satisfactory for re use place balls in No 1 compartment of Parts Tray J 9402 Figure 1D 38 8 Place piston in No 1 compartment of Parts Tray J 9402 with notch in casting web at front end of piston F
320. fter shaft lock pin into place until the extension has been installed on the transmission case Fig 7B 12K Pressing Rear Bearing From Mainshaft MANUAL TRANSMISSION 7B 31 SLEEVE Fig 7B 13K Synchronizer Assembly Reverse Idler Shaft Replacement 1 Place a small punch into hole in extension s reverse idler shaft boss and drive the welch plug and pin into the shaft Fig 7B 17K until the shaft can be pulled from rear extension 2 Insert new idler shaft into extension until hole in shaft lines up with hole in boss Fig 7B 15K Installing Rear Extension Seal 3 Insert roller pin in transmission boss opening and drive the pin into the extension until the shaft is securely locked in place Install new welch plug with sealer in boss opening J 21465 17 W HANDLE J 8092 Fig 7B 14K Removing Rear Extension Bushing Fig 7B 16K Installing Drive Gear Bearing Retainer Seal OVERHAUL MANUAL 7B 32 MANUAL TRANSMISSION Fig 7B 17K Removing Reverse Idler Shaft Roll Pin Transmission Side Cover Although service of the side cover is covered here the transmission does not have to be removed to perform these operations To remove the side cover on the vehicle simply drain the transmission disconnect the Ist 2nd cross shaft and 3rd 4th linkage and remove the attaching bolts 1 Remove the outer shifter lever nuts and lockwasher and pull levers from shafts 2 Carefully push the shifter shafts in
321. fully towards the rear of the transmission The converter used in the CB CD CF CL CM and CT models has six 6 mounting lugs SPEEDOMETER DRIVEN GEAR ASSEMBLY Fig 7A 188C Installing Speedometer Driven Gear and Sleeve E 400 7A 58 AUTOMATIC TRANSMISSIONS SPECIFICATIONS TORQUE SPECIFICATIONS Pump Cover Bolts Parking Pawl Bracket Bolts Center Support Bolt Pump to Case Attaching Bolts Extension Housing to Case Attaching Bolts Rear Servo Cover Bolts Detent Solenoid Bolts Control Valve Body Bolts Bottom Pan Attaching Screws Modulator Retainer Bolt Governor Cover Bolts Linkage Swivel Clamp Nut Converter Dust Shield Screws Transmission to Engine Mounting Bolts Converter to Flywheel Bolts Rear Mount to Transmission Bolts Rear Mount to Crossmember Bolt Crossmember Mounting Bolts Line Pressure Take Off Plug Strainer Retainer Bolt Oil Cooler Pipe Connectors to Transmission Oil Cooler Pipe to Connector Gearshift Bracket to Frame Gearshift Shaft to Swivel Manual Shaft to Bracket Downshift Switch to Bracket AUTOMATIC TRANSMISSIONS 400 7A 59 4 4 E 7 gt J 6116 01 Rear Unit Holding Fixture 9 217952 Part of Above Holding Tool J 8092 Driver Handle J 5384 Converter Holding Strap J 21359 Pump Oil Seal Installer J 21465 01 Bushing Tool Set J 21364 Holding Fixture Adapter Used 4 21465 5 Part of Bushing Tool Set with J 6116 01 Fixture J 21465 3 Part of Bushing Tool Set
322. fying notch in casting web Figure 1D 37 NOTICE Exercise care in handling the Piston and Ring Assembly particularly during assembly into and removal from the cylinder bores to prevent damage to the Teflon piston rings SHOE DISCS SHOULD NOT BE INSTALLED ON REAR of piston during following Gaging operation 8 Rotate shaft and axial plate until high point of axial plate is over the No 1 Piston cylinder bore 9 Lift the axial shaft assembly up a little out of front cylinder half and hold front thrust race and bearing assembly zero race bearing zero race against axial plate hub 10 Position No 1 Piston over No 1 cylinder bore notched end of piston being on bottom and piston straddling axial plate and lower the shaft to allow No 1 Piston to drop into its bore Figure 1D 43 11 Repeat Steps 6 through 10 for Pistons No 2 and No 3 12 NOW INSTALL REAR CYLINDER HALF ONTO PISTONS aligning cylinder with discharge cross over tube hole in front cylinder half Tap into place using a plastic mallet or piece of clean wood and hammer Figure 1D 44 Figure 1D 42 Installing 6 Front Shoe Disc REAR NEEDLE THRUST BEARING AND ZERO THRUST RACES PISTON DRIVE BALL ONLY AT REAR PISTON DRIVE BALL AND ZERO SHOE DISC AT FRONT 4951 Figure 10 43 Installing 6 Piston During Gaging Operation 13 Position discharge cross over tube opening between a pair of Compressing Fixture J 9397 bolts to permit ac
323. g 2 If rear pinion bearing is to be replaced drive outer race from carrier using a drift in slots provided for this purpose 3 Remove rear pinion bearing from pinion shaft using press plate J 8612 for 8 1 2 ring gear and J 22912 for 8 7 8 ring gear as shown in Figure 15B Tighten nuts on tool until plates are under the bearing inner race Then set the tool on a press Make sure the plates straddle the opening on the press Do not position bolts across the opening To do so may bend the bolts when pressure is applied Press bearing from pinion Record the thickness of shim removed from between bearing and pinion head 4 Inspect carrier pinion bearing bores and shoulders for nicks Remove as necessary Clean the bores and the installation tools 5 Lubricate both bearing cups with liberal amounts of hypoid lubricant 6 Install the rear cup with the large end against the bore shoulder using Installer J 8608 for 8 1 2 ring gear and J 0270 14 for the 8 7 8 ring gear as shown in figure 16B 7 Install the front cup with the large end against the bore shoulder using Installer J 8611 01 for the 8 1 2 ring gear or J 7137 for the 8 7 8 ring gear as shown in figure 17B 8 Check both bores to make sure cups are fully seated Setting Pinion Depth and Installing Pinion Bearings 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 pi
324. g 7D 14R Shift Rail and Fork Assemblies 1 Press the two rail seals into the case Seals should be 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 slotted end first with poppet notches up 4 Install shift fork long end inward into rail push rail through to neutral position 5 Install input shaft bearing and shaft into case COVER FLAT Fig 7D 14R Installing Idler Shaft Rear Cover OVERHAUL MANUAL Fig 7D 15R Installing Shift Rail Lock Pins 6 Start range rail into case from front with poppet notches up 7 Install sliding clutch onto fork place over input shaft in case Position to receive range rail and push rail through to neutral position 8 Install new lock pins through holes at top of case and drive them into the forks Fig 7D 15R Tip case on P T O opening when installing range rail lock pin Front Output Shaft and Gear Assembly 1 Install two rows of needle bearings 32 each separated by a spacer in the front low output gear and reatin with a sufficient amount of grease 2 Place front output shaft in soft jawed vise spline end down Install front low gear over shaft with clutch gear facing down and install throust washer pin thrust washer and new snap ring using Tool J 23432 J 22836 SEAL Fig 7D 16R Installing Front Output Bearing Retainer Seal NOTICE Positio
325. g Compressor Adapter Ring Clutch Spring Compressor Snap Ring Pliers Snap Ring Pliers Snap Ring Pliers Torque Wrench 0 140 Ft Lbs Pressure Regulator Valve Compressor Accumulator Piston Adapter Used with J 22269 01 MANUAL TRANSMISSION 7B 1 SECTION 7B CONTENTS 3 Speed 76mm Transmission sss 7B 1 4 Speed 117mm Transmission sees 7B 35 3 Speed 77mm Transmission esee 7B 9 Specifications eene rete eret pee titer 7B 48 4 Speed 76mm Transmission 7B 17 Special Tools 7B 49 4 Speed 83mm Transmission sess 7 25 3 SPEED 76MM TRANSMISSION INDEX Disassembly of Transmission sese 7B 1 Repatrs ere re Potius tie AE 7B 4 Disassembly of Mainshaft 2 2 1 7B 1 Clutch Keys and Spring 22 0 222 7 4 Cleaning and Inspection sese 7 1 Extension Oil Seal or Bushing 0000ceecreeree 7B 4 Transmission Case 22 2 7 1 Clutch Bearing Retainer 7B 4 Front and Rear Bearings eese 7 3 Assembly of 22 2 022 7 5 Bearing Rollers ecrire 7 3 Assembly of Transmission esee 7B 6 e EE 7B 3 Specifications E EE EES 7B 48 Reverse Idler Gear Bushing sess 7 3 Special 7 49 DISASSEMBLY OF TRANSMIS
326. g control valve to seat in the tube by placing J 21601 01 Floating Control Valve Retainer Installer on top of retainer and pushing down by hand fig 5 11C 11 After floating control valve is seated position push rod limiter washer over push rod and down onto floating control valve Air filter element can now be stretched over end of push rod and pressed into power piston tube 12 Assemble power piston diaphragm to diaphragm support plate from side of support plate opposite locking tangs The raised flange of diaphragm is pressed through hole in center of support plate Be sure that edge of center hole fits into groove in flange of diaphragm 13 Pull diaphragm away from O D of support plate so that support plate can be gripped with hands 14 With power piston still positioned on holding tool in vise coat bead of diaphragm that contacts power piston with Power Brake Lube or equivalent 15 Holding support plate by metal with locking tangs down place support plate and diaphragm assembly over tube of power piston The flange of diaphragm will fit into groove on power piston fig 5 12C 16 Press down and rotate support plate clockwise until lugs on power piston come against stops on support plate fig 5 12C OVERHAUL MANUAL 5 16 BRAKES INSPECTION CHART Inspect For Corrective Action Power Piston and Support Cracks distortion 1 Clean up or replace Plate and Reaction chipping damaged lever Retainer seats pitted
327. g downward Figure 1 29 SHELL HOLDING FIXTURE J 9396 Figure 1D 29 A 6 Compressor Installed in Holding Fixture Additional oil may leak from the compressor at this time All oil must be drained into a container so that TOTAL amount can be measured SEE STEP 2 ABOVE A liquid measuring cup may be used for this purpose Drained oil should then be discarded 4 Remove four locknuts from threaded studs on compressor shell and remove rear head Tap uniformly around rear head if head is binding Figure 1D 29 5 Wipe excess oil from all sealing surfaces on rear head casting webs and examine sealing surfaces Figure 1D 30 If any damage is observed the Rear Head should be replaced 6 Remove Suction Screen and examine for any damage or contamination Clean or replace if necessary 7 Paint an identifying mark on exposed face of inner and outer Oil Pump Gears and then remove gears Identifying marks are to assure that gears if re used will be installed on identical position 8 Remove and discard rear head to shell O ring 9 Carefully remove Rear Discharge Valve Plate assembly Use two small screwdrivers under reed retainers to pry up on assembly Figure 10 31 Do not position screwdrivers between reeds and reed seats 10 Examine Valve Reeds and Seats Replace entire assembly if any reeds or seats are damaged 11 Using two small screwdrivers carefully remove Rear Suction Reed Figure 1D 32 Do not pry up on horseshoe shap
328. g service to the Differential assembly or to the Drive Pinion the Pinion Depth and Ring Gear to Pinion Backlash must be checked using a Gear Tooth Contact Pattern Check as outlined below Fig 15 Measuring Rotating Torque OVERHAUL MANUAL 4B 18 REAR AXLE DIFFERENTIAL CODE NUMBER ON ORIGINAL PINION EH Les 001 ADD 002 ADD 003 ADD 004 ADD ADD 004 SUBT ADD ADD ADD 001 001 002 003 SUBT SUBT ADD ADD 002 001 001 002 SUBT SUBT SUBT ADD 003 002 001 001 SUBT SUBT SUBT SUBT 004 003 002 001 Fig 16E Pinion Depth Codes PINION Gear Tooth Contact Pattern Check Prior to final assembly of the differential a Gear Tooth Contact Pattern Check is necessary to verify the correct realtionship between ring gear and drive pinion Gear sets which are not positioned properly may be noisy or have short life or both With a pattern check the most desireable contact between ring gear and drive pinion for low noise level and long life can be assured CONCAVE SIDE COAST CONVEX SIDE DRIVE 2 LY Fig 17E Gear Tooth Nomenclature OVERHAUL MANUAL 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 in end The end of the tooth farthest away from center is the heel e
329. g sleeve from Seal Seat Remover Installer J 23128 install retainer so that outer edge is recessed 1 32 from compressor neck face 7 Install Clutch Plate and Hub assembly as described in A 6 Compressor Clutch Plate and Hub Assembly Replacement procedure A 8 COMPRESSOR PULLEY BEARING Remove 1 Remove Clutch Plate and Hub assembly as described in A 6 Compressor Clutch Plate and Hub Assembly Removal procedure 2 Remove Pulley and Bearing assembly as described A 6 Compressor Pulley and Bearing Assembly Removal procedure 3 Remove pulley bearing retainer ring with a small screwdriver or pointed tool Figure 1D 15 BEARING RETAINER RING Figure 1D 15 Removing A 6 Pulley and Bearing Retainer Ring 4 Place Pulley and Bearing assembly on inverted Support Block J 21352 and using Pulley Bearing Remover J 9398 with Universal Handle J 8092 drive Bearing assembly out of pulley Figure 1D 16 Figure 1D 16 Removing Bearing From A 6 Pulley Assembly Replace 1 Install new bearing in pulley using Pulley and Bearing Installer J 9481 with Universal Handle J 8092 Figure 1D 17 The Installer will apply the force to the outer race of the bearing NOTICE DO NOT CLEAN NEW BEARING ASSEMBLY WITH ANY TYPE OF SOLVENT Bearing is supplied with correct lubricant when assembled and requires no other lubricant at any time 2 Install bearing retainer ring making certain that it is properly seated in ring groove 3
330. gages keys in Second Third synchronizer assembly It may be necessary to tap synchronizer with a plastic hammer to ease assembly 8 Install retaining snap ring on output shaft and measure end play between snap ring and Second Third synchronizer hub with feeler gauge Fig 7B 20B End play should be 0 004 to 0 0014 inch If end play exceeds 0 014 inch replace thrust washer and all snap rings on output shaft assembly ASSEMBLY OF TRANSMISSION 1 Coat transmission case reverse idler gear thrust washer surfaces with vaseline or equivalent and position thrust washer in case Be sure to engage locating tabs on thrust washers in locating slots in case 2 Install reverse idler gear with helical cut gear towards front of case Align gear bore thrust washers case bores and install reverse idler gear shaft from rear of case Be sure to align and seat roll pin in shaft into counterbore in rear of case 3 Measure reverse idler gear end play by inserting feeler gauge between thrust washer and gear End play should be 0 004 to 0 018 inch If end play exceeds 0 018 inch remove idler gear and replace thrust washer 4 Install shaft tool J 25232 in bore of countergear and load a row of needle bearing 25 in each end of gear Use heavy grease or equivalent to hold them in place Install one needle bearing retainer on each end of gear 5 Position countergear thrust washer in case use vaseline or equivalent to hold washers in place Be sure
331. gear is partially engaged before attempting to remove cover Forks must be positioned so rear edge of the slot in the reverse fork is in line with the front edge of the slot in the forward forks as viewed through tower opening 2 Place transmission in two gears at once to lock gears Remove the universal joint flange nut universal joint front flange and brake drum assembly On models equipped with 4 wheel drive transmfer case use Tool J 23070 to remove mainshaft rear lock nut Fig 7B 26L 3 Remove parking brake and brake flange plate assembly on models equipped with propeller shaft parking brake Refer to Section 5 Truck Service Manual 4 Remove rear bearing retainer and gasket 5 Slide speedometer drive gear off mainsahft 6 Remove drive gear bearing retainers and gasket 7 Remove countergear front bearing cap and gasket 8 Pry countergear front bearing out by inserting a two pronged puller J 28509 through the cast slots in case 9 Remove countergear rear bearing retaining rings snap ring from shaft and bearing Using Tool J 22832 and J 8433 1 remove countergear rear bearings Fig 7B 3L This will allow countergear assembly to rest on bottom of case Make sure Tool J 22832 engages full circumference of groove in bearing to prevent tool damage 10 Remove drive gear bearing outer race to case retaining ring 11 Remove drive gear and bearing by tapping gently on bottom side of drive gear shaft and prying direc
332. gs c If both steps of J 21370 5 are below the gage surface the long pin identified by 3 rings should be used GAGING STEPS LOCATED ON THREE SIDES OF TOOL J 21370 9 Cj LONGEST PIN t CN ch LOWER STEP SHORTEST PIN Note PART NO TORQUE Fig 7A 16C Checking Rear Band Apply Pin Models CD and CL d If the gage surface is between the steps the medium pin identified by 2 rings should be used e If both steps are above the gage surface the short pin identified by ring should be used Rear Band Apply Pin Selection Models CD and CL There are six selective pins identified as shown in Figure 7A 17C Selecting proper pin is equivalent to adjusting band a Attach band apply pin selection gage J 21370 9 and J 21370 6 to transmission case lever pivot pin to rear with rear servo cover attaching screws PIN IDENTIFICATION The Identification Rings are 030 and 100 wide Fig 7A 17C Rear Band Apply Pin Indentification OVERHAUL MANUAL AUTOMATIC TRANSMISSIONS Fig 7A 18C Removing Detent Solenoid and Gasket b Attach tool attaching screws finger tight and check freeness of selective pin Torque attaching screws to 15 foot pounds and recheck pin to make certain it does not bind c Apply 25 foot pounds torque to the lever on Tool J 21370 6 Fig 7A 16C Selection of the proper rear band apply pin is determined by the relation of the flat on Tool J
333. gs as follows and retain with petrolatum Fig 7A 144C O D FLANGED RACE THRUST BEARING Fig 7A 144C Installing Rear Internal Gear to Output Shaft Bearing and Races Fig 7A 145C Installing Output Shaft a Place small diameter 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 7A 145C 8 Install output shaft to output carrier snap ring 9 Install O ring on output shaft of models that use an OT ring Models CB CD CF CG and CH do not use an output shaft O ring 10 Turn assembly over and support so that output shaft hangs downward 11 Install reaction carrier to output carrier metal or non metal thrust washer with tabs facing down in pockets of output carrier and retain with petrolatum The production built transmissions use a non metal washer here However the service replacement washer is made of metal 12 Install sun gear I D splines with chamfer down CARRIER Fig 7A 146C Installing Front Internal Gear Ring to Output Carrier 13 Install front internal gear ring over output carrier Fig 7A 146C 14 Install sun gear shaft with long splined end down 15 Install reaction carrier Fig 7A 147C Fig 7A 147C Installing Reaction Carrier AUTOMATIC TRANSMISSIONS 400 7A 47 SUN GEAR SHAFT I D FLANGED
334. h hole in shaft Install retainer pin and move to neutral position 7 Install new shifter shaft hole expansion plugs and expand in place DRIVE GEAR FIG 7B 8L Disassembly 1 Remove mainshaft pilot bearing rollers 17 from drive gear if not already removed and remove roller retainer Do not remove snap ring on inside of drive gear 2 Remove snap ring securing bearing on stem of drive gear 3 To remove bearing position Tool J 22872 to the bearing Fig 7B 9L and using an arbor press and Tool J 0358 press gear and shaft out of bearing Fig 7B 10L Inspection 1 Wash all parts in clearing solvent 2 Inspect roller bearings for pits or galling 3 Inspect bearing diameter in shaft recess for galling 4 Inspect gear teeth for excessive wear 5 Inspect clutch shaft pilot for excessive wear 6 Re oil bearing then rotate drive gear bearing slowly by hand and check for roughness Transmission Cover Interlock Balls 3rd 4th Shifter Shaft Reverse Shifter Shaft Fork Retaining Pin Detent Ball 3rd 4th Shifter Fork C Ring Lock Clip Reverse Shifter Fork Shifter Shaft Hole Plugs 1st 2nd Shifter Fork MANUAL TRANSMISSION 7B 39 Interlock Plunger Spring Reverse Interlock Plunger 1st 2nd Shifter Shaft Interlock Pin Detent Spring Cover Gasket Fig 7B 6L Cover Assembly Exploded View Assembly 1 Press bearing and new oil slinger onto drive gear shaft using Tool J 22872 Fig 7B 11L Slinger sh
335. half being sure to line up marks on the two halves 5 Install differential to ring bolts and lock washers and tighten evenly until ring gear is flush with case flange 6 Remove two guide pins and install remaining two bolts Torque all bolts alternately and evenly to specifications Fig 8G Differential Bearing Installation Reassembly 1 Place new pinion bearing retainer gasket on the retainer and install pinion assembly in carrier NOTICE The pinion assembly should be pressed into the carrier to prevent the possibility of damaging the shims 2 Install pinion bearing retainer bolts and lock washers and torque bolts to specifications 3 Lubricate differential bearing rollers with engine oil and place outer races over them 4 Install differenital assembly in carrier and install adjusting nuts Carefully slide adjusting nuts alongside the bearings so that threads on nuts fit into threads in carrier 5 Install differential bearing caps making sure the marks on the caps line up with the marks on the carrier 6 Install bearing cap bolts and lock washers and tighten until lock washers just flatten out Backlash and Preload Adjustment 1 With differential bearing cap bolts loosened just enough to permit turning the bearing adjustment nuts with Tool J 0972 remove all lash between ring gear and pinion See figure 9G 2 Back off left hand adjusting nut one to two notches to a locking position 3 Tighten right hand adju
336. he boot and boot retainer from the rear housing and push rod Remove the felt silencer from inside Fig 5 1A Unlocking Front and Rear Housings the boot OVERHAUL MANUAL 5 2 BRAKES PRIMARY SUPPORT PLATE PRIMARY DIAPHRAGM POWER HEAD SILENCER AIR VALVE PUSHROD ASSEMBLY RETAINER FILTER O RING SEAL DIAPHRAGM RETAINER POWER PISTON BEARING REACTION BUMPER POWER PISTON SY SECONDARY SUPPORT PLATE SECONDARY DIAPHRAGM PISTON ROD REACTION RETAINER REACTION DISC P REACTION PISTON REACTION BODY RETAINER HOUSING DIVIDER REACTION BODY Fig 5 2A Power Piston Group Explode housing and remove the power piston bearing from the center opening of the rear housing Power Piston Group Fig 5 2A 1 Remove reaction retainer and piston rod from the power piston 2 Remove the power head silencer from the neck of the power piston tube 3 Turn power piston group upside down so that end of push rod is against a hard surface Grasp entire power piston group with both hands and use slight force or impact on push rod to remove diaphragm retainer 4 Remove diaphragms support plates and divider from the power piston Remove center bearing from housing divider 5 Separate both the primary and secondary diaphragms from the support plate 6 Using a screwdriver remove reaction body retainer 7 Remove reaction body OVERHAUL MANUAL 8 Remove reaction disc and reaction piston from the c
337. he car attach the compressor to Holding Fixture J 25008 1 and clamp the Holding Fixture in a vise Figure 1D 76 2 Keep the clutch hub from turning with the Clutch Hub Holding Tool J 25030 and remove discard and later replace the shaft nut using Thin Wall Socket J 9399 Figure 1D 77 3 Thread the Clutch Plate and Hub Assembly Remover J 9401 into the hub Hold the body of the Remover with a wrench and turn the center screw into the Remover body to remove the Clutch Plate and Hub assembly Figure 1D 78 4 Remove the shaft key Replace 1 Install the shaft key into the hub key groove Figure 1D 79 Allow the key to project approximately 3 16 out of the keyway The shaft key is curved slightly to provide an interference fit in the shaft key groove to permit the key projection without falling out 2 Be sure the frictional surface of the clutch plate and the clutch rotor are clean before installing the Clutch Plate and Hub assembly 3 Align the shaft key with the shaft keyway and place the Clutch Plate and Hub assembly onto the compressor shaft NOTICE To avoid internal damage to the compressor do not drive or pound on the clutch hub or shaft 4 Install the Clutch Plate and Hub Installer J 94801 01 as illustrated in Figure 1D 80 5 Hold the hex portion of the Installer Body J 9480 1 with a wrench and tighten the center screw to press the hub onto the shaft until there is a 020 040 inch air gap between the fr
338. ibed earlier in 11 Fill differential with lubricant Dana 10 1 2 Ring Gear section under Gear Tooth Contact Pattern Check Refer to figure 25F 12 Install wheel and tire assembly 8 Using a new gasket install housing cover and torque bolts to specifications CAUTION See Caution on page 1 of this section regarding the fasteners referred 9 Reinstall the rear universal joint and torque U to the above steps bolt nuts to specifications 10 Install axles into carrier and axle flange over hub studs Torque hub stud nuts to specifications Fig 22F Installing Outer Pinion Bearing Cup Fig 23F Installing Inner Pinion Cone and Roller OVERHAUL MANUAL 4B 32 REAR AXLE DIFFERENTIAL Fig 24F Installing Pinion Flange LOW FLANK CONTACT DECREASE PINION SHIM TOE CONTACT INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM Fig 25F Gear Teeth Contact Pattern Check OVERHAUL MANUAL REAR AXLE DIFFERENTIAL 4B 33 TRUCK DIFFERENTIAL 12 1 4 RING GEAR INDEX Case and Drive Pinion esses 4B 34 Ring Gear Replacement 4B 36 Removal 4 34 Differential Bearing Replacement 4B 36 Disassembly EEN 4B 34 Differential Reassembly 4B 36 so treni erret estie inse ie Ree Iter 4B 35 Reassembly EE eene 4
339. ication FRONT GEAR PARTS Rear Sun Gear and Input Drum Fig 7A 85A Inspection 1 Inspect rear sun gear for cracks splits damage spline worn gear or journals and plugged lubrication holes Fig 7A 85A 2 Inspect rear sun gear bushing for damage or scoring 3 If necessary remove input drum to rear sun gear snap LO amp REVERSE ring and remove sun gear from input drum CLUTCH HOUSING e 4 Inspect input drum for damage 5 Inspect 4 tanged input drum to low and reverse clutch housing thrust washer for scoring or distorted tangs 6 If damaged replace rear sun gear to input drum snap ring INPUT DRUM REAR SUN GEAR SNAP RING THRUST WASHER INPUT DRUM TO DRUM TO HOUSING REAR SUN GEAR Fig 7A 84A Installing Input Drum and Rear Sun Gear Fig 7A 85A Rear Sun Gear and Input Drum OVERHAUL MANUAL 200 7A 22 AUTOMATIC TRANSMISSION REAR SUN GEAR THRUST WASHER Fig 7A 86A Installing Thrust Washer IDENTIFICATION Fig 7A 87A Front Sun Gear Identification Fig 7A 88A Installing Front Sun Gear QVERHAUL MANUAL Reassembly 1 Install rear sun gear into input drum spline side first and retain with snap ring 2 Install 4 tanged thrust washer on input drum over sun gear end align tangs into input drum and retain with petrolatum Fig 7A 86A 3 Install rear sun gear and input drum assembly Fig 7 84 Front Sun Gear 1 Inspect front sun gear splines and teeth for damage wear
340. ich directs oil models are different Note the side to either side of the rack piston The cover differences in the sketch rack piston converts hydraulic power below into mechanical force This force is transmitted to the mating pitman NOTICE Whenever a part which shaft teeth through the pitman shaft forms a sealing surface for an O to the steering linkage ring is removed the O ring seal should also be removed and The model 800 incorporates a replaced with a new seal When recirculating ball system in which ever one of the Pitman shaft or stub shaft seals are removed all adjacent seals should be removed and replaced with new seals Lub ricate all new seals with power steering fluid to ease assembly steel balls act as a rolling thread between a steering worm shaft and the rack piston The model 605 uses an acme thread on the worm which mates with an acme thread in the rack piston Round side cover held in Rectangular side cover held in place with retaining ring place with tour bolts Te SMALL GEAR LARGE GEAR 605 MODEL 800 MODEL Fig 3B3 6C Overhaul 800 and 808 Gears Chart A OVERHAUL MANUAL Rey We Port Mame HOUSING STEERING GEAR 2 RACE THRUST BEARING WORM 3 BEARING ASSY ROLLER THRUST WORM 4 RACE THRUST BEARING WORM 5 WORM STEERING 6 SEAL O RING STUB SHAFT 7 SHAFT STUB 8 SPOOL VALVE 9 SEAL O RING SPOOL 10 BODY VALVE 11 RING VAL
341. icks or other damage These parts are the key to control of fluid or air flow and should account for the majority of troubles traceable to leakage In case of doubt install new parts for safety 2 Inspect in accordance with Inspection Table The table is organized by power brake unit groups GENERAL ASSEMBLY Be certain that all rubber parts are clean at reassembly Rewash in specified cleaning fluid if there is any doubt of cleanliness Be careful during rebuild process that no grease or mineral oil comes in contact with rubber parts of power MANUAL 5 14 BRAKES LOCK RING Fig 5 AC Removing Lock Ring From Power Piston brake unit Lubricate rubber parts with Delco approved lubricant or equivalent Front Housing Group Assembly 1 Install a new vacuum check valve using a new grommet lubricated with power brake lubricant equivalent 2 Place new front housing seal in housing so flat surface of cup lies against bottom of depression in housing REACTION RETAINER REACTION LEVERS Bo POWER PISTON N REACTION PLATE Fig 5 bC Removing Reaction Retainer OVERHAUL MANUAL SUPPORT PLATE DIAPHRAGM POWER PISTON SUPPORT PLATE REMOVER J 21524 Fig 5 6C Positioning Support Plate Retainer in Vise Power Piston Group Assembly 1 Place new ring in groove on the master cylinder piston rod Wipe a thin film of Power Brake Lube or equivalent on O ring 2 Master cyl
342. ictional surfaces of the clutch plate and clutch rotor 6 Install a new shaft nut with the small diameter boss of the nut against the crankshaft shoulder using Thin Wall Socket J 9399 Hold the Clutch Plate and Hub assembly with Clutch Hub Holding Tool J 25030 and tighten to 8 12 foot pounds 11 16 torque using a 0 25 pounds 0 60 N m torque wrench 7 If operation is performed with compressor on car connect drive belt tighten mounting brackets and adjust belt tension R 4 COMPRESSOR CLUTCH ROTOR AND OR BEARING Remove 1 Remove the Clutch Plate and Hub assembly as described in R 4 Compressor Clutch Plate Hub Assembly Removal procedure 2 Remove Rotor and Bearing assembly retaining ring using snap ring pliers J 6083 324 Fig 1D 81 Mark the location of the clutch coil terminals 10sse1dui07 Fu JO pepojdx3 p Qg e1nBi4 SPECIAL WASHER PULLEY RIM PULLEY RIM MOUNTING SCREW LOCKING 7 i O RING PRESSURE y COIL AND HOUSING ASSEMBLY RELIEF VALVE PRESSURE RELIEF ROTOR BEARING d ROTOR PULLEY RIM ue a MOUNTING SCREW x RETAINER RING SHIPPING 7l ROTOR AND BEARING ASSEMBLY M lt pe THRUST WASHERS 1 2 O RING d BELLEVILLE Ao N DISCHAR lt lt Setz ZS AI CLUTCH DRIVE ASSEMBLY e CLUTCH HUB KEY SHAFT NUT VALVE RETAINER RING PLATE THRUST WASHER KIT T MAIN BEARING CYLINDER AND SHAFT ASSEMBLY
343. igure 1D 37 into the dimpled groove of Parts Tray compartment 9 Repeat Steps 5 through 9 for Pistons No 2 and No 3 10 Remove rear combination of thrust races and thrust bearing from shaft Discard races and bearing 11 Remove shaft assembly from front cylinder half If the Discharge Cross Over Tube remained in the front cylinder half it may be necessary to bend discharge cross over tube slightly in order to remove shaft 12 Remove front combination of thrust races and bearing from shaft Discard races and bearing Fig 1D 39 13 Examine surface of Axial Plate and Shaft Replace as an assembly if necessary A certain amount of shoe disc wear on axial plate is normal as well as some markings indicating load of needle bearings on shaft 14 Remove Discharge Cross Over Tube from cylinder half using self clamping pliers This is necessary only on original factory equipment as ends ofthe tube are swedged into cylinder halves The discharge cross over tube in Internal Cylinder and Shaft Assemblies that have been previously serviced have an O ring and bushing at EACH AIR CONDITIONING COMPRESSOR OVERHAUL 1D 15 Figure 1D 38 A 6 Parts Tray i THRUST RACE SUPPORT BLOCK J 21352 Figure 1D 39 Removing 6 Front Thrust Races and Bearings END of the tube and can be easily removed by hand see Figure 1D 58 15 Examine piston bores and needle bearings in front and rear cylinder halves Replace Front and Rear Cylinder
344. ime of publica tion approval The right is reserved to make changes at any time without notice IMPORTANT SAFETY NOTICE Proper service and repair is important to the safe reliable operation of all motor vehicles The service procedures recommended and described in this service manual are effective methods for performing service operations Some of these service operations require the use of tools specially designed for the purpose The special tools should be used when and as recommended It is important to note that this manual contains various Cautions and Notices which should be carefully read in order to minimize the risk of personal injury to service personnel or the possibility that improper service methods will be followed which damage the vehicle or render it unsafe It also is important to understand that these Cautions and Notices are not exhaustive The manufacturer could not possibly know evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way Consequently the manufacturer has not undertaken any such broad evaluation Accord ingly anyone who uses a service procedure or tool which is not recommend ed must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects Oe SECTION INDEX SECTION NAME 1979 UNIT REPAIR OVERHAUL MANUAL AIR CONDITIONI
345. imited Slip Exploded 4 Install both pinion gears and thrust washers into the case and install pinion shaft 5 Place the case onto an axle shaft supported in a vise 6 Insert a screwdriver between the pinion shaft and the face of the side gear Force the screwdriver in until the clutch pack is compressed 7 Check the backlash between side gear and pinion gears If backlash does not fall into the range of 005 to 008 adjust the shim dimension as required Increasing shim thickness will decrease backlash to increase backlash decrease the thickness of the shim Service shims are availabel from 070 to 122 in increments of 004 8 Remove the pinion shaft pinion gears side gear clutch pack and shim from the case 9 Install the opposite gear clutch pack and original shim into the opposite side of the case Place both pinion gears and thrust washers into position and install the pinion shaft 10 Follow the procedure in steps 5 6 and 7 to determine the proper shim dimension 11 When the proper shims have been determined to achieve 005 to 008 backlash between both pinion gears and both side gears install shims clutch packs and side gears into case 12 Mount the case onto the axle shaft locked in a vise Place both pinions and thrust washers into position 180 apart and carefully roll in by turning the case on the shaft A large C clamp may be used to apply slight compression against pinio
346. in Bearing Head and drive the bearing into the Front Head The Installer J 24895 must seat against the Front Head to insert the bearing to the proper clearance depth see Figure 1D 107 3 Assemble the Front Head to the cylinder using a new O ring as described in RA Compressor Front Head Replacement procedure 4 Evacuate and Charge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR A C SYSTEMS in the AIR CONDITIONING section R 4 COMPRESSOR SHELL AND OR O RINGS Remove 1 Discharge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR SYSTEMS in the AIR CONDITIONING section 1D 40 AIR CONDITIONING COMPRESSOR OVERHAUL J 24895 BEARING INSTALLER Figure 1D 107 Installing RA Main Bearing 2 Thoroughly clean exterior of compressor to prevent dirt from getting into compressor during shell removal 3 Remove the Clutch Plate and Hub assembly as described in R 4 Compressor Clutch Plate and Hub Removal procedures 4 Perform Steps 1 through 4 of R 4 Compressor Clutch Rotor and or Bearing Removal procedure but do not loosen or remove the pulley rim mounting screws so as to remove the Clutch Rotor and Bearing Clutch Coil and Pulley Rim as a TOTAL assembly Be careful not to drop the Puller Guide J 25031 when removing the assembly 5 Pry the shell retaining strap away from the
347. in can be installed in the pin slot Fig 7A 157A 11 Install manual valve with the inside detent lever pin groove to the right 12 If removed install new seal ring on 1 2 accumulator piston 13 Oil and install 1 2 accumulator piston spring pocket side out into 1 2 accumulator piston bore of valve body Control Valve Assembly Installation When installing NEW control valve assembly always be sure to use one with the same casting number as the original 1 Inspect 1 2 accumulator spring for damage 2 Install 1 2 accumulator spring into case Fig 7A 158A 3 Inspect control valve assembly and spacer plate for damage Fig 7A 159A NOTICE The size of the 5 check balls used in the case and control valve assembly is 6 35 m 250 m The size of the check ball used in the pump is 7 14 m 281 m Do not interchange or damage may occur 4 Install 5th check ball in case as shown Fig 7A 160A 5 Install 2 guide pins as shown Fig 7A 161A 6 Install 4 check balls into ball seat pockets in control valve assembly and retain with petrolatum See Fig 7A 162A fo check ball location r 7 Place the control valve assembly to spacer plate gasket marked VB on the control valve assembly 8 Place the valve body spacer plate on the gasket marked VB 9 Place the spacer plate to case gasket marked C on the spacer plate AUTOMATIC TRANSMISSION 200 7 41 5th CHECK BALL T V EXHAU
348. inder piston rod is now inserted through the reaction retainer so round end of piston rod protrudes from end of the tube on reaction retainer 3 Place J 21524 power piston wrench in a vise Position power piston on wrench with three lugs fitting into notches in power piston Fig 5 7C Positioning Power Piston on Support Plate Remover PPORT PLATE POWER PISTON SUPPORT PLATE P di REMOVER AND 4 INSTALLER J 21524 Fig 5 8C Removing Support Plate 4 Position new O ring on air valve in second groove from push rod end 5 On reassembly of power piston floating control valve assembly must be replaced with a new one since the force required to remove it distorts component parts SNAP RING POWER PISTON PUSH ROD AIR VALVE ASSEMBLY Fig 5 9C Removing Power Piston Snap Ring BRAKES 5 15 D 3 8 EXTENSION Fig 5 10 Air Valve Assembly 6 Place floating control valve on push rod air valve assembly so flat face of valve will seat against valve seat on air valve 7 Wipea thin film of Power Brake Lube or equivalent on large O D of floating control valve and on O ring on air valve 8 Press air valve push rod assembly air valve first onto its seat in tube of power piston 9 Place floating control valve retainer over push rod so flat side seats on floating control valve 10 Start floating control valve and its retainer into power piston tube Press the floatin
349. ing Reaction Disc Air Valve Front Housing Seal Poppet Valve Poppet Valve Spring Poppet Retainer Dust Boot Valve Push Rod Filter and Silencers H 1 17 18 19 20 21 22 23 Fig 5 1D Bendix Single Diaphragm Unit Typical BRAKES 5 19 iL m mtt 18 Valve Return Spring Mounting Stud Air Valve Lock Plate Diaphragm Lip Front Housing Front Housing Seal Piston Rod OVERHAUL MANUAL 5 20 BRAKES Air Valve Lock Diaphragm Plate Reaction Disc Piston Rod Diaphragm Return Spring Front Housing Front Housing Seal Grommet Check Valve Rear Housing Mounting Brackets Push Rod Boot Foam and Felt Air Filter Silencers Rear Housing Rear Housing Seal Diaphragm Air Valve Push Rod Assembly Fig 5 2D Bendix Power Booster Components Typical 7 The edge of the rear housing contains twelve lances Four of these lances one in each quadrant are deeper than the other lances fig 5 3D The metal that forms the four deep lances must be partially straightened so that the lances will clear the cutouts in the front housing If the metal tabs that form the deep lances crack or break during straightening the housing must be replaced Fig 5 3D Lances in Rear Housing QVERHAUL MANUAL 8 Place Spanner Wrench J 9504 over studs on rear housing and attach with nuts and washers Draw nuts down tight to eliminate bending or damaging of studs fig 5 2A 9 Press down on Spanner
350. ing and then place the retaining ring over the accumulator fig 5 7E Place Tool J 26889 over accumulator 17 Using Tool J 22269 01 or a large C clamp 6 minimum depress the accumulator making certain that the accumulator is compressed straight fig 5 6E 1 24551 JB8 JF9 PISTON J 25083 JD3 JD5 BAFFLE AND SPRING RETAINER OR 7 8 SOCKET Fig 5 14E Installing Baffle and Spring Retainer 18 Snap the retaining ring into the housing groove by pushing it down all the way around with a small screwdriver 19 Remove Tool J 22269 01 or C clamp and retaining cap Tool J 26889 CAUTION Carefully check to make sure the retaining ring was completely installed properly 20 Position the mounting bracket on the booster The tab on the inside diameter of the large hole in the bracket should fit into a slot in the threaded portion of the booster hub 21 Install the NEW bracket nut with the staking groove outward on the threaded hub of the booster Using Fig 5 15E Installing Mounting Bracket Nut BRAKES 5 27 SLOT IN BOOSTER HUB Fig 5 16E Staking Mounting Bracket Nut Tool J 24554 and a torque wrench fig 5 15E tighten the nut to 110 ft Ibs CAUTION See Caution on Page 1 of this section 22 Use a hammer and a small punch inserted into the staking groove of the nut at the slot in the booster hub fig 5 16E to stake the nut in place Be sure
351. ing Direct Clutch Snap Ring DIRECT CLUTCH HOUSING DIRECT CLUTCH CLUTCH OUTER SEAL PISTON LIP UP Fig 7A 100A Removing or Installing Direct Clutch Inner Snap Ring Fig 7A 101A Removing Direct Clutch Piston Outer Seal 200 7A 26 AUTOMATIC TRANSMISSION DIRECT CLUTCH CLUTCH INNER SEAL PISTON LIP UP Fig 7A 102A Removing Direct Clutch Piston Inner Seal DIR CT CLUTCH CENTER SEAL HOUSING LIP UP Fig 7A 103A Removing or Installing Center Seal of Direct Ciutch Housing DIRECT CLUTCH CLUTCH INNER SEAL PISTON LIP UP Fig 7A 104A Installing Direct Clutch Piston Inner Seal OVERHAUL MANUAL 5 Oil seals and install direct clutch piston Fig 7A 106A To make the piston easier to install insert tool between seal and housing rotate tool around the housing to compress the lip of the seal while pushing down slightly on the piston See Fig 7A 107A 6 Remove seal protector J 25010 7 Install release spring guide with the omitted rib over the check ball in the piston as shown in Fig 7A 108A 8 Install retainer and spring assembly Models BR CX PA and PY use a direct clutch retainer and spring assembly which contains 16 release springs All other models use a retainer and spring assembly with 10 release springs NOTICE Retainer could locate in snap ring groove and forcing retainer to compress springs could damage retainer plate when installing 9 Using J 23327 tool compress retainer and
352. ing gear To seals Lubricate all new seals with power determine this gear from our large steering steering fluid to ease assembly gear see difference in side cover below Round side cover held in Rectangular side cover held in place with retaining ring place with four bolts SMALL GEAR LARGE GEAR 605 MODEL 800 808 MODEL Key No Pari Name Key No Part Name 1 HOUSING STEERING GEAR 20 SHAFT ASSY STUB 2 RETAINER STRG COUPLING SHIELD 21 SEAL RING SHAFT TO WORM 3 BEARING ASSY NEEDLE STUB SHAFT 22 WORM ASSY PIN amp STRG 4 SEAL STUB SHAFT 23 RING RETAINING SHAFT TO WORM 5 SEAL STUB SHAFT DUST 24 RING RACK PISTON 6 RING RETAINING STUB SHAFT SEAL 25 SEAL O RING RACK PISTON 7 BEARING ASSY NEEDLE PITMAN SHAFT 26 RACK PISTON NUT B SEAL PITMAN SHAFT 27 BEARING ASSY SUPPORT amp IWR THR 9 WASHER SEAL BACK UP PITMAN SHAFT 28 SEAL O RING ADJUSTER PLUG 10 SEAL PITMAN SHAFT DUST 29 PLUG ADJUSTER VI RING RETAINING PITMAN SHAFT SEAL 30 NUT ADJUSTER LOCK 12 WASHER LOCK PITMAN SHAFT 31 SPRING SIDE COVER 13 NUT PITMAN ARM 32 SEAL O RING ADJUSTER PLUG 14 BEARING ASSY RACE amp UPPER 33 GEAR ASSY PITMAN SHAFT 15 RING VALVE BODY 3 34 COVER ASSY HOUSING SIDE 16 SEAL O RING VALVE BODY 3 35 RING RETAINING SIDE COVER 17 BODY ASSY VALVE 36 NUT PRELOAD ADJUSTER SEALING 18 SEAL O RING DAMPNER 37 CONNECTOR INVERTED FLARE 2 19 SPOOL VALVE AES Fig 3
353. ining pin 2 3 shift valve spring 2 3 modulator valve bushing 2 3 modulator valve 3 2 intermediate spring and 2 3 shift valve Model CZ does not use a 2 3 shift valve spring 7 From next bore down remove retaining pin bore plug spring spacer and 3 2 valve 8 At other end of assembly top bore remove retaining pin and bore plug detent valve detent regulator valve spring and spacer 9 From the next bore down remove the 1 2 accumulator valve train as follows a Model CP CZ and CK Remove the grooved retaining pin bore plug 1 2 accumulator valve and spring b Models CB CD CJ and CL Remove the grooved retaining pin bore plug 1 2 accumulator valve c Models CF CH CG CM CT and CW Remove the grooved retaining pin bore plug 1 2 accumulator secondary spring and 1 2 accumulator valve Inspection NOTICE See Fig 7A 66C Do not remove the teflon oil seal ring from the front accumulator piston unless the oil seal ring requires replacement For service the oil seal ring is cast iron l Inspect all valves for scoring cracks and free movement in their respective bores 2 Inspect bushings for cracks scratches or distortion 3 Inspect body for cracks or scored bores 4 Check all springs for distortion or collapsed coils 5 Inspect accumulator piston and oil seal ring for damage Reassembly 1 Install front accumulator spring and piston into valve body 2 Install Special Tools J 22269
354. istribute oil to all cylinder and piston areas AIR CONDITIONING COMPRESSOR OVERHAUL 10 43 10 Install a shaft nut on the compressor crankshaft if the drive plate and clutch assembly are not installed 11 Using a box end wrench or socket and handle rotate the compressor crankshaft or clutch drive plate on the crankshaft several turns to ensure piston assembly to cylinder wall lubrication 12 Connect the Charging Station HIGH pressure line or a HIGH pressure gage and Gage Adapater J 5420 to the Test Plate J 9625 HIGH side connector 13 Attach on Adapter J 5420 to the suction or LOW pressure port of the Test Plate J 9625 to open the schrader type valve NOTICE Oil will drain out of the compressor suction port adapter if the compressor is positioned with the suction port downward 14 Attach the compressor to the Holding Fixture J 25008 1 R 4 compressor and J 9396 A 6 compressor and clamp the Holding Fixture in a vise so that the compressor can be manually turned with a wrench 15 Using a wrench rotate the compressor crankshaft or drive plate hub 10 complete revolutions at a speed of approximately one revolution per second NOTICE Turning the compressor at less than one revolution per second can result in a lower pump up pressure and disqualify a good pumping compressor 16 Observe the reading on HIGH pressure gage at the completion of the tenth revolution of the compressor The pressure reading for a good pumping comp
355. ith occasional slight scratches on races or rollers This does not indicate a defective bearing 2 Inspect pinion splines and flange splines for evidence of excessive wear 3 Inspect ring gear and pinion teeth for possible scoring cracking or chipping QVERHAUL MANUAL EEN 4 Inspect differential case for cracks or scores on 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 DIFFERENTIAL CASE Reassembly 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 3 Install pinion shaft in differential case Align hole in shaft with hole in case then install lock pin Peen hole to prevent pin dropping out of case 4 Position ring gear to case then install cap screws Tighten cap screws evenly and alternately to specifications 5 With an arbor press press differential side bearings onto case using Tool J 22175 Do not install shims at this time 6 Place differential case in carrier and install bearing caps Care should be taken to install caps in original position Use mark placed on caps and carrier at removal Tighten caps just enough to keep bearing caps in place 7 Install dia
356. ivers between bearing cup and housing on ring gear side of case and pry ring gear into mesh with pinion gear as far as it will go Rock ring gear to allow bearings to seat and gears to mesh With force still applied set indicator to O 4 Reposition screw drivers on opposite side of ring gear and pry ring gear as far as it will go Now take and indicator reading Repeat until the same reading is obtained every time This reading will be the necessary amount of shims Fig 4C 10 Installing Pinion Flange between the differential case and differential bearing on the ring gear side Remove differential bearing from the ring gear side and assemble proper amount of shims Reassemble bearing 5 Remove the differential bearing from the opposite side of ring gear To determine the amount of shims needed here use the following method a Subtract the size of shim pack just installed on ring gear side of case from the reading obtained and recorded in step 10 of Differential Case Reassembly b To this figure add an additional 015 shims to compensate for preload and backlash Example If reading in step 10 of Differential Case Reassembly was 085 and the shims installed on ring gear side of case was 055 the correct amount of shim will be 085 055 015 045 6 Install shims as indicated in step 5 which will give the proper bearing preload and backlash and install side bearing Installation 1 Spread differenti
357. ixture J 9625 Figure 1D 25 on rear head of compressor and connect gage charging lines or pressurize SUCTION SIDE low pressure side of compressor on vehicle with Refrigerant 12 vapor to equalize pressure to the drum pressure Temporarily install the shaft nut and with compressor in horizontal position and oil sump down rotate the compressor shaft in normal direction of rotation several times by hand Leak test the Seal with Electronic Leak Detector J 23400 Correct any leak found Remove discard and later replace the shaft nut 8 Remove any excess oil resulting from installing the new seal parts from the shaft and inside the compressor neck 9 Install the new absorbent sleeve by rolling the material into a cylinder overlapping the ends and then slipping the sleeve into the compressor neck with the overlap towards the top of the compressor With a small screwdriver AIR CONDITIONING COMPRESSOR OVERHAUL 10 11 STRAIGHT EDGE WIRE GAUGE 026 SHOULD oo 075 SHOULD NOT GO OR SHOULD JUST GO ABSORBENT SLEEVE SLEEVE RETAINER SEAL SEAT RETAINER RING SEAL SEAT 0 RiNG SEAL ASSEMBLY Figure 1D 24 A 6 Compressor Shaft and Seal LEAK TEST ADAPTER J 9625 OIL DRAIN FITTING Figure 1D 25 Leak Testing 6 Compressor or similar instrument carefully spread the sleeve until the ends of the sleeve butt at the top vertical centerline 10 Position the new metal sleeve retainer so that its flange face will be against th
358. l indicator on carrier with indicator button contacting back of ring gear Fig 4C 7 Rotate differential case and check for runout If runout is greater tha 002 the assembly should be removed and the ring gear n removed from case Again install differential case and check runout at differential case flange 8 Should runout of case flange be greater than 002 the defect is probably due to bearings or differential case and should be corrected before proceeding further 9 Position two screwdrivers between bearing cup and carrier on opposite side of ring gear away from dial indicator side Pull on screwdrivers and force differential case as far as possible toward the dial indicator Rock the ring gear to set the bearings With force still applied set indicator at OT 10 Reposition screwdrivers between bearing cup and carrier on ring gear side Pull on screwdrivers and force differential case as far as possible toward center of carrier Repeat several times until the same reading is obtained Record the indicator reading This will be the total amount of shims needed less preload for setting backlash later during assembly 11 Remove differential from carrier DRIVE PINION Installation and Adjustment of Depth and Preload Ring gears and pinions are supplied in matched sets only Matching numbers on both pinion and ring gear are etched for verification If a new gear set is being used verify the numbers of each pinion and ring
359. l may have to be driven from the bearing reatiner if it is being replaced 7 Drive the pinion front and rear bearing cups from the bearing retainer using a drift 8 To remove the rear bearing use J 22912 as shown in figure 11E 9 Drive the pinion straddle bearing from the carrier housing using a drift as shown in figure 12E OVERHAUL MANUAL 4 16 REAR AXLE DIFFERENTIAL J 8614 11 Fig 8E Removing Pinion Nut Inspection 1 Clean all parts in a suitable solvent and dry with air 2 Inspect the drive pinion for chipped cracked or excessively worn teeth and inspect the splines for wear 3 Inspect the bearings for worn or pitted rollers or races Inspect the pinion flange splines for wear 4 Inspect the bearing retainer for cracks imperfections corrosion pits and grooves 5 Replace parts as required Reassembly 1 Lubricate all parts with hypoid lubricant 2 Press pinion rear bearing onto drive pinion as shown in figure 13E using J 24433 3 Install the front end rear pinion bearing cups into the bearing retainer using driver handle J 8092 on J 8608 for the front cup and on J 24432 for the rear cup 4 Install the pinion straddle bearing into the carrier housing using driver handle J 8092 and installer J 23322 as shown in figure 14E J 861 4 3 J 8614 2 J 8614 11 Fig 10E Pressing Drive Pinion from Bearing Retainer 5 Place bearing retainer with cups in position onto th
360. ld piston rings by CAREFULLY slicing through the ring with a knife or sharp instrument holding the blade almost flat with the piston surface Be careful not to damage the aluminum piston or piston groove in cutting to remove the ring CAUTION Exercise personal care in cutting the piston ring for removal 2 Clean the piston and piston ring grooves with naphtha stoddard solvent kerosene or equivalent solvent and blow the piston dry with dry air 3 Set the piston on end on a clean flat surface and install the Ring Installer Guide J 24608 2 on the end of the piston Figure 1D 51 4 Install a Teflon ring on the Ring Installer Guide J 24605 2 as shown in Figure 1D 51 with the dished or dullside down and glossy side up 5 Push the Ring Installer J 24608 5 down over the Installer Guide J 24608 2 to install the Teflon ring in the piston ring groove Figure 1D 52 If the Teflon ring is slightly off position in the ring groove it can be positioned into place by fingernail or blunt edged tool that will not damage the piston The Ring Installer J 24608 5 will retain the Installer Guide J 24608 2 internally when the Teflon ring is installed on the piston Remove the Installer Guide from the Ring Installer and do not store the Installer Guide in the Ring Installer as the Ring Installer Segment Retainer O Ring J 24608 3 will be stretched and possibly weakened during storage This could result in the O Ring J 24608 3 not holding the Ring Inst
361. le housing and cover and place new gasket over axle housing 2 Assemble differential carrier to axle housing install lockwashers and bolts and tighten securely Fig 10G Checking Backlash OVERHAUL MANUAL 4B 38 REAR AXLE DIFFERENTIAL 4 Assemble rear universal joint LOCK NUT CAUTION This propeller shaft to pinion ADJUSTING i flange fastener is an important attaching CREW ors A wl part in that it could affect the performance of vital components and systems and or could result in major repair expense It must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of this part Fig 11G Ring Gear Thrust Pad Adjustment 8 8 5 Install axle shafts as outlined in applicable axle installation procedure in Service Manual 3 Replace axle housing inspection cover if removed sing new gasket 6 Fill axle with lubricant to a level even with bottom of filler hole See Section Om the Truck Service Manual for proper lubricant LIMITED SLIP DIFFERENTIAL UNITS INDEX Eaton Limited Slip 5 5 denen 4B 39 Power Lok Dfferenal 4B 46 Disassembly i n use rente ege 4 39 Disassembly Ree 4 46 UE 4B 40 Inspections ires tarte d ade e need 4B
362. lers 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 worn washers Fig 7B 5J Removing Countershaft OVERHAUL MANUA 7B 20 MANUAL TRANSMISSION Fig 7B 6J Removing Reverse Idler Gear Shaft Gears 1 Inspect all gears for excessive wear chips or cracks and replace any that are worn or damaged 2 Check both clutch sleeves to see that they slide freely on their hubs Reverse Idler Gear Bushings The bushing used in the idler gear is pressed into the gear 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 machined the bushing is not serviced separately REPAIRS Clutch Keys and Springs The clutch hubs and sliding sleeves are a selected assembly and should be kept together as originally assembled but the keys and two springs may be replaced if worn or broken Fig 7B 7J Removing 3rd and 4th Synchronizer Snap Ring OVERHAUL MANUAL Fig 7B 8J Rear Bearing to Mainshaft Snap Ring 1 Mark hub and sleeve so they can be matched upon reassembly 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 each
363. lling Input Shaft Bearing Retainer Seal Input Gear Bearing Retainer Seal Replacement Remove bearing retainer attaching bolts retainer and gasket from housing Discard gasket 2 Pry seal out of reatiner and discard 3 Position new seal to retainer and install using tool J 21359 Fig 70 168 4 Position bearing retainer and gasket to housing Install attaching bolts and tighten to specifications REAR OUTPUT SHAFT HOUSING REAR Disassembly 1 Remove speedometer driven gear from rear section of rear output housing 2 Pry old seal out of bore using screwdriver or other suitable tool 3 Using a screwdriver pry behind open ends of snap ring and remove snap ring retaining rear bearing in housing Fig 7D 17S 4 Pull or tap bearing from housing 5 To remove the front bearing insert a long drift through rear opening and drive the bearing from the housing Fig 7D 18S Remove and discard rubber seal Assembly 1 Position rear bearing in housing and tap into place 2 Install snap ring retaining bearing to case Retaining ring is a select fit Use service ring size B C or D as required to provide tightest fit 3 Position rear seal to bore and drive into place using tool J 22388 Fig 7D 19S or other suitable tool until approximately 1 8 to 3 16 below housing face 4 If the vent seal falls out or is knocked out during disassembly reinstall new seal or thoroughly clean and dry the area and re cement th
364. llowing items 1 Check driving lugs for wear 2 Check clutch cover for distortion or cracks 3 Check release levers for wear or cracks ASSEMBLY 1 Lay the pressure plate on the block in the press and coat the lugs with a thin film of approved lubricant such as lubriplate See Fig 7C 6E 2 Assemble lever eyebolt and pin holding eyebolt and lever as close together as possible and with the other hand grasp strut as shown in Fig 7C 7E 3 Insert strut in the slots in the pressure plate lug drop slightly and tilt the lower edge until it touches vertical 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 pressure plate and near the strut as in Fig 7C 5E 5 Slide the strut upward in the slots of the lug lifting it over the ridge on the short end of the lever and drop it Fig 7C 2E Compressing Clutch OVERHAUL MANUAL 7C 4 CLUTCHES Ww U 2 Fig 7C 3bE Disassembly of Clutch into the groove in the lever as shown in Fig 7C 4E 6 Assemble the pressure springs on the small bosses of the pressure plate in accordance with Fig 7C 8E in order to retain original balance NOTICE 1f there are spaces for more springs than specified for the particular assembly or if two different colors of springs are used Fig 7C 8E shows the proper sequence It is very important that each group be arranged in like sequence
365. lunger of indicator is resting on end of the input shaft J 5492 may be used to support the dial indicator as shown in Figure 7A 109B Zero the indicator c Push up on the transmission output shaft and observe the total indicator movement d The indicator should read 010 to 044 If the reading is within limits the proper selective fit washer is being used If the reading is not within limits it will be necessary to remove the pump and change to a thicker or thinner selective fit thrust washer as required to obtain the specified clearance Repeat the above checking procedure Selective fit thrust washers are available in thicknesses of 066 083 and 100 25 Install new pump assembly in case gasket SLIDE HAMMER Ge f Fig 7A 109B Checking End Play for Proper Thrust Washer Selection AUTOMATIC TRANSMISSION 350 7 35 26 Install new pump assembly to case square cut oil seal ring 27 Install guide pins into case 28 Install pump assembly into case Install attaching bolts with new washer type seals 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 installed to index the faced plates with their respective parts This condition must be corrected before the pump is pulled into place Speedometer Drive Gear and Extension 1 Place speedometer drive gear retaining clip into hole in output shaft 2 Heat a new spee
366. ly pin or replacement of piston is required proceed as follows Disassembly and Reassembly 1 Using small flat edge screwdriver remove intermediate pin to snap ring retainer as shown in Fig 7A 148A 2 Install retainer on band apply pin Install snap ring on band apply pin 3 Install band apply pin retainer end first through intermediate servo pistons 4 If removed install new intermediate servo piston inner and outer seal rings Make sure cut ends are assembled in the same relationship as cut Make sure rings are seated in the grooves to prevent damage to the rings Retain with petrolatum 5 Lubricate with petrolatum and install new seal ring on intermediate servo cover NOTICE The intermediate servo cover seal rings must be well lubricated with petrolatum to prevent damage or cutting of ring 6 Install intermediate servo piston assembly into intermediate servo cover 7 Install intermediate servo assembly into case Fig 7 149 IDENTIFICATION INTERMEDIATE SERVO PISTON ASSEMBLY 0 RING SEAL INTERMEDIATE SERVO COVER Fig 7A 149A Installing Intermediate Servo Into Case OVERHAUL MANUAL 200 7 38 AUTOMATIC TRANSMISSION INTERMEDIATE SERVO RETAINING RING 7A 150A Installing Retaining Ring NOTICE Make sure the tpaered end of the band apply pin is properly located against the band apply lug 8 Using two oil pan bolts install J 28653 on case and depress servo cover as in Fig
367. m 040 The identification ring is located on the band end of the pin f Remove tools J 25014 2 and J 25014 1 FRONT UNIT PARTS Removal 1 Check front unit end play as follows a Install J 25013 1 sleeve on output shaft first then bolt J 25013 5 on end of case Fig 7A 18A b Turn transmission to vertical position pump side up c Remove pump to case bolt and washer and install 278mm 11 long bolt and locking nut as shown Fig 7A 19A d Push turbine shaft downward e Install J 25022 on J 24773 tool and secure on end of turbine shaft Fig 7A 19A f Mount dial indicator and clamp assembly on bolt positioning indicator point against cap nut of J 24773 Move output shaft upward by turning the adjusting screw on J 25013 5 until the white or scribed line on sleeve J 25013 1 begins to disappear Fig 7A 18A then set dial indicator to zero h Pull J 24773 on turbine shaft upward and read end play Front unit end play should be 0 56mm 1 30mm 022 051 Selective washer controling this end play is located between the output shaft and turbine shaft If more or less washer thickness is required to bring end play within specifications select proper washer from the chart shown in figure 7A 20A i Remove dial indicator clamp assembly J 24773 and J 25022 Fig 7A 19A OVERHAUL MANUAL 200 7A 6 AUTOMATIC TRANSMISSION FRONT UNIT END PLAY CHART THICKNESS IDENTIFICATION Number and or Color _
368. m plate hub Remove the air valve push rod assembly from the diaphragm plate Remove the reaction disc from its location in the diaphragm plate bore insert the piston rod or other suitable tool through diaphragm plate extension and push disc from its seat Exercise care so as not to chip surface of passages in the diaphragm plate NOTICE Perform Step 4 only if seal is defective and a new seal is available Do not reuse seal once it has been removed from the unit 4 Support outer surface of rear housing on blocks of wood or other suitable material stud side up and drive out seal with a punch or a thin blade screwdriver Discard seal BRAKES 5 21 Front Housing Group 1 Remove check valve from grommet and then remove grommet from front housing discard valve and grommet 2 Remove front housing and holding fixture from vise then remove holding fixture from front housing Cleaning Use clean brake fluid to thoroughly clean all reusable brake parts Immerse in the cleaning fluid and brush metal parts with hair brush to remove foreign matter Blow out all passages orifices and valve holes Air dry and place cleaned parts on clean paper or lint free clean cloth If slight rust is found inside either the front or rear half housing assemblies polish clean with crocus cloth or fine emery paper washing clean afterwards Dirt is the major cause of trouble and wear in service Be sure to keep parts clean until re assembly Re wash at r
369. m gear assembly with bearing remover attached in an arbor press supporting the bearing remover on both sides 4 Install a 1 1 2 to 1 3 4 diameter plug J 8107 4 on gear hub Press against plug with ram of press to remove thrust ring Keep all components in the proper order OVERHAUL MANUAL 4B 54 REAR AXLE DIFFERENTIAL TIUS GUIDE CUP ratis SOUL DUE ON DOE GEAR HUE gt T Za n orar SPLimeD Disc LANGE Shue Fig 4B 9H Cam Plate and Clutch Discs Reassembly Replace cam plate and or clutch discs as necessary and reassemble as follows 1 Place gear on bench with hub end up 2 Assemble cam plate with cam form down to mate with cam form on gear 3 Assemble onto cam plate 2 eared discs 1 splined disc and 1 wave spring alternately as shown Fig 4B 9H 4 Assemble onto gear hub 4 eared discs and 3 splined discs alternately as shown Begin and end with an eared disc 5 Locate cam gear assembly in arbor press with hub end up Place thrust ring on gear hub and press to shoulder making sure that ring is square with hub NOTICE Compress disc pack by pushing down on the discs to keep the splined discs from becoming wedged between the thrust ring and gear shoulder while pressing the sub assembly together Completed sub assembly should be checked for proper disc sequence Also make sure the first splined disc large spline is properly located on the cam
370. mage and should be replaced if necessary OVERHAUL MANUAL Fig 7C 3A Clutch Pilot Bearing Removal Typical 6 Examine splines in hub and make sure they slide freely on splines of transmission 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 NOTICE 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 transmission pilot hole in clutch housing by removing a flywheel bolt and installing a dial indicator The run out should be within 000 015 10 Lubricate ball stud before reassembly 11 Lubricate bearing LD and groove before reassembly ASSEMBLY 1 Install the pressure plate in the cover assembly lining up the punch marks on the edge of the pressure plate with the punch marks on the edge of the cover 2 Install pressure plate retracting springs and drivestrap to pressure plate bolts and lock washers and tighten to 11 ft Ibs torque The clutch is now ready to be installed To remove install Tool J 1448 and remove bearing from crankshaft as shown in Fig 7C 3A In replacing this bearing use Tool J 1522 Place bearing on pilot oF tool with radius in bore of bearing next to shoulder on tool and drive into crankshaft Lubricate with several dro
371. may occur 6 Install intermediate clutch piston inner seal and outer seal on piston EXHAUST TT INTERMEDIATE CLUTCH DIRECT CLUTCH COOLER IN TO RADIATOR SUCTION COOLER OUT FROM RADIAT PUMP ADIATOR PRESSURE REVERSE DIRECT CLUTCH OUTER INTERMEDIATE CLUTCH EXHAUST PUMP COVER AND STATOR SHAFT ASSEMBLY Fig 7A 68B Pump Cover Oil Passages DIRECT CLUTCH DRUM PISTON RETURN SPRING SEAT DIRECT CLUTCH PISTON ASSEMBLY RETAINING RING CUSHION SE AUTOMATIC TRANSMISSION 350 7 21 STEEL SEPARATOR PLATES FACED PLA TE se DIRECT CLUTCH PRESSURE PLATE RETAINING RING Fig 7A 69B Direct Clutch Assembly Exploded View 7 Install pump outside diameter to case square cut ring seal 8 Install intermediate clutch piston assembly into pump cover being careful not to damage seals 9 Install spring retainer with attached clutch return springs align pump body to cover and install five 5 attaching bolt Tighten bolts to 18 pound feet 10 Align pump body to cover and start bolts O VERRUN CLUTCH DIRECT CLUTCH ASSEMBLY Fig 7A 70B Removing Overrun Clutch Retaining Ring and Retainer DIRECT CLUTCH AND INTERMEDIATE OVERRUN ROLLER CLUTCH FIG 7A 69B Disassembly 1 Remove intermediate overrun clutch drum front retaining ring and retainer fig 7A 70B 2 Remove intermediate clutch overrun outer race fig 7A 70B 3 Remove intermediate overrun
372. mbly Then lift the Shaft Seal assembly out see Figure 1D 23 Discard the Seal 7 Remove and discard the seal seat O Ring from the compressor neck using O Ring Remover J 9533 see Figure 1D 22 8 Recheck the shaft and inside of the compressor neck for dirt or foreign material and be sure these areas are perfectly clean before installing new parts 1D 10 AIR CONDITIONING COMPRESSOR OVERHAUL SEAL SEAT REMOVER J 23128 O RING REMOVER J 9553 Figure 10 22 Removing A 6 Shaft Seal Seat and O Ring Zoe INSTALLER J 21508 INSTALLER SEAL PROTECTOR J 22974 J 9392 Figure 1D 23 Replacing A 6 Seal and O Ring Inspection Seals should not be reused Always use a new seal kit on rebuild see Figure 1D 20 Be extremely careful that the face of the Seal to be installed is not scratched or damaged in any way Make sure that the Seal Seat and Seal are free of lint and dirt that could damage the seal surface or prevent sealing Replace 1 Coat the new seal seat O ring in clean 525 viscosity referigerant oil and assemble onto O Ring Installer J 21508 see Figure 1D 23 2 Insert the O Ring Installer J 21508 completely down into the compressor neck until the installer bottoms Lower the movable slide of the O Ring Installer to release the O ring into the seal seat O ring lower groove The compressor neck top groove is for the shaft seal retainer ring Rotate the Installer to seat the O ring and remove
373. mission Band Adjuster THM 250 only Accumulator Piston Adapter Used with J 22269 01 Fig 7A ST 350 Special Tools AUTOMATIC TRANSMISSIONS 400 7A 1 SECTION 7A INDEX Transmission Disassembly and Reassembly TA 3 Output Shaft Rear Internal Gear Disassembly of Major Unite ees 7A 3 Sun Gear and Shaft ENNEN 7 41 Governor Speedometer Driven Gear Pan Filter Sun Gear Shaft Bushing Front ss 7 41 and Intake 222 00 009 00 3 Sun Gear Shaft Bushing Rear se 7 41 Control Valve Assembly Solenoid Connector Main Shaft Inspection EE 7 41 Governor Pipes and Detent Spring 7 4 Front and Rear Bands 7A 41 Rear Servo Valve Body Spacer Gasket Case 0 020 4 0 06 7 41 Front Setup ise entente 74 5 Modulator and Valve ENEE 7A42 Rear Band Apply Pin 74 6 Manual and Parking Linkage Inspection 7 42 Manual Linkage eite inei 7 7 Case Assembly Inspection eee 7 42 Rear Seal and Case Extension 9 Case Assembly Bushing eee 74 44 Front Unit End Play Checking Procedure 7 9 Converter 0 7 44 Oil Pump and Internal Case Components 7A 10 Conver
374. mmended that the filter be replaced rather than cleaned whenever the transmission is disassembled 3 Install filter retainer bolt Fig 7A 7C 4 Install new bottom pan gasket and bottom pan with attaching screws Torque to 12 ft Ibs VACUUM MODULATOR Fig 7A 186C Installing Vacuum Modulator and Valve INSTALLATION OF MODULATOR VALVE AND VACUUM MODULATOR 1 Install modulator valve into case stem end out Fig 7A 186C 2 Install O ring seal on vacuum modulator 3 Install vacuum modulator into case Fig 7A 187C Installing Governor Assembly AUTOMATIC TRANSMISSIONS 400 7A 57 Models CB CK and CZ use a modulator that is different than the modulator used on the other models Refer to parts catalog book for correct usage 4 Install modulator retainer and attaching bolt Torque bolt 18 ft Ibs INSTALLATION OF GOVERNOR ASSEMBLY 1 Install governor assembly into case Fig 7A 187C 2 Attach governor cover and gasket with four 4 attaching bolts Torque bolts to 18 ft Ibs INSTALLATION OF SPEEDOMETER DRIVEN GEAR ASSEMBLY 1 Install speedometer driven gear assembly Fig 7A 188C 2 Install speedometer driven gear retainer and attaching bolt INSTALL CONVERTER ASSEMBLY With the transmission in cradle or portable jack install the converter assembly into the pump assembly making certain that the converter hub drive slots are fully engaged with the pump drive gear tangs and the converter installed
375. must be drilled through sleeve and gear Locate hole position 90 degrees from existing hole center punch and then while supporting governor in press drill new hole through sleeve and gear using a standard 1 8 inch drill 6 Install split retaining pin 7 Wash governor assembly thoroughly to remove any chips that may have collected Assembly 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 assemblies 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 5 Check governor valve for free movement in governor sleeve 400 7 18 AUTOMATIC TRANSMISSIONS TEFLON SEAL RING SERVO PIN SERVO SPRING SPRING RETAINER SERVO PISTON Fig 7A 61C Front Servo Assembly Exploded View Front Servo Parts Inspection See Fig 7A 61C 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 1 Inspect servo pin for damage 2 Inspect piston and oil ring for damage 3 Check fit of servo pin in piston and case bore SERVO PISTON ei UE 4 ang ACCUMULATOR PISTON Fig 7A 62C Removing Rear Accumulator Piston from Rea
376. n Figure 5 2 Install O ring and spool valve plug fig 5 9E 3 Push spool valve plug in and install retaining ring 4 Coat the piston bore and the piston seal with clean power steering fluid and assemble the NEW seal in the NO 4 EASY OUT TUBE SEAT HOUSING Fig 5 TOE Removing Tube Seat OVERHAUL MANUAL 5 26 BRAKES 1 6217 HOUSING TUBE SEAT Fig 5 11E Installing Tube Seat Using J 6217 bore The lip of the seal must be toward the rear away from the master cylinder mounting flange Be sure the seal is fully seated in the housing 5 Lubricate the input rod end NEW input rod seals and Seal Installer with clean power steering fluid Slide the seals on the tool with the lip of the cups toward the open end of the tool fig 5 I2E 6 Slide the tool over the input rod end and down to the second groove then slide the forward seal off the tool and into the groove Assemble the other seal in the first groove Be sure that both seals are fully seated NOTICE Only one seal is used on JD3 and JD5 applications INPUT ROD AND PISTON J 24553 J88 J 28485 JD3 JD5 J 28497 JF9 SEALS LIPS OF SEALS TOWARD OPEN END OF TOOL Fig 5 12E Installing Input Rod Seals OVERHAUL MANUAL J 24551 JB8 JF9 J 25083 JD3 JD5 INPUT ROD AND PISTON Fig 5 13E Installing Input Rod and PistonAssembly into Booster Typical 7 The piston counterbore on JF9 applications is of a different
377. n end first into governor feed pipe hole in case hole nearest the center of the transmission Fig 7A 183C If transmission is in vehicle before installing the control valve assembly and governor pipes as outlined in Step 3 below insert the governor screen 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 7A 183C GUIDE PINS Fig 7A 184C Installing Control Valve Assembly and Governor Pipes DETENT ROLLER AND PRING ASSEMBLY __ Fig 7A 185C Installing Detent Roller and Spring Assembly 3 Install control valve assembly and governor pipes on transmission while carefully aligning the governor feed pipe over the governor screen Fig 7A 184C Make certain gasket and spacer do not become mispositioned Check manual valve to make sure it is indexed properly with pin on detent lever and check governor pipes to make certain they are properly seated in case holes 4 Start control valve assembly attaching bolts If transmission is in the vehicle remove feeler stock before tightening any control valve bolts 5 Remove guide pins and install detent roller and spring assembly and remaining bolts Fig 7A 185C INSTALLATION OF FILTER AND INTAKE PIPE 1 Install case to intake pipe ring seal on intake pipe and assemble into filter assembly 2 Install filter and intake pipe assembly Fig 7A 8C It is reco
378. n flywheel with gauge plate center NOTICE On assemblies with three levers the three flat machined lands of the gauge plate must be located directly under the levers 3 Depress each lever several times with a hammer handle to settle all parts into working position as shown in Fig 7 12 4 Position height gauge J 6456 01 on the hub of the gauge plate and the bearing surface of one lever Refer to Fig 7C 13E Turn adjusting nut until lever is flush with the 12 step of J 6456 01 Adjust remaining levers in same manner 5 Stake adjusting nut as shown in Fig 7C 14E to eyebolt with a dull punch to lock adjustment Fig 7C 6E Greasing Lug CLUTCHES 7 5 RELEASE Fig 7C 7E Installing Lever 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 3 SPRINGS 9 SPRINGS PAINTED UNPAINTED LIGHT BLUE ADJACENT TO LEVERS d ba ih a B s 3 SPRINGS 9 SPRINGS PAINTED PAINTED LIGHT GRAY ORANGE ADJACENT TO LEVERS Fig 7C 8E Spring Arrangement Diagram Fig 7C 10E Assembling Cover and Pressure Plate OVERHAUL MANUAL 7C 6 CLUTCHES 12 J 6456 01 ADJUSTING Fig 7C 13E Coil Spring Clutch Adjustment Fig 7C 11E Gauge Plate Position Fig 7C 12E Depressing Lever Fig 7C 14E Staking Nut OVERHAUL MANUAL CLUTCHES 7 7 SPECIAL
379. n gears to aid the rolling in procedure 13 Tap the preload spring into place with a hammer 14 Install the pinion shaft and lock screw 15 Install the side bearings and ring gear using the procedure outlined for conventional units 16 Place the differential unit in the carrier and adjust ring gear and pinion backlash and gear tooth pattern OVERHAUL MANUAL 4B 44 REAR AXLE DIFFERENTIAL BORG WARNER CONE TYPE DESCRIPTION The limited slip differential can be identified by a tag attached to the lower right section of axle cover It is designed to direct the major driving force to the wheel with greater traction thereby reducing the posibility of the car becoming stuck while driving under adverse conditions All rear axle parts of vehicles equipped with the limited slip differential are interchangeable with those equipped with the conventional differential except for the case assembly It is similar in all respects to the conventional case assembly with the addition of cone clutches splined to each side gear 20 FT LBS 4 3 SCH F 3 ET CLUTCH CONE SIDEGEAR SPRING BLOCK PINION THRUST WASHER PINION PINION GEAR SPRING BLOCK SPRING CLUTCH CONE SIDE GEAR Fig 4B 16D Limited Slip Cone Type OVERHAUL MANUAL LUBRICATION The differential should be checked for leaks and level every oil change Maintain level to within 3 8 of the filler plug opening If n
380. n groove 5 Inspect for free operation of governor weights 6 Inspect for damaged mispositioned or tilted springs Models and CX use one spring all other models use two 7 Inspect for presence of 2 check balls 8 Inspect shaft for damage 9 Inspect governor washer for damage 10 If damaged cut seal ring off governor shaft NOTICE Do not damage seal ring groove when removing seal or damage may occur Installation 1 If removed install new seal ring on shaft and place seal ring end into governor cover to size seal lubricate with petrolatum 2 Lubricate with petrolatum and install 2 new seal rings on governor cover NOTICE The governor cover seal rings must be well lubricated with petrolatum to prevent damage or cutting of the rings Also make sure 2 check balls are in the governor before installation 3 Install governor assembly seal ring end first into cover NOTICE Do not use any type of hammer to install governor assembly and cover into case Damage to case governor or cover could result 4 Install governor and cover assembly aligning governor shaft with shaft hole in case Fig 7 142 AUTOMATIC TRANSMISSION 200 7A 35 FRONT UNIT END PLAY CHART THICKNESS IDENTIFICATION Number and or Color 1 66 1 77mm 0 065 1 79 1 90mm 0 070 1 92 2 08mm 0 076 2 05 2 16mm 0 081 2 18 2 29 0 086 2 31 2 42 0 091 2 44 2 55 0 096 2 57 2 68mm 0 101
381. n of inner race is toward pinion head Then using a suitable length of 2 inch pipe press bearing onto shaft until it seats against the pinion head When pressing bearing on pinion exercise care to prevent damage to ground surface of pilot 5 Slide oil seal retainer on pinion shaft then tap drive flange onto pinion splines 6 Clamp drive flange in a bench vise and install flange washer and nut Torque to specifications and install cotter pin without backing off on nut Fig 4G Pinion Oil Seal Installation OVERHAUL MANUAL 4B 36 REAR AXLE DIFFERENTIAL LOCK RING DRIVER Fig 5G Pinion Rear Bearing Lock Ring Installation Differential Disassembly 1 Check differential case to make sure that the two halves are marked so they may be reassembled in same relation See figure 6G 2 Remove bolts holding case and cover together Ring gear is mounted on the case 3 Separate cover from case and remove differential side gears and thrust washers pinion gears with thrust washers and differential spider Differential Inspection 1 Wash 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 arms for wear and distortion 5 Inspect splines and teeth of differential side gears and pinions for chipping or excessive wear 6 Check thrust wa
382. n oil pick up tube cavity 14 Lubricate Oil Pick Up Tube with 525 viscosity refrigerant oil and install into cavity rotating compressor mechanism to align tube with hole in shell baffle Figure 1D 69 FRONT DISCHARGE VALVE PLATE ASSEMBLY 5 DOWEL 5 ow 4 SUPPORT BLOCK J 21382 Figure 10 64 Installing 6 Front Discharge Valve Plate SUCTION REED LARGER DIA HOLE RECESS FRONT DISCHARGE VALVE PLATE REAR DISCHARGE VALVE PLATE 4953 Figure 1D 65 Front and Rear A 6 Discharge Valve Plates 15 Now install new O ring and bushing on rear end of discharge cross over tube See Figure 1D 58 16 Install Rear Suction Reed over dowel pins with slot TOWARDS sump 17 Install Rear Discharge Valve Plate assembly over dowel pins with reed retainers UP 18 Position Inner Oil Pump Gear over shaft with previously applied identification mark UP 19 Position Outer Oil Pump Gear over inner gear with previously applied identification mark up and when standing facing oil sump position outer gear so that it 1D 24 AIR CONDITIONING COMPRESSOR OVERHAUL ES FRONT HEAD CASTING DISCHARGE VALVE PLATE ASSEMBLY e SUPPORT BLOCK Figure 1D 66 Installing A 6 Front Head Casting OIL PUMP Figure 1D 69 Installing A 6 Oil Pick up Tube 4950 meshes with inner gear at the 9 o clock position The resulting cavity between gear teeth is then at 3 o clock SUPPORT iti Fi 1D 70 BLOCK
383. n the snap ring so that the opening is opposite the pin 3 Position front wheel hi gear and washer in case Install sliding clutch in the shift fork then put fork and rail in the front wheel drive 4 Hi position with the clutch teeth in mesh with the teeth of the front wheel hi gear 4 Line up washer high gear and sliding clutch with bearing bore Insert front output shaft and low gear assembly through the high gear assembly 5 Install new seal in bearing retainer using Tool J 22836 Fig 7D 16R and install the front output bearing and retiner in the case 6 Clean and grease rollers in front output rear bearing retainer Install onto case using one gasket Dip bolts into sealant Install bolts and torque to 30 ft Ibs 7 Install front output yoke washer and lock nut Torque nut to 150 ft Ibs J 23431 BEARING Fig 7D 17R Installing Rear Output Shaft Housing Bearing TRANSFER CASES 70 7 Rear Output Shaft Assembly 1 Install two rows of needle bearings 32 each separated by a spacer into the output low gear Use sufficient grease to retain needles 2 Install thrust washer onto rear output shaft tang down in clutch gear groove Install output low gear onto shaft with clutch teeth facing down 3 Install thrust washer over gear with tab pointing up and away from gear Install washer pin and also large thrust washer over shaft and pin Rotate washer until tab fits into slot approximately 90 degrees awa
384. n threaded shell studs and tighten evenly to 25 Ib ft 34 torque using a 0 50 Ib ft 0 60 torque wrench 26 Invert compressor in Holding Fixture and install compressor Shaft Seal as described in A 6 Compressor Shaft Seal Replacement procedure 27 Install compressor Clutch Coil and Housing assembly as described in A 6 Compressor Clutch Coil and Housing Assembly Replacement procedure 28 Install compressor Pulley and Bearing assembly as described in 6 Compressor Pulley and Bearing Replacement procedure 29 Install compressor Clutch Plate and Hub assembly as described in A 6 Compressor Clutch Plate and Hub Assembly Replacement procedure 30 Add required amount of 525 viscosity refrigerant oil see C C O T Refrigerant Oil Distribution in the AIR CONDITIONING section 31 Check for external and internal leaks as described in the following 6 Compressor Leak Testing procedure found at the end of this OVER HAUL section 32 Evacuating and Charge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR A C SYSTEMS the AIR CONDITIONING section REAR HEAD SLIGHTLY ROTATE FRONT HEAD IF NECESSARY f UNE UP LOCATOR PINS AND HOLES So Figure 1D 72 Installing A 6 Rear Head 1D 26 AIR CONDITIONING COMPRESSOR OVERHAUL MINOR REPAIR PROCEDURES FOR THE R 4 COMPRESSOR THE FOLLOWING OPERATIONS TO THE R 4 COMPRESS
385. n unless the piston or apply ring requires replacement The apply ring is identified as shown in Fig 7A 82A 15 Inspect direct clutch piston assembly for distortion cracks damage and check ball for free operation 16 Remove center seal from direct clutch housing and discard Fig 7A 103A 17 Inspect direct clutch housing for cracks wear and open oil passages 18 Check for free operation of check ball 19 Inspect direct clutch housing snap ring grooves for damage SELECTIVE WASHER Fig 7A 97A Location of Front Selective Washer AUTOMATIC TRANSMISSION 200 7A 25 DIRECT DIRECT DIRECT FLAT DIRECT CLUTCH CLUTCH CLUTCH STEEL CLUTCH PISTON APPLY RETAINER PLATE BACKING amp SPRING PLATE ASSEMBLY RELEASE SNAP COMPOSITION DIRECT DIRECT CLUTCH SPRING RING FACED PLATE CLUTCH PISTON ASSEMBLY GUIDE HOUSING Fig 7A 98A Direct Clutch Assembly Exploded 20 Inspect direct clutch bushings for damage or scoring SNAP RING Reassembly 1 Install clutch apply ring on piston 2 Install new inner and outer seals on piston with lips facing away from clutch apply ring side Figs 7A 104A and 7A 105A 3 Install new center seal on direct clutch housing with lip facing up 4 Install seal protector J 25010 Fig 7A 105A 6 NOTICE Use care when installing direct clutch piston HOUSING past larger direct clutch snap ring groove Groove could cut outer seal on piston Fig 7A 99A Removing or install
386. nchor pin Fig 7 25 FRONT GEAR PARTS Removal 1 Remove output shaft to turbine shaft front selective washer Fig 7A 26A This washer may be stuck to the end of the turbine shaft 2 Check Rear Unit end play as follows a Loosen J 25013 5 adjusting screw on output shaft and push output shaft downward Fig 7A 18A b Install gauge clamp on case as shown Fig 7A 27A c Install dial indicator J 8001 and plunger extension J 7057 Position extension against end of output shaft and set dial indicator to zero Fig 7A 27A d Move output shaft upward by turning adjusting screw on J 25013 5 until the white or scribed line on sleeve 1 25013 begins to disappear then read end play Rear unit end play should b 0 10 0 63mm 004 025 e Selective washer controlling this end play is located between the front internal gear thrust washer and output shaft snap ring If more or less washer thickness is required to bring end play within specifications select proper washer from the chart shown in Fig 7A 28A Fig 7A 26A Location of Front Selective Washer AUTOMATIC TRANSMISSION 200 7A 7 DIAL INDICATOR 18001 Fig 7A 27A Checking Rear Unit End Play REAR UNIT END PLAY CHART THICKNESS IDENTIFICATION Number and or Color 0 119 1 Orange 0 126 2 White 0 133 3 Yellow 0 140 4 Blue 0 147 5 Red 0 154 6 Brown 0 161 7 Green 0 168 8 Black 0 175 9 Purple Fig 7A 2
387. nd 4th speed clutch assembly 9 Install the rear bearing retainer over end of mainshaft Spread the snap ring to drop around the rear 2ND GEAR 1 2 SYNCHRO ASSEMBLY 15 GEAR BUSHING Fig 7B 21K Installing 1st Gear Sleeve MANUAL TRANSMISSION 7B 33 1ST GEAR REAR BEARING Fig 7B 22K Installing Rear Bearing bearing Release snap ring when it aligns with groove in rear bearing 10 Install the reverse gear shift collar to rear 11 Install a snap ring the speedometer drive gear and a second snap ring onto the mainshaft ASSEMBLY OF TRANSMISSION 1 Place the transmission case on its side with the shift cover opening toward the assembler Position the countergear tanged washers in place using a heavy grease to retain them NOTICE Be sure the tangs are in the notches of the thrust face 2 Install the countergear in the case aligning the bore of the countergear with the case opening With the thrust washers in place slide the loading tool to the front of the case and install the countergear shaft from the rear of the case Install the woodruff key and tap shaft into gear until shaft is flush with rear face of transmission case 3 Install front reverse idler gear teeth forward and thrust washer in case Use a heavy grease to hold thrust washer in position 4 Using a heavy grease install sixteen 16 roller bearings and washer into main drive gear Mate main drive gear with mainshaft assembly Posi
388. nd Toe end of tooth is smaller than heel end See Figure 17E Pattern Check 1 Wipe oil out of carrier and carefully clean each tooth of ring gear 2 Use gear marking compound and apply this mixture to ring gear teeth When properly applied the area of tooth contact will be clearly visible after load is applied 3 Tighten bearing cap bolts to specifications 4 Apply load to gears by expanding brake shoes or by wrapping a heavy rag around the companion flange to resist rotation NOTICE A test made without loading the gears will not give a satisfactory pattern Turn companion flange with wrench so that ring gear rotates one full revolution then reverse rotation so that ring gear rotates one revolution in opposite direction Excessive turning of ring gear is not recommended 5 Observe pattern on ring gear teeth and compare with figure 18 Make adjustments as outlined below 6 The important thing to achieve in the pattern check and subsequent adjustments is to locate the contact pattern centrally on the face of the ring gear teeth Pinion Depth Adjustment 1 The pinion depth shim may be replaced as necessary to place the drive at the correct depth See figure 18E 2 Depth shims are available from 006 inch to 024 inch in increments of 001 inch Backlash Adjustment 1 Remove locking retainers adjusting nuts 2 Move adjusting nuts an equal amount in or out to achieve proper backlash from side be
389. nd of reaction block A light tap on the yoke may be needed to seat it in the housing 5 Install left side reaction block on the yoke with flange side up Use original block unless severely scored or worn If new block is used determine face to face thickness of original block with calipers and replace with a service block of the same thickness NOTICE Right and left side reaction blocks may not be the same thickness If blocks are broken or cannot be accurately measured for thickness the entire differential must be replaced Incorrect block thickness will disturb critical clearances and may result in differential failure 6 Install governor assembly and latching barcket in their respective locations Place straight end of latching bracket spring over and to the outside of the governor shaft to preload the latching bracket against the governor assembly 7 Install the original 3 eared and 2 splined clutch plates on the left side gear alternately starting and ending with an eared disc NOTICE Original discs must be used Attempts to install other than original discs will disturb critical clearances and may result in differential failure 8 Install 6 clutch pack guide clips on the left side disc pack assembly using grease for retention 9 Install original shim in left side case half NOTICE Original shim must be used Attempts to install other than original shim will disturb critical clearances and may result in differ
390. nd seal and slide seal from rod 3 Remove vacuum check valve and grommet 4 Remove dust boot and silencer from operating valve rod 5 Remove dust guard retainer dust guard and silencers from rear plate hub with an awl Then reinstall steel retainer on hub 6 Squirt denatured alcohol down the operating valve rod to lubricate rubber grommet in the valve plunger 7 Position two small blocks of wood on either side of air valve rod and install end of air valve rod in vise leaving just enough clearance to position two 2 open end wrenches between the vise and retainer on hub of rear plate 8 Using the wrench nearest the vise as a pry force the air valve off the ball end of the rod DO NOT damage the plastic hub or allow vacuum cylinder to fall to the floor fig 5 1B and 5 2B 9 The edge of the rear housing contains twelve 12 lances Four 4 of these lances one in each quadrant are deeper than the other lances The metal that forms the four 4 deep lances must be partially straightened so that the lances will clear the cutouts in the front housing If the metal tabs that form the deep lances break during straightening the housing must be replaced fig 5 3B 10 Remove the hydraulic push rod and vacuum seal from the front housing Fig 5 1B Removing Air Valve Rod 11 Attach base of Holding Fixture J 22805 to front housing with nuts and washers and draw down tight to eliminate bending or damage to studs 12
391. ner Disengage the tabs of the spring retainer from the ledge inside the opening near the master cylinder mounting flange of the booster Remove the retainer the piston return spring and output rod from the opening fig 5 3E 7 Place the booster cover in a vise equipped with soft jawed devices Remove the five screws that secure the booster housing to the cover Fig 5 2E Removing Booster Pedal Rod Typical OVERHAUL MANUAL 5 24 BRAKES BAFFLE AND SPRING RETAINER d yon OUTPUT ROD PISTON RETURN SPRING Fig 5 3E Output Rod Spring and Retainer 8 Remove the booster assembly from the vise and while holding the unit over a pan separate the cover from the housing Remove the figure eight seal from the housing cover discard the seal 9 Remove the input rod and piston assembly the spool assembly and spool spring from the booster housing Compare spool valve condition to Figure 5 4E If spool valve is defective the complete unit must be replaced 10 Inspect power piston If scratches big enough to be felt with a fingernail are present the input rod and piston must be replaced 11 Remove the input rod seals from the input rod end and the piston seal from the piston bore in the housing discard the seals 12 Place the accumulator retaining cap Tool J 26889 over the master cylinder stud and install the nut as shown in Figure 5 6E 13 Using Tool J 22269 01 or a large C clamp 6 minimum depres
392. ner cup side down spring and washer on servo pin 2 Install 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 accumulator piston if removed and assemble into bore of servo piston CONTROL VALVE DISASSEMBLY INSPECTION AND RE ASSEMBLY Fig 7A 67C Disassembly 1 Position control valve assembly with cored face up and accumulator pocket nearest operator 2 Remove manual valve from upper bore 3 Install Special Tools J 22269 J 24675 on accumulator piston and remove retaining ring Fig 7 65C ACCUMULATOR PISTON Fig 7A 65C Installing Compressor Tool to Front Accumulator Piston 400 7 20 AUTOMATIC TRANSMISSIONS Ai D RETAINING E RING Y N OIL SEAL RING Y TEFLON l del NM Ee SPRING ACCUMULATOR PISTON A Fig 7A 66C Front Accumulator Assembly Exploded View 4 Remove front accumulator piston and spring Fig 7A 66C 5 On the right side adjacent to the manual valve remove the 1 2 valve train as follows a Models CG CJ and CP Remove retaining pin 1 2 modulator bushing 1 2 valve spring 1 2 modulator valve and 1 2 shift valve b All other models Remove retaining pin 1 2 modulator bushing 1 2 regulator valve 1 2 regulator spring 1 2 detent valve and 1 2 shift valve 6 From next bore down remove reta
393. new seal rings will return to their normal shape and fit freely in their bores 5 The teflon seal rings allow for a free fit in their bores after operation The free fit of the rings in their bores does not indicate leakage during operation Snap Rings Do not over expand snap rings when removing or installing Thrust Washer Surfaces The thrust washers and thrust bearings will polish the surfaces they protect This is not to be considered a damaged part because of this condition EXTERNAL PARTS REMOVAL 1 Remove oil pan and discard gasket 2 Remove oil screen and discard gasket Fig 7A 3A Fig 7 A 3A Removing Oil Screen OVERHAUL MANUAL THROTTLE LEVER amp BRACKET ASSEMBLY THROTTLE LEVER TO CABLE LINK Fig 7A 4A Removing Throttle Valve and Bracket Assembly The two oil screen attaching bolts are about 10mm 3 87 longer than the control valve assembly attaching bolts and they are not interchangeable 3 Control Valve Assembly a Remove throttle lever and bracket assembly Fig 7A 4A Do not bend throttle lever link T V exhaust valve lifter and spring may separate from throttle lever and bracket assembly b Remove manual detent roller and spring assembly Fig 7A 5A c Remove remaining control valve assembly attaching bolts NOTICE Do not drop manual valve or damage may occur d Holding manual valve with finger remove control valve assembly spacer plate and gaskets together to p
394. ng Pin from Case OVERHAUL MANUAL 400 7A 8 AUTOMATIC TRANSMISSIONS RETAINING SPRING f MANUAL Fig 7A 25C Removing Parking Shaft Retaining Spring SHAFT DETENT LEVER 5 Remove attaching screws and parking bracket Fig 7A 23C Fig 7A 22C Removing Detent Lever and Jam Nut from 6 Remove parking pawl return spring Fig 7A 24C Manual Shaft The following steps are to be completed only if 1 or more of the parts involved require replacement 3 Remove manual shaft and jam nut from case Fig 7A 22C Do not lose jam nut as it becomes free from manual shaft 8 Remove parking pawl shaft cup plug by inserting a screwdriver between the parking pawl shaft and the case rib and prying outwards Fig 7A 26C 7 Remove parking pawl shaft retainer Fig 7A 25C 4 Remove parking actuator rod and detent lever assembly 9 Remove parking pawl shaft and parking pawl Fig 7A 26C RETURN SPRING PARKING PAWL SHAFT Fig 7A 23C Removing Parking Bracket Fig 7A 26C Removing Parking Pawl Shaft and Cup Plug OVERHAUL MANUAL AUTOMATIC TRANSMISSIONS 400 7 9 Fig 7A 27C Removing Rear Oil Seal from Case Extension Removal of Rear Oil Seal and Case Extension and Front Unit End Play Check 1 If necessary to replace pry rear oil seal from case extension Fig 7A 27C 2 Remove case extension to case attaching bolts 3 Remove case extension to case gasket Fig 7A 28C 4 Make front u
395. ng Tools on Rear End of Case OUTPUT SHAFT PARKING PAWL OUTPUT SHAFT REAR CARRIER REAR INTERNAL GEAR Fig 7A 72A Installing Rear Carrier Into Rear Internal Gear Fig 7A 74A Installing Rear Unit Parts OVERHAUL MANUAL AUTOMATIC TRANSMISSION 200 7 19 LO amp REVERSE LO amp REVERSE CLUTCH LO amp REVERSE CLUTCH LO amp REVERSE HOUSING LO amp REVERSE CLUTCH APPLY SPRING STEEL CLUTCH ASSEMBLY PISTON SEALS RING RETAINER PLATE HOUSING LO amp REVERSE WAVE SNAP LO amp REVERSE RING TO CASE PISTON RELEASE RING COMPOSITION HOUSING SPACER ASSEMBLY SPRING FACED PLATE TO CASE Fig 7A 75A Low and Reverse Clutch Housing Exploded View 2 Remove waved spring Fig 7A 77A 3 Remove low and reverse clutch piston 4 Remove outer and inner piston seals Figs 7A 78A and 7A 79A 5 Remove clutch apply ring Inspection 1 Inspect low and reverse clutch housing for damage plugged feed hole 2 Inspect low and reverse clutch housing bushing for LO amp REVERSE damage or scoring CLUTCH HOUSING 3 Inspect low and reverse clutch splines and snap ring groove for damage or burrs Remove any burrs on splines or snap ring groove Fig 7A 76A Removing or Installing Low and Reverse Clutch Spring Retaining Snap Ring WAVE RELEASE LO amp REVERSE SPRING CLUTCH HOUSING LO amp REVERSE CLUTCH PISTON CLUTCH OUTER SEAL LIP UP Fig 7A 77 A Removing or Installing Low and Reverse Clutch Fig
396. ng adjusting nuts using J 24429 as shown in figure 3E 7 Remove differential from carrier Side Bearing Replacement 1 Install bearing puller J 8107 onto one side bearing with puller screw centered on pilot plug as shown in figure 4E Be sure to install puller fingers into notches of case in order to pull on inner race only 2 Tighten puller screw while rotating bearing to insure that bearing cage is not being distorted 3 Remove the other bearing in the same manner OVERHAUL MANUAL 4 14 AXLE DIFFERENTIAL Fig 2E Cover Removed from Carrier 4 Inspect bearings and hub for nicks burrs or evidence of abnormal wear 5 To install bearings place bearing onto hub and use driver handle J 8092 and bearing installer J 24430 to drive bearing onto hub until it seats against the shoulder 6 When installing the second bearing support case on pilot plug as shown in figure 5E to prevent damage to first bearing installed Ring Gear Replacement 1 Remove the ring gear bolts and lock washers and use a soft faced hammer to tap the ring gear from the case 2 Place new ring gear into position on case and install lock washers and bolts 3 Torque bolts alternately to specifications Disassembly of Case 1 Mark the case and cover halves with a scribe line for reassembly in the same position 2 With ring gear removed separate case and cover 3 Remove the internal parts and keep separated so they may
397. ng outer seal 4 Using flat edged small screwdriver or piston installing tool shown in Fig 7A 107A install low and reverse clutch piston while rotating and pushing down into place Fig 7A 80A 5 Remove seal protector J 25011 6 Install waved release spring Fig 7A 77A 7 Install retainer cupped faced down 8 Compress retainer and install snap ring Fig 7A 76A Installation 1 Oil and install the lo and reverse clutch plates into the case starting with a flat steel and alternating composition faced and flat steel clutch plates See Clutch Plate Usage Chart Fig 7A 82A 2 Install low and reverse clutch housing to case spacer ring in case Fig 7A 81A 3 Install low and reverse clutch housing assembly aligning reverse clutch housing feed hole to reverse clutch case feed passage using J 25012 Fig 7A 83A If the low and reverse clutch housing does not seat past the case snap ring groove proceed as follows a Remove tool J 25012 b Using rear sun gear and input drum as a tool install input drum and rear sun gear in case c Rotate rear sun gear back and forth tapping lightly with input drum to align roller clutch race and low and reverse clutch hub splines Fig 7A 84A d Remove tool input drum and rear sun gear It may be necessary to loosen adjusting screw on J 25013 5 on output shaft to install snap ring e Repeat the above steps if low and reverse clutch housing is not fully seated pa
398. ng picks such as J 23432 1 remove the gear retaining ring from the shaft Fig 7D 5R and discard 6 Remove thrust washer and pin from shaft 7 Remove gear needle bearings 32 per row and spacer 8 If necessary to replace front output shaft rear T HANDLE W z 2 EASY OUT WELDED ON END Fig 7D 6R Removing Shift Fork Pins TRANSFER CASES 70 3 RANGE SHIFT RAIL 4 WHEEL SHIFT RAIL 4 WHEEL SHIFT RAIL Fig 7D 7R Shift Rail Removal bearing support cover and press bearing from cover Position new bearing to outside face of cover and using a piece of pipe or wood to cover outside diameter of bearing press bearing into cover until flush with opening Shift Rail and Fork Assemblies 1 Remove the two poppet nuts on top of case two poppet springs and using a magnet remove the poppet bails 2 Drive cup plugs into case using a 1 4 inch punch 3 Position both shift rails in neutral and using a long narrow punch drive shift fork pins through shift rails into the case Fig 7D 6R 4 Remove clevis pins and shift rail link 5 Remove shift rails Fig 7D 7R upper range rail first then lower 4 wheel rail 6 Remove shift forks and sliding clutch from case 7 Remove the front output high gear wahser and bearing from the case Remove the shift rail cup plugs and pins from the case Input Shaft Assembly 8 Remove snap ring in front of bearing Using a soft hammer tap shaft out rear of case Ta
399. nge of the housing center hole fits into the groove of the power piston bearing The thin lip of the bearing will protrude to the outside of the housing 29 Coat the I D of the power piston bearing with silicone lubricant Final Assembly Fig 5 10A 1 Mount Tool J 23456 in vise and position rear housing in tool Retain rear housing with two nuts 2 Install the power piston assembly to the rear housing by pressing the tube of the power piston through the rear housing bearing Press down until the housing divider seats in the rear housing and the power piston bottoms against the housing 3 Install power piston return spring over reaction body retainer 4 Lower front housing over rear housing and position bar on front housing Be sure scribe marks are aligned 5 Tighten down on front housing and fit the tangs in the appropriate slots on the rear housing 6 Rotate the bar clockwise into locked position Remove bar from front housing Stake housing interlocks at 2 new locations 180 apart fig 5 9A Gaging 1 Insert the master cylinder piston rod flat end first into the piston rod retainer 2 Press down on the master cylinder piston rod with approximately a 40 50 pound load to be sure it is properly seated 3 Remove the front housing seal to assure that no vacuum is in the power head while gaging 4 Place Gage J 22647 over the piston rod in a position which will allow the gage to be slipped to the left or
400. ngs making sure cut ends are assembled in the same relationship as cut Fig 7A 120A Also make sure rings are seated in the grooves to prevent damage to the rings during reassembly of mating part over rings Retain with petrolatum 9 Install pump to case seal ring chamfered side out making sure the ring is not twisted 10 Install pump to direct clutch thrust washer and retain with petrolatum Fig 7 127 11 Remove holding bolt or screwdriver 12 Install new pump to case gasket on pump and retain with petrolatum 13 Install 2 pump to case alignment pins in case as shown in Fig 7 138 Before installing pump make sure intermediate band anchor pin lug is aligned with band anchor pin hole in case 14 Install pump assembly and finger start pump to case bolts and new washers except one bolt hole Fig 7A 139A which will be used to make the front unit end play check NOTICE If turbine shaft cannot be rotated as pump is being pulled into place the forward or direct clutch housings have not been installed properly to index with all the clutch plates This condition must be corrected before pump is pulled fully into place 15 Replace 2 alignment pins with 2 bolts and new washers 16 Torque pump to case bolts to 20 0 27 0 m 15 20 ft Ibs Make sure turbine shaft rotates freely Check Front Unit End Play Fig 7A 139A 1 Install 278mm 11 bolt and locking nut as shown in Fig 7A 139A 2 Push turbine
401. ning the special washer against two opposite sides of the hex head screw using vise grip pliers Form a portion of the lock washer down over the pulley rim or over the Inertia Ring slot to secure the screws in place DO NOT move the screw heads from the torqued position See Figure 1D 92 17 Install the Clutch Hub and Drive Plate as described in R 4 Compressor Clutch Plate and Hub Assembly Replacement procedures 18 Install the compressor drive belt and adjust for proper tension 19 Operate the air conditioning system to check for proper operation MAJOR R 4 COMPRESSOR REPAIR PROCEDURES Service repair procedures to the Compressor Shaft Seal Pressure Relief Valve Pressure Switch or disassembly of the Internal Compressor Cylinder and Shaft Assembly are considered Major since the refrigeration system must be completely purged of refrigerant before proceeding and or because major internal operating and sealing components of the compressor are being disassembled and serviced When replacing the shaft seal assembly see Fig 1D 20 pressure relief valve see Figure 1D 102 or Pressure Switch see Figures 1D 27 and 1D 102 even if the compressor remains on the vehicle during the operation it will be necessary to purge the system of refrigerant as outlined in the air conditioning section see Discharging Adding Oil Evacuating and Charging Procedures for C C O T A C Systems The same holds true for any AIR CONDITIONING COMPR
402. nion gear sets are matched in a special test machine which permits adjustment of pinion depth in ring gear until a point is reached where best operation and proper tooth contact under load is obtained At this point the setting of the pinion with reference to the centerline of the ring gear is indicated by the machine This setting may vary slightly from the design or nominal setting due to allowable variation in machining the parts When a pinion is found haivng a plus or minus reading recorded in OVERHAUL MANUAL 4B 6 REAR AXLE DIFFERENTIAL A SERVICE SPACER B SERVICE SHIM C FEELER GAUGE BEARING CARRIER Tool J 22779 RING GEAR EXAMPLE RING GEAR SIDE OPPOSITE SIDE Thickness of Tool J 22779 Combined total of 250 required to force ring Service Spacer A 265 gear into contact with Service Shim B 3 pinion Feeler Gauge C 5 TO MAINTAIN PROPER BACKLASH 005 008 ring gear is 010 0 3 po R 010 2407 moved away from pinion subtracting 010 shims from ring gear 275 side and adding 010 shims to other side 004 TO OBTAIN PROPER PRELOAD side bearings add 004 shims 004 to each side 244 Shim dimension required Shim dimension required 279 for ring gear side for opposite side Fig 7B Determining Side Bearing Shim Requirements OVERHAUL MANUAL Fig 8B Measuring Gage Plate Thickness thousandths on the rear face of the pinion this indicates
403. nit end play check as follows Fig 7 29 Remove one front pump attaching bolt and bolt washer See Fig 7A 29C for location b Install a 3 8 16 threaded slide hammer bolt or J 9539 into bolt hole c Mount a dial indicator on rod and index indicator to register with end of turbine shaft GASKET Fig 7A 28C Case Extension and Gasket DIAL INDICATOR J 8001 Fig 7A 29C Checking Front Unit End Play d Push on turbine shaft rearward e Push output shaft forward f Set dial indicator to Zero g Pull turbine shaft forward Read resulting travel or end play Should be 003 024 Selective washer controlling this end play is the washer located between pump cover and forward clutch housing If more or less washer thickness is required to bring end play within specifications select proper washer from the chart shown in Fig 7A 30C An oil soaked washer may tend to discolor so it will be necessary to measure washer for its actual thickness FRONT END WASHER THICKNESS Thickness Number Color 060 064 0 Yellow 071 075 1 Blue 082 086 22 5 Red 093 097 3 104 108 4 115 119 5 Black Brown Green 126 130 6 Fig 7A 30C Front End Washer Selection Chart OVERHAUL MANUAL 400 7A 10 AUTOMATIC TRANSMISSIONS Fig 7A 33C Removing Forward Clutch Assembly and Turbine Shaft Fig 7A 31C Removing Front Seal and Internal C
404. nizer spring should be installed into different key cavities on either side Slide the sleeve onto the hub aligning the marks made before disassembly A groove around the outside of the synchronizer 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 greater recess depth Fig 7 B 7 A Removing 2nd 3rd Clutch Hub Retaining Ring OVERHAUL MANUAL Fig 7B 8A Removing Rear Bearing Retaining Ring Extension Oil Seal or Bushing If bushing in rear of extension requires replacement remove seal and use Tool J 5778 to drive bushing into extension housing Fig 7B 11A Using the same tool drive new bushing in from the rear Coat I D of bushing and seal with transmission lubricant then install new oil seal using Tool J 21426 or J 5154 Fig 7B 12A Clutch Bearing Retainer Oil Seal If the lip seal in the reatiner needs replacement pry the old seal out Fig 7 13 and replace with a new seal using Installer Tool J 23096 or similar tool until seal seats in its bore Fig 7B 14A Fig 7B 9A Removing Rear Bearing From Mainshaft Fig 7B 10A Synchronizer Assembly ASSEMBLY OF MAINSHAFT FIG 7B 15A Turn the front of the mainshaft upward Install the following components of the mainshaft 1 Install the second speed gear with clutching teeth upward the rear face of the gear will butt against the flange on the mainshaft 2 Inst
405. nizer cone on pilot end of mainshaft and slide rearward to clutch hub Make sure three cut out sections of 4th speed synchronzier cone align with three clutch keys in clutch assembly 6 Install snap ring on drive gear bearing O D Index cut out portion of drive gear teeth to obtain clearance over countershaft drive gear teeth and install clutch gear assembly onto case Raise mainshaft to get clutch gear started and tap bearing outer race with plastic tip hammer 7 Install drive gear bearing retainer using a new gasket Install bolts and tighten to 15 18 ft Ibs 8 Install appropriate tool in countergear front bearing opening in case to support countergear and rotate case onto front end Fig 7B 24L 9 Install snap ring on countergear rear bearing O D position bearing on countergear and using Tool J 22874 1 drive bearing into place Fig 7B 25L Rotate case install snap ring on countershaft at rear bearing and then remove Tool J 22874 1 10 Tap countergear front bearing assembly into case 11 Install countergear front bearing cap and new gasket Torque screws to 20 30 lbs 12 Slide speedometer drive gear over mainshaft to bearing 13 Install rear bearing retainer with new gakset Be sure snap ring ends are in lube slot and cut out in bearing retainer Install bolts and tighten to 15 18 ft lbs Install brake backing plate assembly on models equipped with propeller shaft brake On models equipped with 4 wheel
406. not turn counter clockwise after installation See Figure 7A 108C INTERMEDIATE CLUTCH OUTER RACE ROLLER ASSEMBLY INTERMEDIATE CLUTCH Fig 7A 107C Installing Intermediate Clutch Outer Race to Direct Clutch Fig 7A 108C Intermediate Roller Clutch Rotation 13 Install intermediate clutch retainer and snap ring Fig 7A 109C and 7A 110C 14 Place direct clutch assembly over center support and air check operation of direct clutch Fig 7A 111C 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 normal Apply air through left oil feed hole to actuate piston and move direct clutch plates DISASSEMBLY INSPECTION AND RE ASSEMBLY OF CENTER SUPPORT Disassembly 1 Remove four 4 oil seal rings from the center support Fig 7A 112C Fig 7A 109C Installing Intermediate Clutch Retainer AUTOMATIC TRANSMISSIONS 400 7A 35 snap RING CLUTCH RETAINER Fig 7A 110C Installing Intermediate Clutch Retainer Snap Ring Fig 7A 112C Center Support and Oil Seal Rings 400 7A 38 AUTOMATIC TRANSMISSIONS INTERMEDIATE CLUTCH RELEASE SPRING 3 Fig 7A 113C Removing Intermediate Clutch Piston Snap Fig 7A 115C Removing Clutch Release Springs Ring 2 Compress spring retainer and remove snap ring 7A 4 Remove intermediate clutch spring guide Fig 7A 113C 116C 3 Remove spring ret
407. nstalling Clutch Bearing Retainer Seal TABBED THRUST WASHER SHARP EDGE MUST FACE OUT Fig 7B 18B Installing Tabbed Thrust Washer 2 Install First Reverse sleeve and gear half way onto hub with gear end of sleeve facing rear of shaft Index sleeve to hub with marks made during disassembly 3 Install spring in First Reverse hub Make sure spring is bottomed in hub and covers all three key slots Position three synchronizer keys in hub with small ends in hub slots and large ends inside hub Push keys fully into hub so they seat on spring Then slide First Reverse sleeve and gear over keys until the keys engage in the synchronizer sleeve Fig 7B 13B 4 Place first gear blocking ring on tapered surface of gear Install First gear on output shaft Rotate gear until notches in blocking ring engages keys in First Reverse hub 5 Install tabbed thrust washer sharp edge facing out and retaining snap ring on output shaft Fig 7B 18B SECOND GEAR BLOCKING RING Fig 7B 19B Installing Second Gear MANUAL TRANSMISSION 78 15 Fig 7B 20B Measuring Output Shaft End Play 6 Place second gear blocking ring on tapered surface of gear and install second gear on output shaft with tapered surface of gear facing front of output shaft Fig 7B 19B 7 Install Second Third synchronizer assembly with flat portion of synchronizer hub facing rearward on output shaft Rotate Second gear until notches in blocking ring en
408. o 5 Newton Metres E 2 al 4 Ft Lbs Install Pitman shaft bearing Install Pitman shaft seals Fig 3B3 10C Overhaul 800 and 808 Gears Chart E OVERHAUL MANUAL STEERING 3B 17 11 REMOVE AND INSTALL CONNECTORS amp CHECK VALVE REMOVE 13 PITMAN SHAFT OVER CENTER SECTOR ADJUSTMENT INSTALL 1 Remove parts as shown 1 Install parts as shown NOTICE Some models Installer J 6217 will not use connectors Remover 4 check valve or spring Screw Extractor Tangs on check valve to be pointing down When gear is on center flat on stub shaft is normally on same side as INVERTED 2 and parallel with side cover FLARE Spring should be seated in counter bore of port A Using spanner wrench J 7624 tighten adjuster plug until thrust bearing is firmly bottomed 27 Newton Metres 20 Ft Lbs Mark housing and face of adjuster Turn adjuster counterclockwise until mark on face of adjuster lines up with second mark on housing CONNECTORS en EI CHECK VALVE 2 SPRING Measure back counterclockwise 13 mm and place a second mark on housing Using punch in notch tighten lock nut securely Hold adjuster plug to maintain alignment of the marks The block tooth on the Pitman shaft is in line with the over center preload adjuster B Back off preload adjuster C Turn adjuster in until until it stops then turn it in one full turn With gear
409. obtained 3 Back off the left adjusting nut approximately two slots Install locking fingers into holes and fasten fingers to bearing cap 4 Tighten right adjusting nut firmly to force the case into solid contact with the left adjusting nut 5 Loosen right adjusting nut until it is free from its bearing then retighten until it contacts the bearing 6 Tighten right adjusting nut approximately two slots if used bearings are being installed or three slots if new bearings are being installed 7 Install locking retainer into holes and attach fingers to bearing cap 8 Torque bearing cap bolts to specifications At this point the differential bearings are properly preloaded If any additional adjustments are required in the following procedures make sure that the preload remains as established If one adjusting nut is loosened the other nut must be tightened an equal amount to maintain this preload 9 Mount a dial indicator on the housing and measure the backlash between the ring gear and pinion Backlash should be from 003 to 012 with 005 to 008 preferred Refer to figure 6E If backlash is more than 012 loosen the right adjusting nut one slot and tighten left adjusting nut one slot If backlash is less than 003 loosen the left adjusting nut one slot and tighten the right adjusting nut one slot Fig 7E Removing Retainer Bolts DRIVE PINION ASSEMBLY Removal 1 Remove differential as previously outlined
410. oded 400 7A 34 AUTOMATIC TRANSMISSIONS DIRECT CLUTCH BACKING PLATE FLAT STEEL PLATES E COMPOSITION PLATES L o A WAVED STEEL PLATE Fig 7A 104C Install Direct Clutch Backing Plate Composition Plates and Steel Plates followed alternately by four 4 composition plates and three 3 flat steel plates Fig 7A 104C b Models CB CD and CL Oil and install six 6 composition and six 6 flat steel plates starting with a flat steel plate and alternating composition and flat steel clutch plates 9 Install clutch backing plate 10 Install backing plate retaining snap ring Fig 7A 105C Install rollers that may have come out of the roller cage by compressing the energizing spring with forefinger and inserting the roller from the outer side DIRECT CLUTCH BACKING PLATE r a DIRECT CLUTCH HOUSING Fig 7A 105C Installing Direct Clutch Housing to Backing Plate Snap Ring INTERMEDIATE CLUTCH ROLLER ASSEMBLY DIRECT CLUTCH HOUSING AND CAM ASSEMBLY Fig 7A 106C Installing Intermediate Clutch Roller Assembly 11 Turn unit over and install the intermediate clutch roller assembly onto the intermediate clutch inner cam fig 7 106 12 Install the intermediate clutch outer race with a clockwise turning motion fig 7A 107C Intermediate roller clutch is not released for the CB CD and CL models The sprag assembly is released for these models Outer race should
411. oe coven WORM BEARING SS ADJUSTER LOCKNUT iA PRELOAD ADJUSTER SHIM WORM BEARING e ADJUSTER PRELOAD ADJUSTER LOWER WORM 1 BEARING CUP LOWER WORM BEARING LOWER BEARING RETAINER PITMAN SHAFT BALL NUT d WORMSHAFT SIDE COVER GASKET UPPER WORM eg E HOUSING KA STONE SHIELD g ADAPTER 7 BALLS e COUPLING LL PINCH BOLT BALL GUIDE BALL GUIDE CLAMP UPPER WORM CLAMP SCREWS BEARING CUP PITMAN SHAFT SEAL e WORM SHAFT SEAL e STEERING SHAFT COUPLING Fig 3B2 1 Manual Gear Exploded View OVERHAUL MANUAL 3B 2 STEERING REMOVE AND INSTALL WORM SHAFT SEAL GEAR ASSEMBLED REMOVE Wrap0 1mm to 0 2 mm 1 005 to 0087 shim stock around shaft and insert between shaft and seal Pry seal out INSTALL Install parts as shown J 21421 01 SCREWDRIVER WORM SHAFT WORM SHAFTS SEAL SHIM STOCK WORM SHAFT SEAL Love rr Install seal NOTICE Do not turn steering wheel hard against stops when linkage is disconnected 2 REMOVE AND INSTALL PITMAN SHAFT AND SIDE COVER REMOVE INSTALL Before installing turn preload adjuster screw counter clockwise until it bottoms then back screw off one half turn 2 Install parts as shown 1 Center steering gear 1 2 Remove parts as shown PRELOAD ADJUSTER NUT ut replacing gasket only do not remove d COVER BoLTS i amp sot cover mon e TER 2 22 ADJUS SHIM
412. of the right hand axle tube In addition the three digit axle code appears on astrip of tape attached to the outboard end of the axle tube 5 Check fit of differential side gears in case Differential Bearing Replacement 1 Install Tool J 22888 and Adapter Plug J 8107 4 assuring puller legs are fitted securely in notches in case and against bearing cone as shown in figure 3B 2 Tighten puller screw to remove bearing 3 Place new bearing on hub with thick side of inner race toward case and drive into place using J 22175 for 8 7 8 or J 22761 for 8 1 2 ring gear and Driver Handle J 8092 as shown in figure 4B 4 Before bearing installation on opposite hub support differential case on Adapter Plug J 8107 4 This allows differential case to rest on adapter instead of bearing cage See figure 4B Install remaining bearing as instructed in step 3 OVERHAUL MANUAL Ring Gear or Differential Case Replacement 1 Remove the ring gear bolts and using a soft drift and a hammer tap ring gear off the case NOTICE Do not attempt to pry ring gear from case To do so may damage machined surfaces 2 Remove any nicks or imbedded dirt from case flange surface which mates with ring gear Clean all surfaces 3 Liberally coat the differential case pilot with hypoid lubricant Pre align ring gear and differential case bolt holes and press on adaptor plug J 8107 4 to initially start ring gear on case pilot as shown in figure 5B
413. of the ring gear teeth Adjustments Affecting Tooth Contact Two adjustments can be made which will affect tooth contact pattern These adjustments are backlash and position of drive pinion in carrier The effects of bearing preloads are not readily apparent on hand loaded teeth pattern tests however these adjustments should be within specifications before proceeding with backlash and drive pinion adjustments It may be necessary to adjust both pinion depth and backlash to obtain the correct pattern The position of the drive pinion is adjusted by increasing or decreasing the shim thickness of the inner shim located between the rear bearing cup and the carrier housing Increasing the shim thickness will move the pinion closer to centerline of the ring gear Decreasing shim thickness will move pinion farther away from centerline of the ring gear OVERHAUL MANUAL 4B 26 REAR AXLE DIFFERENTIAL TOE CONTACT INCREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM LOW FLANK CONTACT DECREASE PINION SHIM HEEL CONTACT DECREASE BACKLASH Fig 13F Gear Teeth Contact Pattern Check Backlash is adjusted by means of the side bearing adjusting shims which moves the entire case and ring gear assembly closer to or farther from the drive pinion The adjusting shims are also used to set side bearing preload To increase backlash increase right shim and decrease left shim an equal amount To decrease backlash decrease right shim
414. olts retaining front output shaft front bearing retainer Fig 7D 4S Remove bearing retainer and gasket from transfer case Discard gasket 5 Using a hoist or other suitable lifting tool position assembly on blocks Fig 7D 5S OVERHAUL MANUAL 6 Remove bolts retaining rear section of rear output housing from front section of rear output housing and disengage Remove shims and speedometer gear from output shaft INPUT GEAR FRONT OUTPUT SHAFT ASSY CHAIN HOUSING RANGE SELECTOR HOUSING COUNTER GEAR Fig 7D 1S Front View of Transfer Case LOCKOUT CLUTCH SHIFT RAIL KSE PLUG REAR OUTPUT HOUSING RANGE SELECTOR N amps e Ze SHIFTER SHAFT 7 ke CHAIN HOUSING FRONT OUTPUT BEARING REAR COVER REAR OUTPUT SHAFT ASSY Fig 7D 2S Rear View of Transfer Case a Remove bolts retaining front section of rear output housing assembly from transfer case Remove housing from case b Remove O ring seal from front section of rear output housing and discard c Disengage rear output shaft from differential carrier assembly 7 Slide carrier unit from shaft NOTICE A 1 1 2 to 2 water hose band type clamp may be installed on the input shaft at this time to prevent loosening bearings when removing input shaft assembly from the range box 8 Raise shift rail and drive out pin retaining shift fork to rail Fig 70 68 9 Remove shift rail poppet ball plug gasket spring and ball from case Fig 7D 7S A
415. on points with power steering fluid Whenever the booster is disassembled and all disturbed seals and damaged tube inserts should be replaced All of these parts are included in a kit If any of the accumulator valve components are damaged or lost replace all the valve components 1 Clean all metal parts in a suitable solvent Be careful to avoid losing small parts 2 Inspect the valve spool and the valve spool bore in the housing for corrosion nicks scoring or other damage Discoloration of the spool or bore particularly in the grooves is not harmful and is no cause for replacement 3 If the valve spool or the valve spool bore has nicks or scoring that can be felt with a fingernail particularly on the lands the entire booster should be replaced as an TWO DUMP RING FUNCTION VALVE VALVE HOUSING Fig 5 8E Accumulator Valves BRAKES 5 25 BOOSTER MASTER CYLINDER Fig 5 9E Spool Valve Plug Removal assembly NOTICE The clearance between the spool valve and the spool valve bore of the housing assembly is important Because of this the valve spool valve and the housing assembly make up a selective assembly The spool valve is selected to match the spool valve bore 4 Inspect the piston for scratches nicks etc If scratches on the outside diameter can be felt with a fingernail the input rod and piston must be replaced Assembly 1 Install tube seat with Tool J 6217 as shown i
416. onnector assemblies and compressor capacitires none of which will affect the following Overhaul Procedures When servicing the compressor it is essential that steps be taken to prevent dirt or foreign material from getting on or into the compressor parts and system during disassembly or reassembly of the compressor CLEAN TOOLS AND CLEAN WORK AREA ARE VERY IMPORTANT FOR PROPER SERVICE The compressor connection areas and Assembly On Car 1D 30 Replace Rotor and Bearing Assembly On Bench 1D 31 R 4 Compressor Clutch Coil and or Pulley Rim eem 1D 32 R 4 Compressor Inertia Ring Installation 1D 32 Major R 4 Compressor Repair Procedures eemper rr 1D 34 RA Compressor Shaft 1D 35 Seal Leak Detection oes 1D 35 R 4 Compressor Shaft Seal Replacement On 1D 35 R 4 Compressor Shaft Seal Replacement Off 1D 37 R 4 Compressor Pressure Relief Valve or Pressure Switch sss 1D 37 R 4 Compressor Front Head and or O Ring csoma aiaa 1D 37 R 4 Compressor Thrust and Belleville Washers eese 1D 39 RA Compressor Main 1D 39 R 4 Compressor Shell and or TEE 1D 39 R 4 Compressor Discharge Valve Plate and or
417. ont Servo Piston Washer and Pin ocate feeler stock ee GUIDE 52 on edge of front servo i piston so front accumulator iston can enter bore Fig 7A 177C Front Servo Group In Vehicle Installation during operation The teflon ring should only be replaced if it shows damage or if evidence of leakage during operation exists If transmission is in the vehicle assemble front servo group as shown in Figure 7A 61C and install this group of parts into front servo bore in case and hold Slip a length of straight clean feeler gage or shim stock about 020 between spacer plate and front servo piston to temporarily retain front servo group Figure 7A 177C 10 Install O ring seal on electrical connector 11 Lubricate and install electrical connector with lock tabs facing into case positioning locator tab in notch on side of case Fig 7A 178C 12 Install detent wire to electrical connector Fig 7A 12C Fig 7A 178C Installing Electrical Connector and OQ Ring Seal AUTOMATIC TRANSMISSIONS 400 7A 55 REAR SERVO ASSEMBLY Fig 7A 179C Checking Rear Band Pin Installation of Rear Servo Assembly 1 Check rear servo band apply pin Fig 7A 179C a Attach band apply pin selection Gage J 21370 6 and J 21370 5 to transmission case lever pivot pin to rear with attaching screws Attach tool attaching screws finger tight and check freeness of selective pin Torque attaching screws to 15 ft
418. oper preload on the pinion bearing a 4 ON 8 Bolt Differential Bearing Bolt Ring Gear Pinion Shaft Thrust Washer Pinion Pinion Cover and Plug Lock Pin Pinion Shaft Differential Case Shims Differential Adjusting Cone and Roller Differential Bearing Side Gear Cup Differential Thrust Washer Side Bearing Gear Cap Differential Bearing Fig 14F Dana Differential With 9 3 4 Ring Gear Exploded View DIFFERENTIAL CASE Removal 1 Place vehicle on hoist with rear axle hanging free 2 Remove wheel and tire assemblies 3 The axle shafts are full floating type with flanged outer end of shaft attached to wheel hub by studs and nuts Wheel 1s supported by tapered roller bearings at outer end of axle housing a Remove axle shaft to hub attaching nuts b Rap on axle shaft to loosen shaft from hub and remove shafts 4 Remove plug in carrier and drain lubricant 5 Remove cap screws and lock washers attaching cover to carrier Remove cover and gasket 6 Mark one side of carrier and matching cap for reassembly Remove cap screws attaching bearing caps to carrier 7 Using spreader Tool J 24385 and dial indicator as shown in figure 15F spread carrier a maximum of 020 NOTICE Do not exceed this dimension as carrier may be permanently damaged OVERHAUL MANUA 4B 28 REAR AXLE DIFFERENTIAL Fig 15F Tool J 24385 Mounted on Carrier 8
419. or rough holes Worn seal surfaces Replace tubes Rough or uneven floating Replace valve seat Open passages and flow Clean holes Reaction Levers or Plates Cracks distortion tears Replace and heavy wear Floating Control Valve Deterioration of rubber Replace or warped valve face Air Valve Push Rod Air valve scratches Do not repair Replace Assembly dents distortion or corrosion of 1 0 or O D All seats to be smooth and free of nicks and dents Push rod must move freely If worn replace air valve in air valve but must not push rod assembly pull out Front and Rear Housings Scratches scores pits Replace unless easily repaired dents or other damage affecting rolling or seal ing of diaphragm or other seals Cracks damage at ears Replace unless easily repaired damaged threads on studs Bent or nicked locking Replace unless easily repaired lugs Loose studs Replace or repair Air Filters Dirty Replace OVERHAUL MANUAL INSTALLER J 21601 POWER PISTON Fig 5 11C Installing Floating Control Valve Assembly 17 This assembly can now be turned over and placed SUPPORT PLATE POWER PISTON SUPPORT PLATE REMOVER AND INSTALLER J 21524 Fig 5 12C Installing Support Plate on Power Piston BRAKES 5 17 tube down in a tool fabricated from a piece of wood 2 x 4 x 8 long with a 1 3 8 hole in the center clamped
420. orn washers Fig 7B 3A Removing Reverse Idler Shaft E Ring Fig 7B 4A Removing Rear Extension From Main Shaft Gears 1 Inspect all gears for excessive wear chips or cracks and replace any that are worn or damaged 2 Inspect reverse gear bushing and if worn or damaged replace the entire gear Reverse gear bushing is not serviced separately 3 Check both clutch sleeves to see that 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 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 machined the bushing is not serviced separately Fig 7B 5A Removing Counter Gear Shaft OVERHAUL MANUAL 7B 4 MANUAL TRANSMISSION Fig 7B 6A Removing Reverse Idler Shaft REPAIRS Clutch Keys and Springs Replacement The clutch hubs and sliding sleeves are a selected assembly and should be kept together as originally assembled but the keys and two springs may be replaced if worn or broken 1 Mark hub and sleeve so that they can be matched upon reassembly 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 each side of hub so all three keys are engaged by both springs Fig 7B 10A The tanged end of each synchro
421. orque fixture holding screw Cleanliness is an important factor in the overhaul of the transmission Before attempting any disassembly operation the exterior of the transmission should be throughly cleaned to prevent the possibility of dirt entering the transmission internal mechanism During inspection and reassembly all parts should be thoroughly cleaned with cleaning fluid and then air dried Wiping cloths or rags should not be used to dry parts NOTICE Do not use solvents on neoprene seals composition faced clutch plates or thrust washers or damage may occur Teflon Seals If any teflon seal rings are damaged distorted cut scored etc or do not rotate freely in their groove and replacement is necessary do the following 1 Remove and discard old angle cut seal rings full circle rings must be cut off 2 Inspect seal ring groove for burrs or damage 3 When installing angle cut seal rings do not over stretch Make sure cut ends are in same relation as cut Fig Fig 7A 1A Transmission Holding Fixture OVERHAUL MANUAL 200 7 A 2 AUTOMATIC TRANSMISSION Fig 7A 2A Teflon Oil Seal Rings 7 2 Also make sure rings are seated in the grooves to prevent damage to the rings during reassembly of mating part over rings Retain with petrolatum 4 New angle cut or full circle teflon seal rings may appear to be distorted after being installed Once exposed to normal transmission oil temperatures the
422. oseness or breakage 7 Inspect second gear synchronizing ring for excessive wear 8 Inspect bronze synchronizer cone on 2nd speed gear for excessive wear or damage Also inspect clutch gear synchronizer cone and third speed gear synchronizer cone for excessive wear or damage 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 up on front end of half tooth internal splines and remove by honing as necessary SNAP RING Fig 7B 8L Drive Gear Assembly OVERHAUL MANUAL Fig 7B 9L Positioning Tool J 22872 to Drive Gear 9 Inspect all gear teeth for excessive wear Assembly 1 Using Tool J 22873 press 2nd speed bushing onto mainshaft until it bottoms against shoulder Fig 7B 16L Lubricate bushing with E P oil before pressing NOTICE 1st 2nd and 3rd speed gear bushings are sintered iron exercise care when installing or damage may occur 2 Press 151 and 2nd speed synchronizer hub onto mainshaft until it bottoms against shoulder with annulus toward rear of shaft 3 Install 1st and 2nd synchronizer keys and springs if previously removed 4 Using Tool J 22873 press lst speed gear bushing onto mainshaft until it bottoms against hub Fig 7B 17L Lubricate all bushings with E P oil before installation of gears MANUAL TRANSMISSION 7 41 J 2
423. ot pounds of torque Be sure to index cap to case with alignment marks and that oil return slot in cap is aligned with oil return hole in case 28 Install large snap ring on rear bearing 29 Install rear bearing on output shaft by hand Drive bearing onto shaft and into case with tool J 22609 make sure snap ring groove is facing rear of shaft Fig 7B 23B 30 Install smaller snap ring on output shaft to hold rear bearing in place 31 Engage speedometer gear retainer in hole provided in output shaft with retainer loop forward slide speedometer gear over output shaft and into position Fig 7B 24B 32 Position extension housing gasket on case and install extension housing to case Tighten bolts to 42 to 50 foot pounds torque 33 Install expansion plug in Second Third shift rail bore in front of case Be sure plug is fully seated in bore and is approximately 1 16 inch below front face of case 34 Install upper detent plug in detent bore then install long detent spring on top of plug Install transmission fill plug and tighten 10 to 20 foot pounds torque 35 Install top cover and gasket on case and secure with attaching bolts Tighten bolts 20 to 25 foot pounds torque 4 SPEED 76MM TRANSMISSION INDEX Disassembly of Transmission sees 7B 17 7 20 Disassembly of Mainshaft 1 7B 19 Clutch Keys and Springs Replacement
424. ould want to add 003 more shims than would be required if the pinions were etched O By adding 003 shims the mounting distance of the pinion was decreased 003 which is just what a 3 etching indicated See figure 20F If the old ring and pinion set is to be reused measure the old shim pack and build a new shim pack to this same dimension If baffle is in the axle assembly it is considered as part of the shim pack To change the pinion adjustment shims are available in thicknesses of 003 005 and 010 NOTICE If baffle or slinger is bent or mutilated it should be replaced OVERHAUL MANUAL 4B 30 REAR AXLE DIFFERENTIAL Fig 20F Marking From Nominal on Pinion Measure each shim separately with a micrometer and add together to get total shim pack thickness from original build up If a new gear set is being used notice the plus or minus etching on both the old and new pinion and adjust the thickness of the old shim pack to compensate for the difference of these two figures For example If the old pinion reads 2 and the new pinion is 2 add 004 shims to the original shim pack 1 Determine proper inner shim pack for setting pinion depth by using chart in figure 21F 2 Install inner shim pack and oil slinger in inner cup bore and drive inner cup into position using Tool J 21059 used with J 8092 3 To the outer shim pack for setting preload add or remove an equal amount as was added o
425. ould be located flush with bearing shoulder on drive gear See Figure 7B 8L for direction of slinger installation NOTICE Exercise care to prevent distortion of the oil slinger 2 Install snap ring to secure bearing on drive gear shaft 3 Install bearing retainer ring in groove on O D of bearing The bearing must turn freely after it is installed on the shaft 4 Install snap ring on I D of mainshaft pilot bearing bore in clutch gear if previously removed 5 Apply a small amount of grease to bearing surface in shaft recess install transmission mainshaft pilot roller bearings 17 and install roller bearing retainer Fig 7B 121 This roller bearing retainer holds bearing in position and in final transmission assembly is pushed forward into recess by mainshaft pilot DRIVE GEAR BEARING RETAINER OIL SEAL Replacement 1 Remove retainer and oil seal assembly and gasket 2 Pry oil seal out of retainer 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 bottoms on retainer Fig 7B 13L OVERHAUL MANUAL 7B 40 MANUAL TRANSMISSION Fig 7B 7L Shifter Shaft Installation 5 Install new gasket on retainer and install retainer on transmission case when assembling transmission MAINSHAFT ASSEMBLY Disassembly Fig 7B 14L 1 Remove first speed g
426. ove parts as shown Push on stub shaft DO NOT remove upper bearing assembly see stub shaft seal removal INSTALL 1 Install parts as shown Make sure rack piston teeth are positioned toward Side cover opening Side cover HOUSING ASSEMBLY opening Rack piston teeth STUB SHAFT 4 VALVE ASSEMBLY WORM ASSEMBLY RACK PISTON NUT 6 REMOVE AND INSTALL VALVE AND WORM ASSEMBLY FROM RACK PISTON REMOVE INSTALL t Unscrew valve and worm 1 Install ring and from rack teflon ring as shown 2 Screw worm and valve into rack piston See procedure below 2 Remove teflon ring and rack piston O ring from rack piston VALVE AND WORM ASSEMBLY X e Ve RACK PISTON RING TEFLON VM RACK PISTON O RING SEAL RACK PISTON NUT A Assemble worm and valve to rack piston a Hold rack teeth and worm drive pin in relation shown with light pressure to hold worm thread against piston Turn worm and valve counterclockwise slowly until one Click 15 felt IA C Turn worm and valve clockwise to complete assembly B Check relation of stub shaft and rack piston a Screw worm and valve into rack piston until valve face and rack piston face are STUB SHAFT flush N b With rack piston in position shown flats on stub shaft and piston are to be parallel If not parallel disassemble and repeat A above 7 REMOVE AND INSTALL VALVE ASSEMBLY FROM WORM ASSEMBLY REMOVE INSTALL 1 Remove parts as
427. p bearing out front of case 9 Tip case on P T O and remove two interlock pins from inside of case TOOL J 23429 Fig 7D 8R Removing Idler Gear Shaft OVERHAUL MANUAL 7D 4 591 PWN 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 OVERHAUL MANUAL Rear Output Shaft Locknut Washer Yoke Bearing Retainer Assembly Snap Ring Bearing Speedometer Gear Gasket Housing Gasket Bearing Snap Ring Thrust Washer Thrust Washer Lock Pin Thrust Washer Tanged Low Speed Gear Needle Bearings Spacer Needle Bearings Tanged Washer Rear Output Shaft Needle Bearings Washer and Retainer Shift Fork TRANSFER CASES DIO n 1 6 26 27 28 29 30 31 and Seal 32 33 34 35 36 37 38 40 41 42 43 44 45 46 47 48 D 85 0065 1 009 pe 43 4 ECH 0t poe po 38 Sliding Clutch Input Shaft Transfer Case Poppet Plug Spring and Bail PTO Gasket and Cover Input Shaft Bearing and Snap Ring Snap Ring and Rubber O Ring Shift Link Clevis Pin Range Shift Rail Shift Rail Connector Link Front Wheel Drive Shift Rail Interlock Pins Rear Idler Lock Nut Washer Shift Rail Seals Idler Shaft Bearing Bearing Cup Shims idler Gear Bearing Cup Spacer Idler Shaft Bearing Idler Shaft Cover Gasket Rear Cover Front Output Shaft Locknut Washer Yoke Bearing Retainer and
428. part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of this part CONTENTS Delco Tandem Power Brake Un 5 1 Bendix Tandem Power Brake Unit Ann 5 7 Delco Single Diaphragm Power Brake 5 11 Bendix Single Diaphragm Power Brake 5 18 Bendix Hydro Boost Power Un 5 22 DELCO TANDEM POWER BRAKE UNIT UNIT REPAIR Disassembly 2 Remove the power piston group from the rear Scribe a line across front and rear housing to facilitate assembly 1 Remove and discard the vacuum check valve and grommet from the front housing 2 Mount unlock Tool J 23456 in a vise Position housing assembly on tool so that four studs fit in holes provided See Figure 5 1A J 23456 Mark staked interlocks so they will not be restaked Then straighten staked interlocks Fig 5 9A If all interlocks have been used a new unit must be installed on assembly 3 Position handle over two studs with tubular projections downward Rotate screw to apply downward pressure to handle then rotate front housing counterclockwise to unlock housing It is normal for this operation to require heavy pressure to unlock housing 4 Rotate screw to release spring tension and remove front housing group 5 Remove the power piston return spring 6 Remove rear housing from Tool J 23456 Rear Housing Group 1 Remove t
429. primary diaphragm to the primary support plate Press the raised flange on the I D of the diaphragm through the center hole of the support plate Be sure that the edge of the support plate center hole fits into the groove in the raised flange of the diaphragm Lubricate the diaphragm I D with silicone lubricant 22 Remove Tool J 28458 from power piston 23 Fold the primary diaphragm away from the O D of the primary support plate and place the primary support plate and diaphragm assembly over the power piston and push down until it bottoms fig 5 7A 24 Fold the primary diaphragm back into position on the primary support plate and pull the diaphragm O D over the formed flange of the housing divider Check that the bead on the diaphragm is seated evenly around the complete circumference 25 Place the diaphragm retainer over power piston and onto diaphragm Place Tool J 28458 over power piston onto diaphragm retainer Strike with hammer until retainer is locked on neck of power piston fig 5 8A 26 Install power head silencer over neck of power piston until it rests on retainer 27 Wipe a thin film of silicone lubricant on the O D of the piston rod retainer Insert the master cylinder piston rod retainer into the cavity in the power piston so that the flat end bottoms against the rubber reaction disc in the BRAKES 5 5 bottom of the cavity 28 Place the power piston bearing in rear housing center hole so that the formed fla
430. ps races and rollers for scoring chipping or evidence of excessive wear On pinion bearing rollers inspect large end of rollers for wear This is where wear is most evident on tapered roller bearings 2 Inspect pinion splines and flange splines for evidence of excessive wear 3 Inspect ring gear and pinion teeth for possible scoring 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 Fig 6F Removing Companion Flange OVERHAUL MANUAL EN Fig 7F Installing Side Bearing DIFFERENTIAL CASE Reassembly 1 Assemble new washers to side gears Apply a small amount of hypoid lubricant on the side gear hubs 2 Assemble pinion gears and new washers onto cross shaft 3 Place side gears pinion gears cross shaft and washers into flanged half of case 4 Assemble top half of case to bottom half making sure scribe marks are aligned 5 Assemble body bolts finger tight Then tighten bolts alternately to specifications 6 Install ring gear to differential case 7 Install ring gear to case bolts finger tight then tighten alternately to specifications 8 Place side bearing into position and install using tools J 8092 and bearing installer J 24383
431. ps of machine oil CLUTCHES 7 3 SINGLE PLATE COIL SPRING CLUTCH INDEX Disassembly ees Inspectiono Assembly Adjusting Leyers 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 Hold compressed while the adjusting nuts are removed as shown in Fig 7C 2E Then slowly release pressure to prevent springs flying out 3 Lift off cover and all parts will be available for inspection Note carefully the location of all parts including Release Lever Drive Disc Eyebolt Pressure Plate Strut Anti Rattle Spring Cover Throwout Bearing Adjusting Nut Coil Spring Flywheel Fig 7C 1E Coil Spring Clutch Cross Section Single Plate Jo 4 ANAN L Cu G3 D d c arrangement of springs See Fig 7C 3E 4 To remove levers grasp lever and eyebolt between thumb and fingers as shown in Figure 7C 4E so that inner end of lever and upper end of eyebolt are close together keeping eyebolt pin seated in its socket in lever 5 Lift strut over ridge on end of lever as in Fig 7C 5E 6 Lift lever and eyebolt off pressure plate NOTICE It is important to replace all parts which show wear INSPECTION In addition to applicable items listed under Diaphragm Clutch Inspection check the fo
432. r Servo Piston Rear Servo Assembly Disassembly 1 Remove rear accumulator piston from rear servo piston Fig 7A 62C A 2 Remove E ring retaining rear servo piston to servo pin Fig 7A 63C UE RING SERVO PISTON SERVO PIN Fig 7A 63C Removing Retaining E Ring from Rear Servo Pin AUTOMATIC TRANSMISSIONS 400 7A 19 RETAINING E RING SERVO PISTON ACCUMULATOR PISTON WASHER SERVO SPRING EA SERVO OIL SEAL OIL Pal b RETAINER SERVO PIN Fig 7A 64C Rear Servo and Accumulator Assembly Exploded View 3 Remove rear servo piston and seal from servo pin Fig 7A 64C Exploded view 4 Remove washer spring and spring retainer Inspection NOTICE See Fig 7A 64C Do not remove the teflon oil seal rings from the rear accumulator piston unless the oil seal rings require replacement If the teflon inner oil seal ring small diameter requires replacement for service use the aluminum oil seal ring The rear accumulator piston large diameter ring groove depth is machined shallower to take the large teflon oil seal ring If this ring requires replacement use only the teflon oil seal ring l Inspect freedom of accumulator rings in piston grooves 2 Inspect fit of servo pin in servo piston in case bore 3 Inspect servo pin for scores or cracks 4 Inspect accumulator and servo pistons for scoring cracks or porosity Assembly l Install spring retai
433. r 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 See figure 12F REAR AXLE DIFFERENTIAL 48 25 CONCAVE SIDE COAST Fig 12F Gear Tooth Nomenclature Test 1 Wipe oil out of carrier and carefully clean each tooth of ring gear 2 Use gear marking compound and apply this mixture sparingly to all ring gear teeth using a medium stiff brush When properly used the area of pinion tooth contact will be visible when hand load is applied 3 Tighten bearing cap bolts to specifications 4 Apply load to gears by expanding brake shoes or by wrapping a heavy rag around the companion flange to resist rotation NOTICE A test made without loading the gears will not give a satisfactory pattern Turn companion flange with wrench so that ring gear rotates one full revolution then reverse rotation so that ring gear rotates one revolution in opposite direction Excessive turning of ring gear is not recommended 5 Observe pattern on ring gear teeth and compare with figure 13F Make adjustments as necessary 6 The important thing to achieve in the pattern check and subsequent adjustments is to locate the contact pattern centrally on the face
434. r cover from transfer case Remove gasket and discard 2 Support rear cover and press bearing from cover 3 Position new bearing to outside face of cover and using a piece of wood to cover bearing press bearing into cover until flush with opening 4 Position gasket and cover to transfer case and tap into place 5 Install cover retaining bolts and torque to specifications ASSEMBLY OF TRANSFER CASE FIGS 7D 10S and 70 115 1 Place range box on blocks with input gear side toward bench Fig 70 215 2 Position range box to transfer case housing gasket on input housing 3 Install lockout clutch and drive sprocket assembly on the input shaft assembly A 2 band ciamp may be installed on end of shaft to prevent loosing bearings from clutch assembly 4 Install input shaft lockout clutch and drive sprocket assembly in the range box aligning tab on bearing retainer with notch in gasket 5 Connect lockout clutch shift rail to the connector link and position rail in housing bore Fig 7D 22S Rotate shifter shaft while lowering shift rail into the housing to prevent the link and rail from being disconnected 6 Install drive chain in chain housing positioning the chain around the outer wall of the housing 7 Install the cahin housing on the range box Fig 7D 23S engaging the shift rail channel of the housing to the shift rail Position chain on the input drive sprocket 8 Install the front output sprocket in the case
435. r fork shafts are interchangeable 12 Install 15 roller bearings in clutch shaft bore Use vaseline or equivalent to hold bearings in place NOTICE Do not use chassis grease or a similar heavy grease in clutch shaft bore Heavy grease could plug the lubricant holes in the shaft and prevent proper lubrication of the roller bearing 13 Install blocking ring on clutch gear and place clutch gear through top of case and position in front case bore 14 Install output shaft assembly in case Be sure First Reverse sleeve and gear is in Neutral centered position on hub so gear end of sleeve will clear notch in top of case when output shaft assembly is installed 15 Assemble the clutch gear to the output shaft 16 Move Second Third sleeve rearward to Second gear position and position Second Third shifter fork in groove DVERHAUL MANUAL J 24433 Fig 7B 22B Installing Front Bearing of sleeve Be sure setscrew hold in shifter fork is facing up Second Third fork is the smaller of the two shifter forks 17 Engage Second Third shifter fork in shifter fork shaft and insert Second Third shift rail through front case bore and into shifter fork Tapered end of rail faces front of case 18 Turn shift rail until detent notches in rail face bottom of case Insert a phillips screwdriver in detent bore to depress lower detent plug and push shift rail into rear bore Move rail inward until detent plug engages forward notch in shift
436. r removed from the inner shim pack 4 Install outer cup in carrier bore using installer J 7818 with Drive Handle J 8092 as shown in figure 22F 5 Press inner pinion bearing cone and roller onto pinion shaft using Installer J 9772 on arbor press as shown in figure 23F 6 Install drive pinion and inner bearing cone and roller assembly in differential carrier 7 Install shims and outer pinion cone and roller on pinion shaft using Tool J 5590 and companion flange to press bearing onto pinion as in figure 24F 8 Install flange holding bar and install washer and nut on pinion shaft Torque nut to 255 ft Ibs 9 Remove holding bar and with an inch pound torque wrench measure rotating torque Rotating torque should be 10 to 20 in lbs with original bearings or 20 to 40 in 16 with new bearings Torque reading to start shaft turning must be disregarded 10 If torque requirements preload are not to specifications adjust shim pack as necessary Increase the outer shim pack to reduce rotation torque Decrease shim pack to increase rotating torque 11 Remove nut washer and flange from pinion shaft OVERHAUL MANUAL 12 Install oil slinger gasket and using Tool J 22804 install oil seal 13 Install flange washer and nut Torque nut to specifications DIFFERENTIAL CASE Preload and Adjustment 1 Place differential assembly with pinion assembled into housing Install bearing caps in their proper position and tighten s
437. rail second gear position 19 Secure fork to rail with setscrew and move second third synchronizer to Neutral centered position 20 Install interlock plug in detent bore With Second Third synchronizer in Neutral position top of plug will be slightly below surface of First Reverse shift rail bore TOOL J 22609 Fig 7B 23B Installing Rear Bearing Fig 78 24B Installing Speedometer Retainer and Gear 21 Move first reverse synchronizer forward to first gear position Place First Reverse shifter fork in groove of sleeve Be sure setscrew hole in fork is facing up Rotate fork into position in case engage fork in shifter fork shaft and insert First Reverse shift rail through rear case bore and shifter fork 22 Turn shift rail until detent notches in rail face upward Move rail inward until setscrew hole in fork and setscrew bore in shift rail are aligned Secure fork to rail with setscrew and place First Reverse sleeve and gear into Neutral centered position Fig 7B 20B MANUAL TRANSMISSION 7B 17 23 Install large snap ring on front bearing 24 Install front bearing on clutch gear shaft by hand drive bearing on clutch gear shaft using tool J 24433 Fig 7B 22B 25 Install smaller snap ring on clutch gear shaft 26 Position bearing retainer gasket on case Be sure cut out in gasket is aligned with oil return hole in case 27 Install front bearing retainer and tighten attaching bolts to 30 to 36 fo
438. rd 7 Clean and inspect all components Replace as required Assembly 1 Position bearing to retainer and tap or press into place Ball loading slots should be toward concave side of retainer 2 Install large snap ring securing bearing in retainer Snap ring is a select fit Use size A B C or D as required to provide tightest fit 3 Install low speed gear on shaft with clutch end toward gear end of shaft 4 Position thrust washers on shaft aligning slot in washer with pin in shaft Slide or tap wahser into place 5 Position input bearing retainer on shaft and install snap ring holding bearing in place on shaft Snap ring is a select fit Use size B C or D as required to provide tightest fit 6 Slide spacer and thrust washer onto shaft Align spacer with locator pin 7 Using a heavy grease install roller bearings 15 in end of shaft 8 Install new rubber O ring on end of shaft Range Selector Housing Range Box Disassembly Fig 7D 11S Removing Shifter Assembly 1 Remove poppet plate spring plug and gasket Discard gasket 2 Disengage sliding clutch gear from input gear and remove clutch fork and sliding gear from case 3 Remove shift lever assembly retaining nut and upper shift lever from shifter shaft 4 Remove shift lever snap ring and lower lever 5 Push shifter shaft assembly downward and remove lockout clutch connector link Long end of connector link engages poppet plate 6 Remove shif
439. re 1D 26 or pressure switch see Figures 1D 27 and 28 even if the compressor remains on the vehicle during the operation it will be necessary to purge the system of refrigerant as outlined in the Air conditioning section see Discharging Adding Oil Evacuating and Charging Procedures for C C O T A C AIR CONDITIONING COMPRESSOR OVERHAUL 10 9 Systems The same holds ture for any disassembly of the internal A 6 compressor cylinder and shaft assembly If the 6 Compressor Internal Cylinder and Shaft Assembly is to be serviced or replaced then the oil in the compressor must be drained measured and replaced according to Refrigerant Oil Distribution in the Air Conditioning section to determine addition of proper oil quantity to new assembly A clean workbench preferably covered with a sheet of clean paper orderliness in the work area and a place for all parts being removed and replaced is of great importance as is the use of the proper clean service tools Any attempt to use make shift or inadequate equipment may result in damage and or improper compressor operation These procedures are based on the use of the proper service tools and the condition that an adequate stock of service parts is available All parts required for servicing the internal compressor are protected by a preservation process and packaged in a manner which will eliminate the necessity of cleaning washing or flushing of the parts The parts c
440. re bearings are clean then lubricate with light engine oil and check them for roughness by slowly turning the race by hand ALIGN ROLL PIN WITH COUNTERBORE WHEN INSTALLING REVERSE IDLER GEAR SHAFT Fig 7B 12B Removing Reverse Idler Gear Shaft SPRING UNDER LIP OF FIRST REVERSE SLEEVE AND GEAR 4 A RETAINING SNAP RING FIRST REVERSE SYNCHRONIZER Fig 7B 13B First Reverse Synchronizer Hub Bearing Rollers AU clutch gear and countergear bearing rollers should be inspected closely and replaced if they show wear Inspect countershaft and reverse idler shaft at the same time replace if necessary Replace all worn washers Gears 1 Inspect all gears for excessive wear chips or cracks and replace any that are worn or damaged ALIGNMENT MARKS KEYS 31 SPRING UNDER LIP OF KEYS Fig 7B 14B Second Third Synchronizer Assembly OVERHAUL MANUAL 7B 14 MANUAL TRANSMISSION Fig 7B 15B Installing Extension Housing Bushing 2 Check both clutch sleeves to see that they slide freely on their hubs REPAIRS Synchronizer Keys and Spring Replacement 1 Mark hub and sleeve so they can be matched upon reassembly 2 Push the hub from the sliding sleeve the keys and the springs may be easily removed 3 Install one spring into second third hub Be sure spring covers all three key slots in hub Align second third sleeve to hub using marks made during disassembly and start sleeve onto hub 4
441. re shims than would be required if the pinions were etched O By adding 003 shims the mounting distance of the pinion was decreased 003 which is just what a 3 etching indicated Refer to figure 10F If the old ring and pinion set is to be reused measure the old shim pack and build a new shim pack to this same dimension If baffle is in the axle assembly it is considered as part of the shim pack To change the pinion adjustment shims are available in thicknesses of 003 005 and 010 NOTICE If baffle or slinger is bent or mutilated it should be replaced Measure each shim separately with a micrometer and add together to get total shim pack thickness from original build up If a new gear set is being used notice the plus or minus etching on both the old and new pinion and adjust the thickn ss e of the old shim pack to compensate for the difference of these two figures For example If the old pinion reads 2 and the pinion is 2 add 004 shims to the original shim pack DRIVE PINION Assembly and Installation 1 Determine the correct pinion depth shim by using the chart in figure 9F ooo 0002 00 Fig 9F Dana Pinion Code Chart OVERHAUL MANUAL 4B 24 REAR AXLE DIFFERENTIAL Fig 10F Pinion Code Location 2 Install the pinion depth shim in rear cup bore 3 Install rear bearing cup by using driver handle J 8092 and installer J 24381 4 To the outer shim p
442. ressor should be 50 psi or above for the R 4 and 60 psi or above for the 6 compressor pressure reading of less than 45 psi for the R 4 or 50 psi for the A 6 would indicate one or more suction and or discharge valves leaking an internal leak or an inoperative valve and the compressor should disassembled and checked for cause of leak Repair as needed reassemble and repeat the pump up test Externally leak test 17 When the pressure pump up test is completed release the air pressure from the HIGH side and remove the Gage Adapters J 5420 and Test Plate J 9625 18 On the R 4 compressor tilt the compressor so that the compressor suction and discharge ports are down Drain the oil from the compressor On the A 6 compressor remove oil charge screw and drain the oil sump 19 Allow the compressor to drain for 10 minutes then charge with the proper amount of oil The oil may be poured into the suction port NOTICE If further assembly or processing is required a shipping plate or Test Plate J 9625 should be installed to keep out air dirt and moisture until the compressor is installed STEERING 3B 1 SECTION 3B STEERING CONTENTS OF THIS SECTION Manual Steering 2 222 1 11 1 Power Steering Pump Integral Power Steering Gear Special Tools 5 Ed edo oe ae te e ee dd ree MANUAL STEERING GEARS PRELOAD ADJUSTER NUT SIDE COVER sous d s
443. revent the dropping of 4 check balls located in the control valve assembly Fig 7A 6A MANUAL DETENT ROLLER amp SPRING ASSEMBLY Fig 7A 5A Removing Manual Detent Roller and Spring Assembly AUTOMATIC TRANSMISSION 200 7A 3 VALVE BODY SPACER PLATE Fig 7A 8A Removing Control Valve Assembly from Case Fig 7A 9A Removing Govenor Cover Retaining Ring e Lay control valve assembly down with spacer plate side up and discard gaskets 4 Remove 1 2 accumulator spring Fig 7A 7A 5 Remove 5th check ball located in case Fig 7A 8A 6 Governor Assembly NOTICE To prevent damage to the governor driven gear and speedometer driven gear they must be removed from the transmission before removing the output shaft and rear unit parts a Using small screwdriver remove governor cover retaining ring Fig 7A 9A b Using pliers remove governor cover and discard 2 seal rings seal rings may be located in case Fig 7A 10A Governor assembly may come out with cover Do not use any type of pliers to remove governor assembly Fig 7A 7A Removing 1 2 Accumulator Spring c Remove governor assembly from case It may be necessary to rotate output shaft counterclockwise while removing the governor 5th CHECK BALL T V EXHAUST Fig 7A 8A Removing 5th Check Ball Fig 7A 10A Removing Governor Cover OVERHAUL MANUAL 200 7A 4 AUTOMATIC TRANSMISSION 1 28653 Ze 2 eg INTERMEDIATE SERVO
444. rier which does not have an undercut and spacer ring 2 Inspect band surface on reaction carrier for signs of burning or scoring 3 Inspect roller clutch outer race for scoring or wear 4 Inspect thrust washer surfaces for signs of scoring wear 5 Inspect bushing for damage If bushing is damaged reaction carrier must be replaced 6 Inspect reaction carrier pinions for damage rough bearings or excessive tilt 7 Check pinion end play Pinion end play should be 009 024 Fig 7A 128C 8 Inspect roller clutch for damaged rollers 9 Inspect roller clutch cage and springs for damage 10 Inspect front internal gear output carrier for damaged teeth 11 Inspect output carrier pinions for damage rough bearings or excessive tilt 12 Check pinion end play Pinion end play should be 009 024 Fig 7A 129C 13 Inspect parking pawl lugs for cracks or damage 14 Inspect output locating splines for damage 15 Inspect front internal gear ring for flaking Fig 7A 49C Pinion Replacement Procedure 1 Support carrier assembly on its front face 2 Using 1 2 inch diameter drill remove stake marks 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 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 7A 130C 4 Remove pinions
445. ring Clutch Coil and Pulley Rim as a TOTAL assembly Be careful not to drop the Puller Guide J 25031 when removing the assembly 3 Remove and discard the Shaft Seal parts as described in R 4 Compressor Shaft Seal Removal procedure 4 Remove the four front head mounting screws Figure 1D 103 and remove the Front Head assembly Figure 1D 104 5 Remove and discard the front head O ring Replace 1 Check the Front Head and compressor cylinder area for any dirt lint etc and clean if necessary Install a new Service thrust washer kit if required as described in R 4 Compressor Thrust and Belleville Washers Removal and Replacement procedures 2 Coat the new front head O ring in clean 525 viscosity refrigerant oil and install in the seal groove on the front head Figure 1D 104 1D 38 AIR CONDITIONING COMPRESSOR OVERHAUL MOUNTING SCREWS 4 J 21508 O RING INSTALLER Figure 1D 103 Removing R 4 Front Head Mounting Screws OIL HOLE TO FRONT HEAD SHAFT SEAL AREA SEALING RING Figure 1D 101 Installing R 4 Seal Seat O Ring Off Car THRUST WASHER AND BELLEVILLE WASHER Figure 1D 104 Removing R 4 Front Head Assembly 3 Position the oil hole in the Front Head to be up when assembled to the compressor cylinder to correspond with the up position of the compressor Install the Front Head and tighten the front head mounting screws to an 20 lb ft 27 N m torque 4 Install new specification Ser
446. roller clutch assembly fig 7A 71B Intermediate overrun roller clutch inner race is a press fit Do not remove unless replacement is necessary INTERMEDIATE OVERRUN RO R CLUTCH ASSEMBLY Fig 7A 71B Removing Intermediate Overrun Roller Clutch CVERHAUL MANUAL 350 7A 22 AUTOMATIC TRANSMISSION DIRECT CLUTCH DRUM TO FORWARD CLUTCH HOUSING NEEDLE ROLLER BEARING Fig 7A 72B Direct Clutch Drum to Forward Clutch Housing Needle Roller Bearing 4 Remove direct clutch drum to forward clutch housing needle roller bearing fig 7A 72B 5 Remove direct clutch pressure plate to clutch drum retaining ring and pressure plate fig 7A 73B 6 Remove drive plates and steel driven plates fig 7A 74B RETAINING RING PRESSURE PLATE DIRECT CLUTCH DRUM Fig 7A 73B Removing Direct Clutch Pressure Plate OVERHAUL MANUAL STEEL PLATES LINED PLATES Fig 7A 74B Removing Drive and Driven Plates 7 Using compressor tool J 23327 remove direct clutch piston return spring seat retaining ring spring seat and seventeen 17 clutch return coil springs fig 7A 75B On JA and JH models return coil springs are attached to retaining ring 8 Remove direct clutch piston Fig 7A 75B Compressing Direct Clutch Spring Seat J 23327 1 Fig 7A 76B Removing Direct Clutch Outer and Inner Seals 9 Remove direct clutch piston outer seal and inner seal fig 7A 76B 10 Remove direct clutch piston center seal from
447. rom case OUTPUT RING GEAR AND OUTPUT SHAFT ASSEMBLY Fig 7A 45B Removing Output Ring Gear and Shaft Assembly OVERHAUL MANUAL 350 7A 14 AUTOMATIC TRANSMISSION OUTPUT RING GEAR TANGED THRUST WASHER Fig 7A 46B Removing Output Ring Gear Torrington Bearing 19 Remove reaction carrier to output ring gear torrington bearing fig 7A 46B 20 Remove output ring gear to case needle bearing assembly fig 7A 47B oureur RING GEAR OUTPUT RING GEAR TO CASE NEEDLE BEARING Fig 7A 47 B Removing Output Ring Gear to Case Needle Bearing Assembly OVERHAUL MANUAL Fig 7A 48B Compressing Low and Reverse Clutch Piston Spring Retainer 21 Compress low and reverse clutch piston spring retainer using tool J 23327 fig 7A 48B and remove piston retaining ring and spring retainer 22 Remove seventeen 17 piston springs from piston fig 7A 49B LOW AND REVERSE CLUTCH PISTON RETURN SPRINGS 17 4 B H A d 5 AUN TC a LOW AND REVERSE 29 CLUTCH PISTON Es Fig 7A 49B Low and Reverse Clutch Piston Springs and Piston ow ee AUTOMATIC TRANSMISSION 350 7A 15 A AN APPLY AIR PRESSURE HERE TO REMOVE LOW A N BEVERSE CLUTCH PISTON INNER SEAL Fig 7A 5OB Removing Low and Reverse Clutch Piston Fig 7A 52B Removing Low and Reverse Clutch Piston Center and Inner Seal 23 Remove low and reverse clutch piston assembly by 25
448. rse Idler Gear Case Fill Plug Countergear Front Bearing Gasket Front Cover Cover Screws 18 82 NOISSINSNVUL 7B 38 MANUAL TRANSMISSION J 8433 1 Fig 7B 3L Removing Countergear Rear Bearing 2 Place fork detent ball springs and balls in position in holes in cover 3 Start shifter shafts into cover depress detent balls with small punch and push shafts on over balls See Fig 7B 7L Hold reverse fork in position and push shaft through yoke Install split pin in fork and shaft then push fork in neutral position 4 Hold 3rd and 4th fork in position and push shaft through yoke but not through front support bore J 22832 Fig 7B 4L Removing Mainshaft Rear Bearing OVERHAUL MANUAL 3 Fig 7B 5L Cover Assembly 5 Place two 2 interlock balls in cross bore in front support boss between reverse and 3rd and 4th shifter shaft Install the interlock pin in the 3rd and 4th shifter shaft hole Apply grease to hold in place Push 3rd and 4th shaft through fork and cover bore keeping both balls and pin in position between shafts until retaining holes line up in fork and shaft Install retaining pin and move to neutral position 6 Place two 2 interlock balls between the Ist and 2nd shifter shaft and 3rd and 4th shifter shaft in the cross bore of the front support boss Hold 1st and 2nd fork in position and push shaft through cover bore in fork until retainer hole and fork line up wit
449. rts into the bore valve end first Install outer coiled pin from rough cast surface side aligning pin with slot in bushing 7 In next bore up if removed install shift T V valve larger outside diameter stem end out shift T V spring and coiled pin Then using plastic hammer install new shift T V plug flush with rough casting surface 8 In next bore up install reverse boost valve stem end out reverse boost spring Install bore plug hole side out and coiled pin 9 In next bore up install 1 2 shift valve longer stem end out making sure valve is seated at the bottom of the bore Install 1 2 throttle valve spring into the 1 2 throttle valve bushing and 1 2 throttle valve stem end first into the bushing Install these 3 parts valve end first into the bore aligning bushing so the pin can be installed in the pin slot See Fig 7A 156A for pin slot and identification of 1 2 throttle valve bushing 10 In next bore up install 2 3 shift valve longer stem end out making sure valve is seated at the bottom of the bore Install 2 3 throttle valve spring into the 2 3 throttle valve bushing and 2 3 throttle valve stem end first into the bushing Install these 3 parts valve end first into the bore CONTROL VALVE ASSY 1 2 THROTTLE VALVE BUSHING IDENTIFICATION PIN SLOT CONTROL VALVE ASSY 2 3 THROTTLE PINSLOT VALVE BUSHING Fig 7A 157A Installing 2 3 Throttle Valve Bushing aligning bushing so p
450. s are in their proper location NOTICE Reaction block must be replaced with a block of the identical thickness Incorrect block thickness will disturb critical clearance dimensions and may result in differential failure 5 Install shaft and lock screw 6 Insert governor assembly and latching bracket into case Figure 4B 4H Place straight end of latching bracket spring over and to the outside of the engagement shaft to preload the latching bracket against the governor assembly Press bushing and 1 4 stop pin into case Press bushing for governor assembly into case to give 004 to 020 shaft end play Press bushing for latching bracket into case to remove end play A 3 8 diameter plug or socket will aid in pressing the bushings into the housing Press stop pin flush with top of case NOTICE For the latching bracket use bushing with the tapered hole The bushing for the governor assembly has a straight hole 7 Install ring gear and side bearings using the procedure outlined for conventional differentials 8 Place differential unit in carrier and adjust ring gear and pinion backlash and gear tooth pattern as outlined in the conventional differential section 9 Check operation as outlined in the Service Test Procedure NOTICE Use standard differential lubricant Do not use lubricant designed for Limited Slip differentials 10 1 2 RING GEAR AXLE 3 4 TON AND 1 TON TRUCKS CAUTION Due to critical internal clearance dim
451. s should be replaced remove side bearings by using tools as shown in the 1979 Service Manual 7 If removing ring gear clamp case in vise so jaws are 90 to pinion shaft holes and remove ten ring gear retaining bolts 8 Partially install two bolts on opposite sides of ring gear 9 Remove ring gear from case by alternately tapping on bolts Do not pry between case and ring gear 10 Remove differential case half attaching bolts 11 Lift cap half of case from flange half Remove clutch cone side gears spring blocks preload springs pinion gears and shaft CLUTCH CONE SIDE GEAR Fig 4B 17D Cone Gear Position Be certain that each clutch cone side gear and pinion gear are marked so they can be installed in their original location Cleaning and Inspection 1 Make certain all parts are absolutely clean and dry 2 pinion shaft pinion and side gears brake cone surfaces and corresponding cone seats in case The cone seats in case should be smooth and free of any excessive scoring Slight grooves or scratches indicating passage of foreign material are permissable and normal The land surface on the heavy spirals of male cones will duplicate case surface condition If case or clutch cone side gear are damaged it is necessary to replace case assembly All other parts are serviceable Assembly 1 Install proper cone gear assembly seating it into position in cap half of case Fig 4B 17D Be certain
452. s the accumulator Insert a punch into the hole in the housing and remove retaining ring with a small screwdriver fig 5 6 WORN BUT ACCEPTABLE WORN NOT ACCEPTABLE Fig 5 4E Spool Valve Inspection OVERHAUL MANUAL ACCUMULAT VALVES SHARP EDGE GROUND ON END WILL MAKE TOOL MORE EFFECTIVE Fig 5 5E Removing Accumulator Valves 14 Slowly back off the clamp until tension on the accumulator is released remove accumulator and ring 15 If accumulator valve was determined to be faulty remove valve using a small diameter wire tool fig 5 5 Remove the dump valve by catching the tool under the pin guide near the center of the valve then remove two function valves and seat fig 5 8E 16 Return hose fitting O ring can be removed if leaking 17 Push spool valve plug in and use a small screwdriver to remove retaining ring Fig 5 9E 18 Remove spool valve plug and O ring 19 Remove the tube seats using No 4 easy out as shown in Figure 5 10E Cleaning and Inspection CAUTION Be sure to keep parts clean until reassembly Wash at reassembly if there are any parts dropped or left exposed for eight hours or longer Lubricate all seals and metal friction 1 22269 01 OR 6 C CLAM PRESSURE BOOSTER MASTER Ce Fig 5 6E Compressing Accumulator With J 26889 PRESSURE ACCUMULATOR ACCUMULATOR RETAINING RING MASTER CYLINDER Fig 5 7E Accumulator Installati
453. sassembly 1 Remove sun gear to sun gear drive shell rear retaining ring fig 7A 90B 2 Remove sun gear to drive shell flat rear steel thrust washer fig 7A 91B 3 Remove sun gear assembly from drive shell SUN GEAR DRIVE SHELL FLAT THRUST WASHER Fig 7A 91B Removing Sun Gear to Drive Shell Rear Steel Thrust Washer OVERHAUL MANUAL ASSEMBLY SUN GEAR p o DRIVE SHELL Fig 7A 92B Removing Sun Gear to Drive Shell Front Steel Thrust Washer 4 Remove sun gear to drive shell front retaining ring fig 7A 92B Discard retaining ring 5 If bushing is to be replaced refer to Figure 7A 104B Inspection Check gear and sun gear shell for damage or wear Reassembly 1 Install new sun gear to drive shell front retaining ring 2 Install sun gear assembly into drive shell 3 Install sun gear to drive shell flat steel thrust washer 4 Install new sun gear to sun gear drive shell retaining ring Do not over stress front and rear retaining rings at installation LOW AND REVERSE ROLLER CLUTCH SUPPORT FIG 7A 93B Disassembly 1 Remove low and reverse clutch to sun gear shell thrust washer AUTOMATIC TRANSMISSION 350 7 29 LOW AND REVERSE CLUTCH SUPPORT ROLLER CLUTCH ASSEMBLY SNAP RING INNER RACE E CAGE MUST HAVE 4 EQUALLY SPACED THRUSTWASHER 091 LUBE HOLES ON THIS SIDE IF ROLLER FALLS OUT INSTALL ROLLER FROM OUTSIDE IN AS SHOWN AVOID BENDING SPRINGS
454. seal and intermediate band anchor pin bores for damage 6 Inspect for damaged or stripped bolt holes If any threaded holes require heli coils or equivalent install these to renew the threads 7 Turn transmission to vertical position rear end up 8 Inspect cooler line connectors for damage Do not remove unless replacing 9 Inspect case bushing for damage or scoring 10 If removed install a new oil seal using J 21426 Fig 7A 51A MANUAL SHAFT SEAL MANUAL SHAFT AUTOMATIC TRANSMISSION 200 7 13 11 If removed install new cooler line connector s using a commercial thread sealant on connector thread Torque connector s to 20 0 27 0 N m 15 20 ft Ibs MANUAL SHAFT AND PARKING PAWL PARTS Fig 7A 52A Inspection 1 Align actuator rod tangs with hole in inside detent lever and separate 2 Inspect parking actuator rod for damage or broken retainer lugs 3 Inspect parking actuator spring for damage 4 Inspect actuator for free fit on actuator rod 5 Inspect parking pawl for cracks or damage 6 Inspect parking pawl return spring for deformed end or coils 7 Inspect parking pawl shaft for damage 8 Inspect parking bracket for cracks or wear 9 Inspect inside detent lever for cracks or loose pin 10 Inspect manual shaft for damaged threads and the flats for raised edges File down any raised edges Reassembly 1 Turn transmission to horizontal position oil pan side up PIN MANUAL SHAFT T
455. sher in order to effectively retain the screw 9 Retighten the compressor drive belt to proper belt tension 10 Check compressor and system operation NOTICE If mounting notch screws must be replaced for any reason the screws should be torqued into place 100 in Ibs torque using Loctite 601 or equivalent sealer on the threads and locked into place similar to the original locking method Procedure 11 INERTIA RING AND PULLEY RIM WELDED ASSEMBLY REPLACEMENT NEW PULLEY RIM AND INERTIA RING KIT REQUIRED 1 Loosen the compressor mounting bracket and remove the compressor drive belt 2 Remove the Clutch Hub and Drive Plate assembly as described in RA Compressor Clutch Plate and Hub Assembly Removal procedure 3 To remove as an assembly perform Steps 1 through 4 of RA Compressor Clutch Rotor and or Bearing Removal procedures but do not loosen or remove the pulley rim mounting screws so as to remove the Clutch Rotor and Bearing Clutch Coil Pulley Rim and Inertia Ring as a TOTAL assembly Be careful not to drop the Puller Guide J 25031 when removing the assembly MOUNTING HOLES 3 MOUNTING NOTCHES 3 6197 Figure 1D 91 R 4 Pulley Rim Mounting Location Detail 4 Remove all six pulley rim mounting screws and lockwashers from the assembly and discard 5 Separate the Pulley Rim and Inertia Ring assembly away from the Rotor and Bearing assembly 6 Inspect the drive surfaces of the Rotor and Dri
456. shers for wear and replace if even slight wear is indicated LINE UP MARK Fig 6G Differential Case Line Up Marks OVERHAUL MANUAL Fig 7G Differential Bearing Removal 7 Check differential side bearings and cups for broken races discoloration or roughness 8 Inspect differential case for cracks or distortion Ring Gear Replacement 1 Remove ring gear from case by tapping the back of the gear with a soft faced hammer 2 Inspect ring gear pilot case flange and back of ring gear for dirt or burrs 3 Install two guide pins made from cap screws with heads cut off and ends slotted to new gear diametrically opposite each other 4 Start guide pins through case flange and tap ring gear on case Differential Bearing Replacement 1 Install Tool J 8107 making sure puller legs are fitted securely in notches in case and tighten retaining yoke as shown in figure 7G 2 Tighten puller screw to remove bearing 3 Place new bearing on hub with thick side of inner race toward case and install bearing using J 1488 as shown in figure 8G The side bearing tool is counterbored and has pilot to assure proper installation and seating of bearing Differential Reassembly 1 Lubricate differential side gears pinions and thrust washers 2 Place differential pinions and thrust washers on spider 3 Assemble side gears and pinions and thrust washers to left half of differential case 4 Assemble right half of case to left
457. shim requirements Pinion Shims Ring gears and pinions are supplied in matched sets only Matching numbers on both pinion and ring gear are etched for verficiation If a new gear set is being used verify the numbers of each pinion and ring gear before proceeding with assembly On the rear face of each pinion there is etched a plus number a minus number or a zero 0 number which indicates the best running position for each particular Old Pinion Marking 0 002 0 001 New Pinion Marking 0 004 0 003 0 002 0001 0 003 0 002 0 001 o roe ose rome esr 9 eer oss 0002 ow o ome 0003 0002 oom Tee RECH 0 007 0 006 0 005 0004 0 001 EA 0 001 0 002 0 003 0 004 0005 0 006 0 007 REAR AXLE DIFFERENTIAL 4B 23 gear set This dimension is controlled by the shimming behind the inner bearing cup Whenever baffles or oil slingers are used they become a part of the adjusting shim pack For example if a pinion is etched 3 this pinion would require 003 less shims than a pinion etched 07 This means by removing shims the mounting distance of the pinion is increased by 003 which is just what a etching indicates 3 Or if a pinion is etched 3 we would want to add 003 mo
458. should be taken to avoid chipping or damaging plastic parts in handling Use air to blow out dirt and cleaning solvent from recesses and internal passages Inspection of Rubber Parts Wipe fluid from the rubber parts and carefully inspect each rubber part for cuts nicks or other damage These parts are the key to the control of fluid or air flow If there is any question as to the serviceability of rubber parts REPLACE them Inspecting Metal Parts BADLY DAMAGED ITEMS OR THOSE WHICH WOULD TAKE EXTENSIVE WORK OR TIME TO REPAIR SHOULD BE REPLACED In case of doubt install new parts Assembly Be careful during the rebuild procedure that no grease or mineral oil comes in contact with the rubber parts of the power brake unit Lubricate power unit parts as outlined below with power brake silicone lubricant This lubricant is provided in the service repair kit Front Housing Group Assembly 1 Insert the NEW grommet in the front housing 2 Install the NEW vacuum check valve into the grommet Power Piston Group Fig 5 2A 1 Lubricate the O ring seal with silicone lubricant and place on the air valve 2 Wipe a thin film of silicone lubricant on the large and small O D of the floaing control valve 3 If the floating control valve needs replacement replace the complete air valve push rod assembly 4 Place the air valve end of the air valve push rod assembly into the tube of the power piston Manually press the air valv
459. side of hub so all three keys are engaged by both springs Fig 7B 11J The tanged end of each synchronizer spring should be installed into different key cavities on either side Slide the sleeve onto the hub aligning the marks made before disassembly A groove around the outside of the synchronizer hub identifies the end that must be opposite the fork slot in the sleeve when assembled for the 3 4 synchronizer However Fig 7B 9J Removing Rear Bearing and 1st Speed Gear Fig 7B 10J Removing 1st and 2nd Synchronizer Snap Ring for the 1 2 synchronizer the groove is at the same end as the fork slot This groove indicates the end of the hub with a greater recess depth Extension Oil Seal or Bushing If bushing in rear of extension requires replacement remove seal and use Tool J 5778 to drive bushing into extension housing Fig 7B 12J Using the same tool drive new bushing in from the rear Coat I D of bushing and seal with transmission lubricant then install new oil seal using Tool J 5154 Fig 7B 13J Clutch Gear Bearing Retainer Oil Seal If the lip seal in the retainer needs replacement pry the oil seal out and replace with a new seal using Tool J 23096 until seal seats in its bore Figs 7B 14J and 7B 15J SPRING SLEEVE Fig 7B 11J 3 4 Synchronizer Assembly MANUAL TRANSMISSION 7B 21 Fig 7B 12J Extension Bushing Replacement Lip of seal must face rear of bearing retainer ASSEMBLY OF MAINSHAFT
460. sing a new gasket install housing cover and torque bolts to specifications 19 Reinstall the rear universal joint and torque U bolt nuts to specifications 20 Install axles into carrier and axle flange over hub studs 21 Torque hub stud nuts to specifications 22 Fill differential with lubricant 23 Install wheel and tire assembly CHECKS AND ADJUSTMENTS Four adjustments are essential for proper operation of the differential and its related parts These adjustments are a Pinion Bearing Preload b Side Bearing Preload c Pinion Depth and d Ring Gear to Pinion Backlash Pinion Bearing Preload is set to specifications in step 12 of Drive Pinion Assembly and Installation Side Bearing Preload is set to specifications in step 10 of Differential Case Installation and Adjustment Following service to the Differential Case or to the Drive Pinion and Ring Gear a Gear Tooth Contact Pattern Check must be made to verify the accuracy of the work in setting the pinion depth and the ring gear to pinion backlash GEAR TOOTH CONTACT PATTERN CHECK Prior to final assembly of the differential a Gear Tooth Contact Pattern Check is necessary to verify the correct relationship between ring gear and drive pinion Gear sets which are not positioned properly may be noisy or have short life or both With pattern check the most desireable contact between ring gear and drive pinion for low noise level and long life can be assured Gea
461. spring Replace reaction block Check closely for other damage Replace entire unit if housing side gear or pinion gears are damaged Replace entire unit Fig 4B 4H Governor and Latching Bracket Internal components can be inspected through the windows of the differential housing If the governor assembly and latching bracket are the only items to be replaced proceed only through step No 2 of the disassembly procedure To install new governor and latching bracket begin at step No 6 of the reassembly procedure Disassembly 1 Note position of governor and latching bracket assembly Figure 4B 4H Remove ring gear and side bearings following procedures established for the standard differential Fig 4B 5H Bearing Puller J 26252 REAR AXLE DIFFERENTIAL 4B 51 2 Using bushing puller tool No J 26252 remove governor assembly and latching bracket by pulling the retaining bushings as shown in Figure 4B 5H Pull the latching bracket spring out of the way while pulling the governor assembly bushing to prevent damage Remove the stop pin by driving through the case with a drive pin punch 3 Remove lock screw and pinion shaft and roll out differential pinion gears 4 Remove thrust block and pinion thrust washers 5 Remove cam gear disc pack assembly and disc pack guide clips 6 Remove plain side gear and shims Inspection 1 Clean all parts with solvent Inspect all bearing for chipping or evidence of e
462. spring assembly past the snap ring groove Install the snap ring Fig 7A 100A An arbor press and J 23327 1 can be used to compress the retainer and spring assembly DIRECT CLUTCH ELUTCH OUTER SEAL PISTON LIP UP Fig 7A 105A Installing Direct Clutch Piston Outer Seal DIRECT CLUTCH HOUSING J 25010 DIRECT CLUTCH PISTON Fig 7A 106A Installing Direct Clutch Piston 13 mm 5 15 3 mm R 06 lt 12 AUTOMATIC TRANSMISSION 200 7A 27 152 mm amp 0 FLATTEN TO SECURE THE 381 mm DIA 015 PIANO OR MUSIC WIRE BOTH ENDS 475 mm X DIA TUBING Fig 7A 107A Piston Installing Tool OMITTED RELEASE SPRING CHECK BALL GUIDE ASSEMBLY DIRECT CLUTCH PISTON Fig 7A 108A Installing Release Spring Guide 10 Remove J 23327 1 and or J 6129 11 Oil and install the direct clutch plates into the direct clutch housing starting with a flat steel and alternating composition faced and flat steel clutch plates See Figs 7A 109A and Fig 7A 82A 12 Install backing plate chamfered side up 13 Install snap ring Fig 7 99 Make sure composition clutch plates turn freely 14 Set direct clutch assembly aside Forward Clutch Housing Assembly Fig 7A 110A Inspection 1 Inspect teflon oil seals on turbine shaft for damage and free fit in grooves Do not remove unless replacing 2 Remove and inspect forward clutch to direct clutch thrust washer for damage Fig 7A 1
463. ssembly 14 Install input ring gear rear thrust washer 15 Install input ring gear 16 Install new input ring gear to output shaft snap ring CAUTION Do not over stress snap ring 17 Install input gear front thrust washer 18 Install direct clutch assembly and special thrust washer to forward clutch assembly 19 Install clutch assemblies into case NOTICE Make certain forward clutch face plates are positioned over input ring gear and the tangs on direct clutch housing are installed into slots on the sun gear drive shell or damage may occur 20 Install intermediate clutch overrun brake band 21 Install intermediate clutch pressure plate 22 Install face and steel intermediate clutch plates starting with a face plate and alternating steel and face Notch in steel reaction plates is installed toward selector lever inner bracket 23 Install intermediate clutch cushion spring Pump to Direct Clutch Thrust Washer Selection Procedure 24 To check for proper thickness of selective fit thrust washer between the oil pump cover and direct clutch assembly proceed as follows PUMP COVER TO DIRECT CLUTCH NEEDLE BEARING Fig 7A 108B Pump Cover to Direct Clutch Torrington Bearing a Install torrington bearing fig 7A 108B oil pump gasket and using guide studs from J 3387 set install oil pump Install two pump to case bolts b Move transmission so that output shaft points down Mount a dial indicator so that p
464. ssembly Corvette only 17 Dowel Pins Reservoir Ring Seal End Plate Retaining Ring 18 End Piate Ring Shaft Seal End Plate 19 Pressure Plate O Ring Shaft T d 11 12 13141516 25 26 27 28 AWN Fig 3B3 1 Power Steering Pump Exploded DISASSEMBLY ASSEMBLY 1 REFER TO VIEW A FOR REMOVING 1 INSTALL END PLATE LUBRICATE RETAINING RING WITH POWER STEERING FLUID 2 REMOVE PARTS AS SHOWN AND RETAINING RING AS SHOWN IN VIEW B 2 INSTALL PARTS AS SHOWN PRESS RETAINING RING zz LOCATE RING GAP PRESSURE AT POSITION SHOWN PLATE SPRING MAGNET WIPE CLEAN WITH CLOTH DISASSEMBLY ASSEMBLY 1 REMOVE FILLER CAP AND DRAIN INSTALL PARTS AS SHOWN OIL FROM RESERVOIR BEFORE USE NEW RINGS AND REMOV ING PARTS THEN REMOVE SEALS LUBRICATE ALL SEALS PARTS AS SHOWN WITH POWER STEERING FLUID BEFORE INSTALLATION WELCH PLUG DO NOT REMOVE IF DEFORMED OR DISLODGED REPLACE HOUS ING e NS 7 RESERVOIR STUDS seis SEAL FITTING a contro vue N PING HOUS ING CONTROL VALVE ROCK BY HAND TO REMOVE SPRING ASSEMBLY CAUTION BEFORE PROCEEDING EXAMINE THIS PART Fig 3B3 2 Remove and Replace Reservoir OF DRIVE SHAFT IF IT 15 CORRODED CLEAN WITH CROCUS CLOTH BEFORE REMOVING THIS WILL PREVENT DAMAGE TO THE SHAFT BUSHING WHICH MIGHT REQUIRE REPLACEMENT OF THE ENTIRE HOUSING Fig 3B3 3 Remove Control Valve and End Plate OVERHAUL MANUAL 3B
465. ssembly floating valve retainer push rod limiter washer and air filter 13 Remove floating control valve assembly from push rod as it must be replaced by a new floating control valve assembly at rebuild 14 The master cylinder push rod can now be pushed from center of reaction retainer Remove O ring from groove in master cylinder piston rod CLEANING AND INSPECTION Cleaning of Parts 1 Use denatured alcohol to clean thoroughly all metal brake parts Blow out all passages orifices and valve holes Air dry and place cleaned parts on clean paper or lint free clean cloth 2 If slight rust is found inside either front or rear housing assemblies polish clean with crocus cloth or fine emery paper washing clean afterwards with specified cleaning fluid NOTICE If there is any suspicion of contamination or any evidence of corrosion completely flush hydraulic brake system Failure to clean hydraulic brake system can result in early repetition of trouble Use of gasoline kerosene anti freeze alcohol or any other cleaner with even a trace of mineral oil will damage rubber parts Dirt is the major cause of trouble and wear in service Be sure to keep parts clean Rewash at reassembly if there is any occasion to doubt cleanliness such as parts dropped or left exposed for eight hours or longer Inspection and Replacement of Parts l Inspect all rubber parts Wipe free of fluid and carefully inspect each rubber part for cuts n
466. st Procedure 1 Place the Truck on a frame contact hoist allowing free rotation of the rear wheels 2 Raise hoist until wheels clear floor Holding one wheel stationary slowly rotate other wheel approximately 1 2 revolution per second in both the forward and reverse BUSHING EA BUSHING LOCKSCREW STOP PIN SIDE GEAR THRUST BLOCK REN PINION GEAR P gt 4 LATCHING BRK T ASS Y Fig 4B 1H 1 2 Ton Unit OVERHAUL MANUAL SPLINED DISC 2 2 LATCHING BRK T ASS Y REAR AXLE DIFFERENTIAL 48 49 M SCREW 3 SHIM GUIDE CLIP 6 DISC PACK S A PINION YOKE THRUST BLOCK 2 Fig 4B 2H 3 4 Ton Unit directions Wheel should rotate freely If both wheels attempt to turn together the differential is locking and is defective Rapid wheel rotation will cause a properly operating differential to lock and both wheels will rotate in the same direction 3 Raise hoist to maximum height with one person in vehicle 4 Start engine making sure that carburetor is set to provide a low idle speed of 600 800 rpm 5 Place transmission in drive range and apply brakes With manual transmission depress clutch and place transmission in first gear 6 Lock one rear wheel by pulling one parking brake cable from under the vehicle 7 With engine at low idle slowly release brakes With manual transmission slowly engage clutch 8 Locked rear wheel will remain stationary and free wheel will
467. st case snap ring groove 4 Install low and reverse clutch housing to case snap ring flat side against housing beveled side up Position snap ring gap on opposite side of parking actuator rod AUTOMATIC TRANSMISSION 200 7 21 MODELS DIRECT CLUTCH FORWARD CLUTCH LOW amp REV CLUTCH COMP COMP FLAT COMP FLAT STEEL PLATE FACED APPLY RING WAVED PLATE FLAT STEEL PLATE FACED APPLY RING STEEL FACED APPLY RING PLAT PLATE PLATE PLATE THICKNESS THICKNESS THICKNESS wo io wor no NO TYPE jio wore 17 50mm 4 24 34mm 689 GROOVED 9587 17 50mm 4 077 689 GROOVED 1 3 1 969mm 13 51mm 5 NON 20 14mm 66 GROOVED 793 5 NON 20 14mm d GROOVED 13 51mm 7 6 NON 3 532 GROOVED NOTE THE DIRECT FORWARD CLUTCH FLAT STEEL CLUTCH PLATES AND THE FORWARD CLUTCH WAVED STEEL PLATE SHOULD BE IDENTIFIED BY THEIR THICKNESS 24 34mm 9587 1 969mm 1 585mm 1 969mm PA PY 0777 PG PH CO CR CY BA OS OT 15 94mm 1 628 THE DIRECT AND FORWARD PRODUCTION INSTALLED COMPOSITION FACED CLUTCH PLATES MUST NOT BE INTERCHANGED FOR SERVICE DIRECT AND FORWARD CLUTCH USE THE SAME COMPOSITION FACED PLATES ALL LOW AND REVERSE CLUTCH COMPOSITION FACED PLATES ARE SERVICED WITH THE GROOVED PLATES 5 MEASURE THE WIDTH OF THE CLUTCH APPLY RING FOR POSITIVE IDENTIFICATION Fig 7A 82A Clutch Plate Usage and Apply Ring Identif
468. sting nut firmly to force differential in solid contact with left hand adjusting nut 4 Back off right hand adjusting nut until free of bearing then retighten snugly against bearing 5 Tighten right hand nut from one to two additional notches to a locking position This method of adjustment provides for proper preload of bearings 6 Mount a dial indicator on the carrier and check the backlash between ring gear and pinion as shown in figure 10G Backlash should be from 003 to 012 005 to 008 preferred If backlash is more than 012 inch loosen the right hand adjusting nut one notch and tighten left hand adjusting nut one notch If backlash is less than 003 inch loosen the REAR AXLE DIFFERENTIAL 4B 37 Fig 9G Backlash and Preload Adjustment left hand adjusting nut one notch and tighten right hand nut one notch 7 Tighten bearing cap bolts to specifications 8 Install side bearing adjusting nut locks and torque to specifications Ring Gear Thrust Pad Adjustment 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 turn and tighten locknut to specifications See figure 11G Make sure screw does not turn during locking process This adjustment provides 005 in to 007 in clearance between thrust pad and ring gear face Installation 1 Clean out ax
469. sun gear roller thrust bearing assembly off rear internal gear LO amp REVERSE i Remove rear internal gear off output shaft Fig 7A CLUTCH HOUSING s TO CASE SPACER Fig 7A 35A Removing Low and Reverse Clutch Housing THRUST WASHER REAR Fig 7A 36A Proper Location of Low and Reverse Housing to CARRIER Case Spacer ASSEMBLY Fig 2A 38A Removing Thrust Washers OUTPUT SHAFT REAR INTERNAL GEAR OUTPUT SHAFT Fig 7A 37A Removing Rear Unit Parts Fig 7A 39A Removing Rear Internal Gear OVERHAUL MANUAL 200 7A 10 AUTOMATIC TRANSMISSION REAR OIL SEAL Fig 7A 40A Removing Rear Oil Seal 5 Turn transmission to horizontal position and remove J 25013 5 and J 25013 1 tools from case Turn transmission to vertical position with rear end up 6 If necessary remove rear oil seal Fig 7A 40A MANUAL SHAFT AND PARKING PAWL PARTS Removal 1 Turn transmission to horizontal position oil pan side up MANUAL SHAFT SEAL MANUAL SHAFT es Le m INSIDE DETENT LEVER A Fig 7A 42A Removing Manual Shaft Nut 2 If necessary remove manual shaft and parking linkage as follows a Remove hex nut which holds inside detent lever to manual shaft Fig 7A 42A b Remove parking lock actuator rod and inside detent lever assembly c Remove manual shaft retaining pin from case and slide manual shaft out Fig 7A 43A d Inspect manual shaft to case seal for damage If necessary pry out m
470. sure regulator valve for free operation in bore Do not drop the check ball that is in the pump as the pump body and pump cover are separated 7 Remove pump cover to pump body attaching bolts and separate pump cover from pump body Pump Body Inspection 1 Remove the 7 14mm 281 check ball from the pump body or pump cover and keep it separated from the PUMP BODY PUMP DRIVE GEAR IDENTIFICATION MARKS ON TANGS Fig 7A 129A Removing Pump Drive Gear OVEFRHAUL MANUAL five 6 35mm 250 check balls used in the case and control valve assembly 2 Remove drive gear and driven gear from pump body Fig 7A 129A 3 Inspect drive and driven gears fro scoring galling or damage Driven gear identification marks should be against the pump body gear pocket See Fig 7A 133A for identification The drive gear has 1 identification mark on each drive tang Fig 7A 129A This side should be facing away from the pump body gear pocket 4 Inspect drive and driven gear pocket and crescent for scoring or damage 5 Inspect pump body face for nicks and overall flatness 6 Inspect for open oil passages Fig 7A 130A 7 Inspect for damaged bolt hole threads 8 Inspect for open drainback hoie 9 Inspect bushing for scores or nicks 10 If removed coat outside of seal body with non hardening sealing compound support pump body oil seal side up and using J 25016 install new pump body oil seal Fig 7A 131A
471. t 9 Push the shifter shafts into the housing engaging the long end of the lockout clutch connector link to the outer shifter shaft before the shaft assembly bottoms out 10 Install lower shift lever and retaining ring 11 Install upper shift lever and shifter shaft retaining nut 12 Install shift fork and sliding clutch gear Push fork up into shifter shaft assembly to engage poppet plate sliding clutch gear forward onto the input shaft gear 13 Install poppet spring gasket and plug in top of housing Check spring engagement with poppet plate Input Gear Bearing Replacement 1 Remove bearing retainer attaching bolts retainer and gasket from housing Discard gasket 2 Using snap ring pliers remove snap ring retaining bearing on shaft Discard snap ring 3 Using a screwdriver or other suitable tool pry the bearing from case and remove it from the shaft Inspect input gear for defects such as burrs scoring heat discoloration etc Inspect seal in bearing retainer Replace as required 4 Install new bearing with snap ring on input gear shaft Position bearing to case and tap in o place with a soft hammer Select service ring size A B C or D that will provide tightest fit 5 Install new snap ring to retain bearing on the shaft 6 Position new gasket and the bearing retainer to housing Install retaining bolts tightening to specifications OVERHAUL MANUAL 70 16 TRANSFER CASES Fig 7D 16S Insta
472. t clutch housing become necessary extreme care must be taken in obtaining the correct part for the model involved Production built transmissions use a direct clutch housing with a check ball See Fig 7A 100C If the housing requires replacement and the replacement housing does not contain a check ball replace the direct clutch piston with the service piston which has a check ball Models CB CD and CL service piston has 2 check balls EITHER THE DIRECT CLUTCH HOUSING AND OR THE PISTON MUST BLIND HOLES CONTAIN A CHECK BALL S 4 Place seal protectors Tools J 21362 Inner J 21409 Outer over hub and clutch housing and install clutch Fig 7A 102C Forward and Direct Clutch Piston Identification piston with a rotating motion Fig 7 101 DIRECT CLUTCH FORWARD CLUTCH 5 Install fourteen 14 springs into piston leaving two 6 Place spring retainer and snap ring on retainer pockets diagonally opposite with no springs 7 Using an arbor press and Tool J 4670 with J 21664 compress springs and install snap ring Fig 7A 94C 8 Install direct clutch plates See Fig 7A 103C a For model CZ start with one 1 waved steel plate CHECK BALL DIRECT CLUTCH HOUSING Y b X DIRECT CLUTCH HOUSING 1 WAVED STEEL PLATE 5 COMPOSITION PLATES 4 FLAT STEEL PLATES DIRECT CLUTCH BACKING PLATE SNAP RING Fig 7A 100C Direct Clutch Housing with Check Ball Fig 7A 103C Direct Clutch Assembly Expl
473. t plate hub grasping the air valve plunger and valve return spring as the parts are separated fig 5 5B 25 Remove the square ring seal from the shoulder of the front diaphragm plate hub 26 Remove the reaction disc from inside the front diaphragm plate hub Carefully slide the center plate off the hub of the front plate 27 Remove the diaphragms from the plates 28 Use a blunt punch or 1 1 4 socket to drive seal from rear housing figs 5 6B and 5 7B Cleaning All parts to be reused should be washed in denatured alcohol or brake fluid Dry the parts with compressed air and place them on clean paper or lint free cloth Small rust spots inside the shells may be removed with crocus cloth or fine emery cloth Be sure to clean thoroughly after using any abrasive Inspect all parts and replace any that are damaged or show excessive wear Assembly 1 Press the new bearing and seal into the cavity in the rear housing using Tool J 22677 fig 5 8B The flat rubber surface of the seal should be 5 16 below the flat inside surface of the rear housing 2 Install reaction disc in hub of front plate with small tip toward hole Use rounded rod to seat disc 3 Mount Tool J 22839 in vise 4 Install front diaphragm on front plate Long fold of diaphragm must be facing down 5 Install Tool J 22733 over threads on front plate hub fig 5 9B 6 Apply a light film of silicone lubricant to front plate hub and to seal in cen
474. t ring 3 Place cam gear assembly with bearing remover attached in an arbor press supporting the bearing remover on both sides 4 Install a 1 1 2 to 1 3 4 diameter plug similar to J 8107 4 on gear hub Press against plug with ram of press to remove thrust ring Keep all components in the proper order Figure 4B 6H OVERHAUL MANUAL 4B 52 REAR AXLE DIFFERENTIAL Fig 4B 6H Bearing Remover J 22912 Reassembly Replace cam plate and wave spring or clutch discs as necessary and reassemble as follows See Fig 4B 1H 1 Place gear on bench with hub end up 2 Assemble cam plate with cam form down to mate with cam form on gear 3 Assemble onto cam plate 2 eared discs 1 splined disc and 1 wave spring alternaely as shown 4 Assemble on to gear hub 3 splined discs and 3 eared discs alternately as shown Begin with a splined disc and end with an eared disc 5 Locate cam gear assembly in arbor press with hub end up Place thrust ring on gear hub and press to shoulder making sure that ring 1s square with hub NOTICE Compress disc pack by pushing down on the discs to keep the splined discs from becoming wedged between the thrust ring and gear shoulder while pressing the sub assembly together Completed sub assembly should be checked for proper disc sequence Also make sure the first splined disc large spline is properly located on the cam plate Reassembly 1 Install 4 clutch pack guide clips on the ears
475. t the necessary degree of cleanliness may be maintained Additionally Compressor Clutch Plate and Hub Pulley and Bearing Clutch Coil and Housing and Shaft Seal Removal procedures as described earlier in the OVERHAUL section all are to have been followed Clean hands clean tools and a clean bench preferably covered with clean paper are of extreme importance 1D 12 AIR CONDITIONING COMPRESSOR OVERHAUL gt DISCHARGE SYSTEM BEFORE REMOVING HIGH PRESSURE RELIEF VALVE HI PRESS RELIEF VALVE me REAR HEAD Figure 1D 26 A 6 High Pressure Relief Valve COMPRESSOR PRESSURE SWITCH SNAP RING _ HIGH PRESSURE VENT TO PRESSURE BI gt COMPRESSOR D PRESSURE SWITCH Figure 10 28 6 Compressor Pressure Switch on B An inspection should be made of the Internal Mechanism Cylinder and Shaft assembly to determine if any service operations should be performed A detailed inspection of parts should be made to determine if it is feasible to replace them Removal 1 Before proceeding with disassembly wipe exterior surface of compressor clean 2 All oil in compressor should be drained and measured Assist draining by positioning compressor with oil drain plug down Record the amount of oil drained from the compressor See C C O T Refrigerant Oil Distribution in the AIR CONDITIONING section 3 Invert compressor and Holding Fixture J 9396 with front end of compressor shaft now facin
476. t to case thrust washer tabs in pockets Fig 7A 152C and retain with petrolatum This must be a metal washer ASSEMBLY OF UNITS TO TRANSMISSION CASE The first three steps can be omitted if the parts invoived were not removed on disassembly 1 Install parking pawl tooth toward inside of case and parking pawl shaft Fig 7A 154C 2 Install parking pawl shaft retainer clip Fig 7A 155C Fig 7A 151C Installing Center Support to Reaction Carrier Fig 7A 152C Checking Roller Clutch Rotation THRUST WASHER METAL Fig 7A 183C Installing Case to Output Shaft Thrust Washer Fig 7A 154C Instailing Parking Pawl Shaft Cup Plug RETAINING SPRING Fig 7A 155C Installing Parking Shaft Retaining Spring 3 Install parking pawl shaft cup plug and drive into the case using a 3 8 dia rod until the parking pawl shaft bottoms on the case rib Fig 7A 154C 4 Install parking pawl return spring square end hooked on pawl and other end on case 5 Install parking bracket with guides over parking pawl using two attaching bolts torque to 18 ft lbs 6 Install rear band assembly so that two lugs index with two anchor pins Check to make sure band is seated on lugs Fig 7A 156C 7 Install the center support to case spacer against the shoulder at the bottom of case splines and the gap located adjacent to the band anchor pin Fig 7A 157C Do not confuse this spacer 040 thick and both sides flat
477. tainer from the gear housing together RACK PISTON PLUG Must be removed Separate pitman STUB SHAFT before removing shaft and gasket rack seal from side cover if required HOUSING ASSEMBLY Fig 3B3 8C Overhaul 800 and 808 Gears Chart C OVERHAUL MANUAL 5 REMOVE AND INSTALL ADJUSTER PLUG ASSEMBLY REMOVE Loosen lock nut 1 Use punch against edge of slots INSTALL Install parts as shown Remove adjuster plug using spanner wrench J 7624 ADJUSTER PLUG LOCK NUT 2 NOTICE when installing adjuster plug care should be taken not to cut seals 6 DISASSEMBLE AND ASSEMBLE ADJUSTER PLUG ASSEMBLY STEERING 3B 15 NOSE ONE 7 REMOVE AND INSTALL BEARING WORM AND VALVE ASSEMBLY REMOVE INSTALL Grasp stub shaft and 1 Install parts as remove valve and worm shown assembly as aunit Separate the valve from the worm Note how the pin in the worm fits the slot in the valve THRUST BEARING AND RACES WORM ASSEMBLY NOTICE When reassembling DISASSEMBLE 1 Disassemble parts as shown Lg Driver J 7079 2 Drive bearing and seals from adjuster Bearing remover DJUSTER PLUG tal mene IL 23 Remove bearing and seals 1 Assemble parts ASSEMBLE as shown aN N a al RETAINING RING Z STUB SHAFT DUST SEAL STUB SHAFT SEAL NEEDLE BEARING ADJUSTER PLUG RING SEAL UPPER BEARING RACE LARGE UPPER THRUST BEARING UPPE
478. tallation and Adjustment If there is no preload reading check for looseness of pinion assembly by shaking the companion flange Looseness indicates the need for bearing replacement 3 Install Holder J 8614 11 on flange by using two bolts with flat washers as shown in figure 5F Position J 8614 11 on flange so that the four notches are toward the flange 4 Remove pinion nut and washer Discard pinion nut and use a new one upon reassembly 5 Thread end of J 8614 3 into small O D end of J 8614 2 Then with J 8614 11 installed as in step 3 insert J 8614 2 into J 8614 11 and turn it 1 8 of a turn to locked position Remove flange by turning J 8614 3 while holding J 8614 22 as shown in figure 6F 6 Remove drive pinion from carrier It may be necessary to tap on the pinion with a soft faced hammer 7 With 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 8 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 located behind the inner bearing cup Tag shims for reassembly 9 Remove rear pinion bearing using J 22912 and an arbor press OVERHAUL MANUAL 48 22 REAR AXLE DIFFERENTIAL Fig 5F Removing Pinion Nut Inspection 1 Clean all gears and bearings in cleaning solvent and inspect all bearing cu
479. tch Assy 3rd Speed Synchronizer Ring 3rd Speed Gear 1 1 7 8 2nd Speed Synchronizer Ring 4th Speed Synchronizer Ring 9 1st amp 2nd Speed Clutch Assy Washer 0 151 Gear Bushing 1 1st Speed Synchronizer Ring 2 First Gear MANUAL TRANSMISSION 7 29 2 Blow out bearings with compressed air NOTICE Do not allow the bearings to spin Turn them slowly by hand Spinning bearings may damage the race and balls REPAIRS Synchronizer Keys and Springs Replacement The synchronizer hubs and sliding sleeves are a selected assembly and should be kept together as originally assembled but the keys and two springs may be replaced if worn or broken 1 If relation of hub and sleeve are not already marked mark for assembly purposes 2 Push the hub from the sliding sleeve the keys will fall free and the springs may be easily removed 3 Place the two springs in position one on each side of hub so all three keys are engaged by both springs Fig 7B 13K Place the keys in position and while holding them in place slide the sleeve onto the hub aligning the marks made before disassembly Extension Oil Seal and or Bushing Replacement 1 Pry seal from rear of extension 2 Remove bushing using Tool J 21465 17 with Handle J 8092 Drive bushing from rear of extension housing Fig 7B 14K 3 Using a new bushing and Tool J 21465 17 with Handle J 8092 press bushing into extension from rear of extension 2nd Speed
480. tent lever with detent lever pin toward center of transmission and actuator plunger between parking pawl and parking bracket Fig 7A 56A PARKING PAWL Fig 7A 54A Installing Parking Pawl OVERHAUL MANUAL Fig 7A 55A Installing Parking Pawl Cup Plug PARK BRACKET PARKING PAWL E Fig 7A 56A Installing Parking Pawl Rod NOTICE File any burrs or raised edges off the manual shaft that could damage the seal during installation of the shaft 11 Install manual shaft small identification ring groove first through case Install manual shaft to case retaining pin indexing with larger groove on manual shaft Fig 7A 57A ACTUATOR PLUNGER RETAINING IDENTIFICATION PIN GROOVE PIN GROOVE MANUAL VALVE Fig 7A 57A Installing Manual Shaft Into Case SPEEDOMETER DRIVE GEAR CLIP SPEEDOMETER OUTPUT SHAFT DRIVE GEAR Fig 7A 58A Output Shaft 12 Aligning inside detent lever with flats on manual shaft install inside detent lever on shaft 13 Install hex nut on manual shaft and torque to 27 0 34 0 N m 20 25 ft Ibs REAR GEAR PARTS Output Shaft Fig 7A 58A The service output shaft has one speedometer drive gear clip hole at the front speedometer gear location which is about 6 3 m 1 4 diameter m and opposite this hole is another clip hole which is about 4 0mm 5 32 The shaft also has the same size holes at the rear speedometer gear location 1 Inspect journals
481. ter spring first into throttle bracket c Install link on throttle lever making sure link is hooked as shown Fig 7A 165A d Install throttle lever and bracket assembly locating slot in bracket with coiled pin aligning lifter through valve body hole and link through T V linkage case bore Retain with bolt 15 Torque all control valve assembly to case attaching bolts to 13 0 17 0 N m 9 12 ft Ibs Oil Screen 1 Thoroughly clean air dry and inspect oil screen assembly 2 Install new oil screen gasket on screen and retain with petrolatum 3 Install oil screen assembly and attaching bolts Fig 7A 166A Torque bolts to 13 0 17 0 N m 9 12 ft Ibs Oil Pan 1 Clean and inspect oil pan for damage 2 Install new oil pan to case gasket on case 3 Install oil pan and retaining bolts Torque bolts to 14 0 18 0 N m 10 13 ft Ibs Speedometer Driven Gear Fig 7 167 Inspection 1 Remove speedometer driven gear from housing and inspect for damage 2 Inspect housing for damage and O ring for damage Or cuts 3 If damaged remove and discare O ring EXHAUST DIRECT CL MANUAL DRIVE REVERSE EXHAUST LO 1ST VOID LO SHIFT TV DETENT REVERSE BOOST PUMP INTAKE TV gt PART THROTTLE LINE BOOST 4 CHECK BALLS NOTE 5TH CHECK BALL IN CASE DIRECT CLUTCH DIRECT CLUTCH TV EXHAUST 3RD ACCUMULATOR Fig 7A 162A Location of Four Check Balls AVERHAUL MANUAL MANUAL DETENT
482. ter End Clearance Check 7 44 Rear End Play Checking Procedure 7 11 Assembly of Rear Unit eee 7 45 Gear Unit Assembly 222222 7A 13 Assembly of Units to Transmission Case 7 48 Speedometer Drive 7 15 Install Manual Linkage eee 7 51 Governor Assembly eese 7 16 Rear Extension Assembly eee 7 52 Driven Gear 7 17 Check Balls Front Servo Spacer Solenoid 7 53 Front Servo Parts Inspection 74 18 Rear Servo Assembly eee 7 55 Rear Servo Parts 7 18 Control Valve Assembly and Governor 7 56 Control Valve Service 7 19 Filter and Intake Pipe 2 2 2 2 22 7 56 Oil Pump Service EEN 7 22 Modulator Valve Forward Clutch Serviee 7A 25 and Vacuum Modulator eese 7 57 Direct Clutch and Intermediate Roller Service 7A 31 GOONETTIOE ET 7 57 Center Support Service sss 7 35 Speedometer Driven Gear 2 22 0 0 74 57 Reaction Carrier Roller Clutch and Output Converter Assembly Installation 7 57 Carrier Assembly semen 2 40 SpecifIca lonis
483. ter plate then guide center plate seal first onto the front plate hub being careful not to damage center plate seal Remove Seal Protector J 22733 7 Apply a light coat of silicone lubricant to bearing surfaces of air valve plunger being careful not to apply lubricant to rubber grommet inside plunger Install square ring seal on shoulder of front plate hub and install valve plunger return spring and plunger in base of front plate hub fig 5 10B 8 Set rear plate over hub of front plate and using hands only screw plate on hub making sure that valve and spring are properly aligned E ind torque plates to 150 in Ibs Check travel of valve plunger with index finger 9 Assemble rear diaphragm to rear plate and place lip of diaphragm in groove in rear plate Install diaphragm retainer over rear diaphragm and lip of center plate Using fingers press retainer until it seats on shoulder of center plate fig 5 11B BRAKES 5 9 SQUARE SECTIONED O RING VALVE RETURN SPRING VALVE PLUNGER REAR DIAPHRAGM PLATE REAR DIAPHRAGM REAR DIAPHRAGM RETAINER REAR SHELL VALVE POPPET POPPET RETAINER VALVE ROD SPRING SILENCER SILENCER RETAINE sd DO d p S VALVE OPERATING ROD CENTER PLATE FRONT SHELL REACTION DISC FRONT DIAPHRAGM PLATE RONT DIAPHRAGM Fig 5 5B Diaphragm and Plates 10 Apply talcum powder to inside wall of rear housing and silicone lubricant to the scalloped cuto
484. ter shaft assembly from case and separate the inner and outer shifter shafts Remove and discard O rings 7 Inspect poppet plate for damage If necessary to remove drive pivot shaft from case Remove poppet plate and spring from bottom of case Removing Input Gear Assembly 8 Remove input gear bearing retainer and seal assembly Discard gasket 9 Remove large snap ring from bearing outer diameter 10 Tap input gear and bearing from case 11 Remove snap ring retaining input shaft bearing to shaft and remove bearing from input gear This is a select fit snap ring Snap rings size A B C and D are released for service Select tightest fit Removing Cusrer Gear Assembly Fig 7D 15S 12 From intermediate case side remove counter shaft from cluster gear and case using Tool J 24745 Remove cluster gear assembly from case Recover roller bearings 72 required from gear case and shaft 13 Remove cluster gear thrust washers from case OVERHAUL MANUAL emm 7D 12 TRANSFER CASES Au E 4 7A 8 1112 3 hi 16 17 8 22 23 24 26 pv 64 m 62 ei 60 59 58 57 56 55 54 53 52 1 Adapter 22 Oil Pump 44 Magnet 2 Input Drive Gear Pilot Brgs 23 Speedometer Drive Gear 45 Drive Chain 3 Range Selector Sliding Clutch 24 Brg Retainer Ring 46 Gasket 4 Range Selector Housing 25 Rear Output Rear Brg 47 Brg Outer Ring 5 Low Speed Gear Bushing 26 Rear Output Shaft 48 Front Output Front Brg
485. tershaft 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 Do not install idler shaft E ring yet 4 Using snap ring pliers expand the snap ring in the extension and assemble extension over rear of mainshaft and onto rear bearing Seat snap ring in rear bearing groove Fig 7 4 5 Load the mainshaft pilot bearings 14 into the clutch gear cavity and assemble the 3rd speed blocker ring onto the clutch gear clutching surface with its teeth toward the gear 6 Pilot the clutch gear pilot bearings and 3rd speed blocker ring assembly over the front of the mainshaft assembly Do not assemble bearing to gear yet Be sure the notches in the blocker ring align with the keys in the 2 3 synchronizer assembly Fig 7B 16A Loading Countergear 7 Place extension to case gasket at rear of case holding in place with grease and from the rear of case assemble the clutch gear mainshaft and extension to case as an assembly 8 Install extension to caSe retaining bolts 9 Install front bearing outer snap ring to bearing and position bearing over stem of clutch gear and into front case bore 10 Install snap ring to clutch gear stem and clutch gear bearing retainer and gasket to case The retainer oil return hole should be at the bottom 11 Install reverse idler gear retainer E ring to shaft 12
486. th 3 Refer to the thickness of the shim recorded earlier in Pinion Removal procedures Increase or decrease the shim dimension as indicated by the chart in figure 16E a For example if original shim measured 014 inch original code was 1 and new code is 2 the correct shim would be 014 inch plus 003 017 inch b If original shim was 012 inch original code 2 and new code is 2 the correct shim would be 012 minus 004 008 inch 4 Place the pinion shim as determined in step 3 onto the carrier housing making sure the bolt holes align with those of carrier and that the mating surfaces are clean and 1 24433 Fig 13 Installing Pinion Rear Bearing Fig 14E Installing Straddle Bearing free from foreign material 5 Place the pinion retainer assembly into position and align bolt holes to carrier Install retaining bolts and tighten in a crosswise manner Torque to specifications 6 Following dirve pinion service a Contact Pattern Check must be made CHECK AND ADJUSTMENTS Four adjustments are essential for proper operation of the differential and its related parts These adjustments are a Pinion Bearing Preload b Side Bearing Preload c Pinion Depth and d Ring Gear to Pinion Backlash Pinion Bearing Preload is set to specifications in step 9 of Drive Pinion Reassembly Side Bearing Preload is set to specifications in step 6 of Differential Case Installation and Adjustment Followin
487. that the pinion during testing was found to have best tooth contact at a position varying from design or nominal depth In order to compensate for all of the allowable machining variables a procedure of gaging the carrier and shimming the pinion has been developed After gaging a carrier the assembler must install the appropriate shim between the drive pinion shoulder and rear bearing so that pinion depth can be adjusted to the required position for best tooth contact in each axle assembly Proper pinion depth is determined with Pinion Setting Gage J 21777 01 1 Clean the housing assembly and all gage parts to insure accurate measurements 2 Lubricate front and rear pinion bearings which will be used in final assembly and position them in their respective races in the carrier 3 Use cloverleaf gage plate J 21777 29 for 8 1 2 ring gear or J 21777 36 for 8 7 8 ring gear mounted on preload stud J 21777 43 insert stud through rear bearing and pilot J 21777 35 and through front bearing and pilot J 21777 42 Install the hex nut until snug and rotate the bearings to REAR AXLE DIFFERENTIAL 4B 7 Fig 10B Checking Ring Gear Backlash make sure they are properly seated See figure 18B for illustration of proper positioning 4 Hold the preload stud stationary with a wrench on the flats and tighten hex nut Tighten until 20 in lbs of torque are required to rotate the bearings as shown in figure 19B 5 Mount the side beairng discs
488. that the outer thread of the nut is upset 23 Assemble a boot if used on the pedal rod Then assemble a NEW grommet in the groove near the end of the pedal rod 24 Moisten the grommet with water to ease assembly and insert the grommet end of the pedal rod into the input rod end of the booster housing Push on the end of the pedal rod to seat the grommet in the groove inside the housing NOTICE When the grommet is fully seated the pedal rod will rotate freely with no binding 25 Slide the boot on the pedal rod and assemble the large end of the boot onto the hub of the power section OVERHAUL MANUAL 5 28 BRAKES OANAOPWN gt OVERHAUL MANUAL SPECIAL TOOLS J 4880 Snap Ring Pliers J 21524 Power Piston Remover and Installer J 21601 Power Brake Retainer and Installer J 22657 Bushing Retainer Socket J 22647 Height Gauge J 22677 Power Cylinder Seal Installer J 22733 Seal Installer and Protector J 28458 Power Piston Seal Protector J 22805 Power Cylinder Holding Fixture J 22839 Front Plate Holding Fixture J 22893 Booster Separating Adapter J 23101 Power Piston Holding Tool 20 J 23175 Control Valve Installer J 23188 Secondary Bearing Protector J 24551 Piston Installers J 25083 J 24553 Input Rod Seal Installers J 28485 J 28497 J 24554 Socket J 24569 Pedal Push Rcd Remover J 9504 Power Cylinder Spanner Wrench J 26889 Accumulator Compressor Fig 5 17E Special Tools
489. the last three digits of the piece part number See Thrust Race Size Chart in Figure 1D 46 22 Remove nuts from top plate of compressing fixture J 9397 and remove top plate 23 Separate cylinder halves while unit is in fixture It may be necessary to use a wooden block and mallet 24 Remove rear cylinder half and carefully remove one piston at a time from axial plate and front cylinder half Do not lose the relationship of the front ball and shoe disc and rear ball Transfer each piston ball and shoe disc to its proper place in Parts Tray J 9402 SLEEVE J 8001 2 CLAMP J 8001 1 DIAL INDICATOR J 8001 3 REAR THRUST BEARING amp RACES I Figure 1D 48 Gaging A 6 Rear Thrust Race 25 Now remove rear outer zero thrust race it will be on top from shaft and install the thrust race just selected in Steps 20 and 21 that is presently setting in the right hand slot at bottom center of parts tray J 9402 CHECKING FOR REAR THRUST AND RACE F THICKNESS FRONT THRUST lege EE HEAD CLEARANCE L Figure 1D 49 Checking 6 Piston and Shaft End Play AIR CONDITIONING COMPRESSOR OVERHAUL 1D 19 The removed ZERO thrust race may be put aside for re use in additional Gaging or rebuilding operations 26 Repeat for each piston A 6 COMPRESSOR CYLINDER AND SHAFT ASSEMBLY A 6 Teflon Piston Ring Replacement The Teflon piston ring installing sizing and gaging tools are shown in Figure 1D 50 1 Remove the o
490. ting Tooth Contact Two adjustments can be made which will affect tooth contact pattern These are backlash and position of drive pinion in carrier The effects of bearing preloads are not readily apparent on hand loaded teeth pattern tests however these adjustments should be within specifications before proceeding with backlash and drive pinion adjustments NOTICE It may be necessary to adjust both pinion depth and backlash to obtain the correct pattern The position of the drive pinion is adjusted by increasing or decreasing the shim thickness between the 7 22804 2 23911 Fig 23B Installing Pinion Oil Seal REAR AXLE DIFFERENTIAL 4B 11 Fig 24B Measuring Rotating Torque pinion head and inner race of rear bearing The shim is used in the differential to compensate for manufacturing tolerances Increasing shim thickness will move the pinion closer to centerline of the ring gear Decreasing shim thickness will move pinion farther away from centerline of the ring gear Backlash is adjusted by means of the side bearing adjusting shims which moves the entire case and ring gear assembly closer to or farther from the drive pinion The adjusting shims are also used to set side bearing preload To increase backlash increase right shim and decrease left shim an equal amount To decrease backlash decrease right shim and increase left shim an equal amount The important thing to note is that the contact pattern is cen
491. tion 3rd 4th clutch sliding sleeve forward This will provide clearance for installation as well as hold the assembly together 5 Position new rear bearing retainer to case extension gasket on rear of case Install mainshaft and drive gear assembly into case 6 Align rear bearing retainer with transmission case Install retainer to case locating pin and retainer locking bolt Torque to recommended specifications 7 Place bearing snap ring on front main bearing Position front main bearing to case opening and with a hollow shaft or tool J 5590 tap bearing into case Fig 7B 23K Install spacer washer and selective fit snap ring to secure main drive bearing 8 Install front bearing retainer and gasket Apply sealer to bolts and torque to recommended specification OVERHAUL MANUAL 7B 34 MANUAL TRANSMISSION Fig 7B 23K Installing Front Main Bearing 9 Install rear reverse idler gear engaging the splines with the portion of the gear within the case 10 Place new rear bearing retainer to case extension gasket into position on rear face of bearing retainer Slide reverse gear on shaft Install speedometer gear and two selective fit snap rings 11 Install idler shaft into extension until hole in shaft lines up with hole in boss Insert reverse idler shaft lock pin in transmission boss opening and drive the pin into the extension until the shaft is securely locked in place Install new welch plug with sealer in boss opening
492. tly opposite against the case and bearing snap ring groove at the same time Remove 4th gear synchronizer ring Index cut out section of drive gear in down position with countergear to obtain clearance for removing clutch gear 12 Remove reaer mainshaft bearing retainer ring snap ring and using Tool J 22832 and J 8433 1 remove bearing from case Fig 7B 4L Slide 1st speed gear thrust washer off mainshaft 13 Raise rear of mainshaft assembly and push rearward in case bore then swing front end up and lift from case Remove synchronizer cone from shaft 14 Slide reverse idler gear rearward and move countergear rearward until front end is free of case then lift to remove from case 15 To remove reverse idler gear drive reverse idler gear shaft out of case from front to rear using a drive Remove reverse idler gear from case SUBASSEMBLY OPERATIONS TRANSMISSION COVER Disassembly Fig 7B 5L 1 Using a small punch drive out pins retaining Ist 2nd and 3rd 4th shifter forks to shifter shafts and also drive out expansion plugs The pin retaining the third and fourth shifter fork to the shaft must be removed and the shifter fork removed from the cover before the reverse shifter head pin can be removed 2 With shifter shafts in neutral position drive shafts out of cover and shafter forks NOTICE Exercise care so shaft detent balls springs and innerlock pin located in the cover are not lost as the shifter shafts are removed
493. to engage locating tabs on thrust washer in locating slots in case OVERHAUL MANUAL 7 16 MANUAL TRANSMISSION UPPER DETENT 4 FRONT CASE SPRING LONG UPPER DETENT PLUG FIRST REVERSE SETSCREW BORE SETSCREW BORE INTERLOCK PLUG SECOND THIRD s t SHIFT RAIL LOWER DETENT PLUG LOWER DETENT SPRING SHORT Fig 78 21B Installation Sequence Detent Plugs and Springs 6 Insert countershaft into bore at rear of case just far enough to hold rear thrust washer from being displaced when the countergear is installed 7 Align bore in countergear with countershaft and front thrust washer then start countershaft into countergear Before countershaft is completely installed make sure that roll pin hole in countershaft is aligned with hole in case When holes are aligned tap countershaft into place remove tool J 25232 Fig 7 5 8 Measure countershaft end play by inserting feeler gauge between thrust washer and countergear End play should be 0 004 to 0 018 inch If end play exceeds 0 018 inch remove gear and replace thrust washers 9 After correct end play has been obtained install roll pin in case 10 Lower shorter detent spring in detent bore in case Fig 7B 21B Allow spring to drop into place at bottom of Second Third shift rail bore Insert lower detent plug in detent bore on top of spring 11 Install shifter fork shafts in their case bores with the pivot lug facing up Shifte
494. to cover allowing the detent balls to fall free then remove both shifter shafts 3 Remove interlock sleeve interlock pin and poppet spring 4 Replace necessary parts Fig 7B 18K and assembly by reversing Steps 1 3 ASSEMBLY OF COUNTERGEAR 1 Install roller spacer in countergear if removed 2 Using heavy grease to retain rollers install spacer rollers spacer rollers and spacer in either end of countergear Repeat in other end of countergear Fig 7B 19K 3 Insert a dummy shaft or loading Tool J 24658 into countergear CHECKING COUNTERGEAR END PLAY 1 Rest the transmission case on its side with the side cover opening toward the assembler Put countergear tanged thrust washers in place retaining them with heavy grease making sure the tangs are resting in the notches of the case 2 Set countergear in place in bottom of transmission case making sure that tanged thrust washers are not knocked out of place 3 Position the transmission case resting on its front face OVERHAUL MANUAL SLEEVE mm SPRING 1 2 SHIFTER SHAFT DETENT LOCK DETENT BALL PIN BALL 3 SHIFTER SHAFT Fig 7B 18K Shift Cover Assembly 4 Lubricate and insert countergear pushing loading Tool J 24658 out front of case until woodruff key slot is in its relative installed position do not install key 5 Attach a dial indicator as shown in Fig 7B 20K and check end play of the countergear If end play is greater than
495. to disassembly governor assembly in order to replace driven gear Disassembly may also be necessary due to improper operation In such cases proceed as follows SLEEVE AND CARRIER ASSEMBLY GEAR RETAINING PIN DRIVEN GEAR SPRINGS 2 SECONDARY WEIGHT 2 PRIMARY WEIGHT 2 es 44 eX THRUST CAP Fig 7A 97B Governor Assembly Exploded View Typical Disassembly 1 Cut off one end of each governor weight pin and remove pins governor thrust cap governor weights and springs Governor weights are interchangeable from side to side and need not be identified fig 7A 97B 2 Remove governor valve from governor sleeve Be careful not to damage valve 3 Perform following inspections and replace governor driven gear if necessary Inspection 1 Wash all parts in cleaning solvent air dry and blow out all passages 2 Inspect governor sleeve for nicks burrs scoring or galling 3 Check governor sleeve for free operation in bore of transmission case 4 Inspect governor valve for nicks burrs scoring or galling 5 Check governor valve for free operation in bore of governor sleeve 6 Inspect governor driven gear for nicks burrs or damage 7 Check governor driven gear for looseness on governor sleeve 8 Inspect governor weight springs for distortion or damage 9 Check governor weights for free operation in their retainers 10 Check valve opening at entry and exhaust 020 inch minimum
496. to remove all accumulation of lubricant and dirt Remove all trace of gaskets from surface where used Inspection Carefully inspect all bearings and rollers for evidence of chipping cracks or worn spots that would render bearing unfit for further service Bearings are non adjustable and if worn or damaged must be replaced with new parts Inspect shaft splines and gears If any indication of failure such as chipped teeth or excessive wear is indicated those parts should be replaced with new parts ASSEMBLY OF TRANSFER CASE FIG 7D 9R Idler Gear 1 Press the two bearing cups in the idler gear if previously removed using Tool J 9276 2 and Handle J 8092 Fig 7D 10R 2 Assemble the two bearing cones spacer shims and idler gear on dummy shaft J 23429 with bore up Check end play Fig 7D 11R Limits are 001 to 002 inch _ 3 Install idler gear assembly with dummy shaft into case through front output bore large end first Fig 7D 12R OVERHAUL MANUAL TRANSFER CASES 7D 6 a C Fig 7D 13R Installing Idler Shaft 4 Install idler shaft from large bore side and drive throuhg using a soft hammer Fig 7D 13R 5 Install washer and new locknut Check for end play and free rotation Torque nut to 150 ft Ibs 6 Install idler shaft cover and gasket Torque bolts to 20 ft Ibs NOTICE Flat on cover must be located adjacent to front output shaft rear cover Fi
497. tooth contact pattern These are backlash and position of drive pinion in carrier The effects of bearing preloads are not readily apparent on hand loaded teeth pattern tests however these adjustments should be within specifications before proceeding with backlash and drive pinion adjustments It may be necessary to adjust both pinion depth and backlash to obtain the correct pattern The position of the drive pinion is adjusted by increasing or decreasing the shim thickness between the pinion head and inner race of rear bearing The shim is used in the differential to compensate for manufacturing tolerences Increasing shim thickness will move the pinion closer to centerline of the ring gear Decreasing shim thickness will move pinion farther away from centerline of the ring gear Backlash is adjusted by means of the side bearing adjusting shims which moves the entire case and ring gear OVERHAUL MANUAL 4C 8 FRONT WHEEL DRIVE LOW FLANK CONTACT DECREASE PINION SHIM TOE CONTACT INCREASE BACKLASH HEEL CONTACT DECREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM Fig 4C 12 Gear Tooth Pattern Contact Pattern assembly closer to or farther from the drive pinion The The important thing to note is that the contact pattern adjusting shims are also used to set side bearing preload is centrally located up and down on the face of the ring gear To increase backlash increase right shim and decrease left teeth shim an equal
498. trally located up and down on the face of the ring gear teeth CONVEX SIDE DRIVE CONCAVE SIDE COAST Fig 25B Gear Tooth Nomenclature OVERHAUL MANUAL 4B 12 REAR AXLE DIFFERENTIAL TOE CONTACT INCREASE BACKLASH HIGH FACE CONTACT INCREASE PINION SHIM LOW FLANK CONTACT DECREASE PINION SHIM HEEL CONTACT DECREASE BACKLASH Fig 26B Gear Tooth Contact Pattern Check SERIES 20 30 TRUCK DIFFERENTIAL 10 1 2 RING GEAR INDEX Differential C se 2 eee eret 4B 12 Pinion Bearing Preload sess 4B 17 Removal eo dirette ere ticesseser errato 4B 12 Side Bearing Preload 4B 17 Side Bearing 4B 13 Pinion Depth and Backlash 4B 18 Ring Gear Replacement 4B 14 Gear Tooth Contact Pattern Check 4B 18 Disassembly and Reassembly 4B 14 Installation and 4B 15 DIFFERENTIAL CASE Drive PinlOn eere rr reden SES 4B 15 Removal sic cecinere ite peer ere E 4B 15 Disassembly 56 i Deinde 4B 15 Removal Inspection ceat deti 4B 16 1 Mount axle assembly in a bench vise or holding Reassembl yoe ee tee a 4B 16 fixture Installation and Adjustment sess
499. ts Replace worn and defective parts Assembly Fig 70 115 Installing Countergear Assembly 1 Using Tool J 24745 and a heavy grease install roller bearings 72 required and spacers in clustergear bore 2 Using a heavy grease position countershaft thrust washers in case Engage tab on washers with a slot in case thrust surface 3 Position cluster gear assembly in case and install countershaft through front face of range box into gear assembly Countershaft face with flat should face forward and must be aligned with case gasket installing Input Gear Assembly 4 Install bearing without large snap ring on input gear shaft positioning snap ring groove outward and install new retaining ring on shaft Position input gear and bearing in housing The retaining ring is a select fit Use service ring size A B C or D as required to provide tightest fit SNAP RING Fig 7D 14S Removing Input Shaft Bearing to Retainer Snap Ring Fig 7D 15S Removing Cluster Gear Shaft 5 Install snap ring in outside diameter of bearing 6 Align oil slot in retainer with drain hold in case and install input gear bearing retainer gasket and retaining bolts Tighten bolts to specifications Installing Shifter Shaft Assembly 7 If removed install poppet plate and pivot pin assembly in housing Use sealant on pin 8 Install new O rings on the inner and outer shifter shiafts Lubricate O rings and assemble inner shaft in the outer shaf
500. ts with scribe markings on both halves of case in alignment 7 Install differential case bolts but do not tighten at this time 8 Before tightening bolts use axle shafts and align splines of the side gear and side gear ring on each side Tighten bolts evenly and alternately Remove axle shafts 9 Observe if Power Lok components have been assembled properly Each pinion cross shaft can be tight on its ramp or if there is clearance it should be only a few thousandths and it should be equal at all four cross shaft ends Testing Procedure The Power Lok can be effectively tested for correct operation by placing one rear wheel on good dry pavement and the other on ice snow mud gravel grease etc It can easily be determined whether or not the non slipping wheel is providing pulling power The procedure should then be repeated with the opposite wheels on the dry and slippery surfaces The above testing procedure is a rough test that can be made by the owner of the vehicle However if it is suspected that the unit is not operating properly it can be checked by the following procedure Be sure the transmission 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 across two wheel studs Apply a torque wrench to OVERHAUL MANUAL 4B 48 REAR AXLE DIFFERENTIAL special tool Disregard breakaway torque and observe only the torque req
501. turbine shaft through hole in bench or Holding Fixture J 6116 and remove forward clutch housing to direct clutch hub snap ring Fig 7A 80C 2 Remove direct clutch hub 3 Remove forward clutch hub and thrust washers Fig 7A 81C 4 Remove composition steel clutch plates and waved steel plate Models CL and CD do not use a waved steel plate FORWARD CLUTCH HUB THRUST WASHERS FORWARD CLUTCH HOUSING Fig 7A 81C Removing Forward Clutch Hub and Thrust Washers AUTOMATIC TRANSMISSIONS 400 7A 27 TURBINE SHAFT Fig 7A 82C Removing Turbine Shaft from Forward Clutch Housing 5 If necessary place forward clutch and turbine shaft in arbor press and remove turbine shaft Fig 7A 82C 6 Using J 4670 clutch spring compressor in arbor press with Adapter J 21664 compress spring retainer and remove snap ring Fig 7A 83C 7 Remove spring retainer and sixteen 16 clutch release springs Keep springs separate from direct clutch release springs 8 Remove forward clutch piston J 21664 Fig 7A 83C Removing Forward Clutch Spring Retaining Snap Ring 400 7A 28 AUTOMATIC TRANSMISSIONS CLUTCH OUTER SEAL Fig 7A 84C Removing Forward Clutch Piston Outer Seal 9 Remove inner and outer clutch piston seals Fig 7A 84C 10 Remove center piston seal from forward clutch housing Fig 7A 85C Inspection 1 Inspect composition faced and steel clutch plates for signs of burning scoring
502. two levels The piston rod should always contact the longer section lower level of the gage The piston rod should never contact the shorter section higher level of the gage Move gage from side to side to check piston rod height 7 Any variation beyond these two limits must be compensated for by obtaining the service adjustable piston rod and adjusting the self locking screw to meet the gaging specifications 8 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 BENDIX HYDRAULIC BRAKE BOOSTER HYDRO BOOST UNIT REPAIR CAUTION The accumulator contains compressed gas Always use proper tools and follow recommended procedures or personal injury may result Do not apply heat to accumulator Do not attempt to repair inoperative accumulator OVERHAUL MANUAL always replace with a new accumulator Dispose of an inoperative accumulator by drilling a 1 16 diameter hole through the end of the accumulator can opposite the OQ ring TWO FUNCTION VALVE RETURN PORT FITTING VALVE SEAT PEE OUTPUT O RING DUMP VALVE BRACKET SPOOL VALVE PEDAL ROD BOOT HOUSING COVER POWER PISTON HOUSING SEAL PISTON SEAL TUBE SEAT 2 BRAKES 5 23 SPOOL RETURN SPRING O RING POOL PLUG RETAINER BAFFLE amp SPRING RETAINER PISTON RETURN SPRING x HOUSING ACCUMULATOR O RING RETAINING RING Fig 5 1
503. uired to continuously turn the wheel smoothly If the torque reading is less than 40 foot pounds or more than 200 ft Ibs the unit should be disassembled and the necessary repairs made EATON POSITIVE LOCKING DIFFERENTIAL DESCRIPTION Trucks equipped with locking differentials use one of the Eaton locking units in Figure 4B IH 2H These differentials provide true differential action and also incorporates a speed sensitive device which automatically and positively locks both rear wheels together if either wheel should spin excessively during slow vehicle operation Locking is accomplished through the use of a flyweight governor mechanism cam system and multi disc clutch The flywheights on the governor mechanism move outward to engage a latching bracket whenever the wheel to wheel speed varies by approximately 100 rpm or more This action retards a cam which in turn compresses a multi disc clutch locking one side gear to the case At wheel to wheel LOCK WASHER CAM FORM SIDE GEAR CAM PLATE WAVE SPRING SHIM THRUST RING DISC PACK S A GOVERNOR ASS Y differentials of less than approximatley 100 rpm the unit operates as a standard or open differential At vehicle speeds above approximately 20 mph 32 km h the latching bracket overcomes a spring preload and swings away from the flyweights At this vehicle speed or greater the differential will not lock as the added traction is not necessary Service Te
504. ull on screwdrivers and force differential case as far as possible toward the dial indicator Rock the ring gear to set the bearings With force still applied set indicator at O 10 Reposition screwdrivers between bearing cup and carrier on ring gear side Pull on screwdrivers and force differential case as far as possible toward center of carrier Record the indicator reading This will be the total amount of shims needed less preload for setting backlash later during assembly 11 Remove differential from carrier DRIVE PINION Installation and Adjustment of Depth and Preload Ring gears and pinions are supplied in matched sets only Matching numbers on both pinion and ring gear are etched for verification If a new gear set 15 being used verify the numbers of each pinion and ring gear before proceeding with assembly On the button end of each pinion there is etched a plus 4 number a minus number or a zero 0 number which indicates the best running position for each particular gear set This dimension is controlled by the shimming behind the inner bearing cup Whenever baffles or oil slingers are used they become a part of the adjusting shim pack For example If a pinion is etched 3 this pinion would require 003 less shims than a pinion etched O This means by removing shims the mounting distance of the pinion is increased by 003 which is just what a etching indicates 3 Or if a pinion is etched 3 we w
505. ulling up H bearing operation 15 smooth it does not need removal Check the stub shaft needle bearing for smoothness If O K do not remove HOUSING ASSEMBLY DUST SEAL QVERHAUL MANUAL INSTALL If removed install new Stub shaft needle bearing Bottom tool on housing counterbore NOTICE SERVICE thrust bearing DOES NOT SNAP ON needle bearing If removed install as shown below Install stub shaft seal Liberally coat top of seal with anhydrous calcium grease Install dust seal just deep enough to clear retaining ring groove then install retaining ring STUB SHAFT SEAL RETAINING RING STUB SHAFT NEEDLE BEARING UPPER THRUST BEARING STUB SHAFT NEEDLE BEARING Install from small end of housing HOUSING ASSEMBLY UPPER THRUST BEARING Center on valve body Si Y p 17 RACK PISTON AND VALVE ASSEMBLY Hold in position shown and slip housing assembly on 10 REMOVE AND INSTALL PITMAN SHAFT SEALS AND BEARING REMOVE Clean end of housing thoroughly to prevent dirt from entering and be extremely careful not to score the housing bore Remove retaining ring with snap ring pliers J 4245 Using screw driver pry seals and washer from bore OIL SEAL WASHER DUST SEAL ONE os E RING Installer J 8810 INSTALL Bottom oil seal in counterbore Install washer Coat seal lip and washer face with anhydrous calcium grease Install remaining p
506. umulator piston and compress piston only enough to remove retaining E ring fig 7A 55B NOTICE Piston may be damaged if piston is over compressed 9 Remove direct clutch accumulator piston and metal oil seal ring and spring 10 From the next bore down from the direct clutch accumulator remove the detent actuating lever bracket bolt bracket actuating lever and retaining pin stop spring retainer seat outer spring inner spring washer and detent valve ege DETENT VALVE WASHER DETENT VALVE INNER SPRING DETENT VALVE OUTER SPRING DETENT VALVE OUTER SPRING SEAT DETENT VALVE SPRING RETAINER DETENT VALVE STOP DETENT VALVE ACTUATING LEVER BRACKET DETENT VALVE ACTUATING LEVER RETAINING BOLT 37 RETAINING PIN 38 CAP Fig 7A 56B Valve Body Exploded View OVERHAUL MANUAL Fig 7A 55B Removing Direct Clutch Accumulator Piston Retaining E Ring Inspection 1 Inspect all valves for scoring cracks and free movement in their respective bores 2 Inspect valve body for cracks scored bores interconnected oil passages and flatness of mounting face 3 Check all springs for distortion or collapsed coils Reassembly 1 Install direct clutch accumulator piston spring and piston into valve body PUMP TO CONVERTER HUB LIP SEAL 4 2 H GEAR DRIVE GEAR E BODY ASSEMBLY PUMP COVER AND STATOR SHAFT ASSEMBLY SQUARE CUT RING SEAL NYLON B DIRECT CLUTCH DRUM NEEDLE BEARIN
507. until tool bottoms Fig 7A 179A REAR SUN GEAR 1 Using tool J 25019 14 with Slide Hammer J 7004 1 remove bushing Fig 7A 180A 2 Place rear sun gear with gear side down on block of wood to prevent damaging the gear 3 Using tool J 25019 2 with Driver Handle J 8092 drive or press new bushing into place until tool bottoms Fig 7A 181A J 7004 1 J 25019 16 LO amp REVERSE CLUTCH HOUSING Fig 7A 182A Removing Lo and Reverse Clutch Housing Bushing 4 LO amp REVERSE CLUTCH HOUSING Fig 7A 183A Installing Lo and Reverse Clutch Housing Bushing LO AND REVERSE CLUTCH HOUSING BUSHING 1 Using tool J 25019 16 with Slide Hammer J 7004 1 remove bushing Fig 7A 182A 2 Place lo and reverse clutch housing with splined hub between two blocks of wood to prevent damaging the splines 3 Using tool J 25019 8 with Driver Handle J 8092 drive or press new bushing into place until tool bottoms Fig 7A 183A REAR CARRIER BUSHING 1 Using tool J 25019 16 with Slide Hammer J 7004 1 J 7004 1 J 25019 16 ol d REAR CARRIER Fig 7A 184A Removing Rear Carrier Bushing AUTOMATIC TRANSMISSION 200 7 4 47 J 8092 J 25019 7 REAR CARRIER 0 Fig 7A 185A Installing Rear Carrier Bushing remove bushing Fig 7A 184A 2 Using tool J 25019 7 with Driver Handle J 8092 drive or press new bushing into place until tool bottoms Fig 7A 185A CASE BUSHING
508. unts and then only after actual refrigerant leakage is determined by test Should an R 4 Compressor Shaft Seal ever have to be replaced because it was determined to be the cause of excessive signs of oil leakage in the A C system then the accumulator in this R 4 system must also be removed from the vehicle the oil in the accumulator then must be drained measured and replaced according to C C O T Refrigerant Oil Distribution in the Air Conditioning section to determine oil loss R 4 COMPRESSOR SHAFT SEAL REPLACEMENT Remove On Car 1 Discharge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR A C SYSTEMS in the AIR CONDITIONING section 2 Loosen and reposition compressor in mounting brackets 3 Remove Clutch Plate and Hub assembly from compressor as described in R 4 Compressor Clutch Plate and Hub Assembly Removal procedure 4 Remove the shaft seal seat retainer ring using Snap Ring Pliers J 5403 3 21 See Figure 1D 21 5 Thoroughly clean inside of compressor neck area surrounding the shaft the exposed portion of the seal seat and the shaft itself This is absolutely necessary to prevent any dirt or foreign material from getting into compressor 6 Place Seal Protector J 22974 over the end of the shaft to prevent chipping the ceramic seat Fully engage the knurled tangs of Seal Seat Remover Installer J 23128 into the recessed portion of the seal seat
509. upward 2 Secure from Service parts stock four ZERO thrust races two thrust bearings and three ZERO shoe discs 3 Now install ZERO THRUST RACE then one thrust bearing and a SECOND ZERO THRUST RACE ONTO FRONT END of compressor shaft Lubricate races and bearing with petrolatum 4 Insert threaded end of axial shaft through needle bearing in front cylinder half and allow thrust race and bearing assembly race bearing race to rest on hub of cylinder 5 Now install ZERO THRUST RACE ON REAR END of compressor axial shaft Figure 1D 41 so that it 1D 16 AIR CONDITIONING COMPRESSOR OVERHAUL rests on hub of axial plate Then add one thrust bearing and a SECOND ZERO THRUST RACE onto shaft Lubricate races and bearing with petrolatum At this point BOTH front end and rear end of axial shaft will have a stack up of one ZERO race one bearing one ZERO race THRUST BEARING THRUST RACE THRUST RACE COMPRESSING FIXTURE J 9397 HOLDING FIXTURE J 9396 3 gt B 15070 Figure 1D 41 Installing A 6 Rear Thrust Races and Bearings FRONT CYLINDER HALF 6 Lubricate ball pockets of the No 1 Piston with 525 viscosity refrigerant oil and place a ball in each socket Use balls previously removed if they were considered acceptable for re use 7 Lubricate cavity of a ZERO SHOE disc with 525 viscosity refrigerant oil and place shoe disc OVER BALL IN FRONT END of piston Figure 1D 42 Front end of piston has an identi
510. urning or looseness 2 Inspect bands for cracks or distortion 3 Inspect end for damage at anchor lugs or apply lugs 4 Inspect support to case spacer for burrs or raised edges if present remove with stone or fine abrasive INSPECTION OF CASE EXTENSION ALL EXCEPT CL MODEL 1 Inspect bushing for excessive wear or damage If replacement is necessary remove rear seal and with PLANET PINION PIN HEAD END UP Fig 7A 132C Installing Planet Pinion Pin 400 7A 42 AUTOMATIC TRANSMISSIONS REAR OIL SEAL BALL BEARINGS BEARING SPACER CASE EXTENSION Fig 7A 133C Model CL Case Extension extension housing properly supported remove bushing as follows a With rear seal removed position case extension on bench with seal end up Assemble remover J 21465 17 on handle J 8092 and drive out bushing with lead or brass hammer b Using tool J 21465 17 with Driver Handle J 8092 drive or press replacement bushing into place flush to 010 below oil seal counter bore area Stake bushing using tool J 21465 10 Stake marks to be in bushing lubrication grooves 2 Inspect gasket mounting face for damage 3 Inspect housing for cracks or porosity 4 Be sure rear seal drain back port is not obstructed INSPECTION OF CASE EXTENSION CL MODEL FIG 7A 133C 1 Inspect seal case extension to case groove for damage 2 Inspect for cracks or porosity 3 Inspect dowel pin in rear face for damage MODULATOR VALVE
511. using Tool J 22830 and J 22873 Fig 7B 21L NOTICE Do not over stress snap ring or damage may occur Ring should be tight in groove without side play ASSEMBLY OF TRANSMISSION 1 Lower the countergear into the case until it rests on bottoms of case 2 Place reverse idler gear in transmission case with gear teeth toward the front Install idler gear shaft from rear to front being careful to have slot in end of shaft in facing down Shaft slot face must be at least flush with case 3 Install mainshaft assembly into case with rear of shaft protruding out rear bearing hole in case Position Tool J 22874 in clutch gear case opening and engaging front mainshaft Fig 7B 23L Rotate case onto front end Install 1st speed gear thrust washer on shaft if not previously installed 4 Install snap ring on bearing O D and position rear mainshaft bearing on shaft Using Tool J 22874 1 drive bearing onto shaft and into case Fig 7B 23L Rotate case 1st Speed Gear 2nd Speed Blocker Reverse Driven Gear Ring 1st Gear Bushing 2nd Speed Gear 1st 2nd Gear Thrust Washer Synchronizer Hub 3rd Speed Bushing Assembly 3rd Speed Gear MANUAL TRANSMISSION 7B 43 10 3rd Speed Blocker Ring Ring 4th Speed Blocker 11 3rd 4th Speed Synchronizer Hub Assembly 3rd 4th Speed Synchronizer Sleeve Snap Ring Mainshaft 2nd Speed Gear Bushing Fig 7B 14L Mainshaft Assembly Exploded View and remove Tool J 22874 5 5 Install synchro
512. using a brass drift as shown in figure 8D Repeat removal on opposite gear 8 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 signs of overheating Clutch plates and discs are not serviced separately If replacement is required clutch pack must be replaced as an assembly 2 Inspect preload springs for distortion and other defects 3 Compress springs and determine if they are capable of properly preloading the clutch pack replace springs that are weak or questionable 4 Examine spring retainer for alignment between the retainer halves and for excessive wear at spring seats Fig 3D Installing Bolts to Retain Springs OVERHAUL MANUAL Fig 5D C Clamp and Bar Stock Installed for Spring Removal Reassembly 1 Lubricate clutch plates and discs with special limited slip lubricant 2 Alternately position clutch plate and clutch disc on side gear beginning and ending with clutch plate until assembly of clutch pack is complete See figure 9D 3 Install clutch pack guides on the clutch plate lugs Make sure that 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 5 Lubricate and assemble opposite side gear as above 6 Install one side gear clutch pack assembly an
513. ut drum to reverse clutch housing thrust washer from rear of input drum or from reverse clutch housing 8 Low and Reverse clutch housing assembly a Grind approximately 20mm 3 4 from the end of a 6 3mm No 4 easy out then remove the housing to case cup plug and seal by turning and pulling straight out Discard cup plug and seal Fig 7A 33A b Remove low and reverse clutch housing to case beveled snap ring Fig 7A 34A The flat side of the ring should have been against the low and reverse clutch housing with beveled side up Fig 7A 34A Removing Low and Reverse Housing to Case Snap Ring AUTOMATIC TRANSMISSION 200 7A 9 c Using J 25012 remove low and reverse clutch housing assembly by moving J 25012 back and forth Fig 7 35 d Remove low and reverse clutch housing to case spacer ring Fig 7 36 REAR GEAR PARTS Removal 1 Make sure the governor has been removed then grasp the output shaft and lift out remainder of rear unit LO amp REVERSE parts and lay down in a horizontal position Fig 7A 37A CLUTCH HOUSING 2 Roller clutch and rear carrier assembly a Remove roller clutch and rear carrier assembly off output shaft b Remove the 4 tanged rear carrier to rear internal gear thrust washer off the end of the rear carrier or inside the rear internal gear Fig 7A 38A 3 Remove low and reverse clutch plates off output shaft 4 Rear internal gear a Remove rear internal gear to rear
514. ut shaft downward Fig 7A 94A Do not install clamp assembly on any machined case surfaces 2 Install gauge clamp on case as shown in Fig 7A 95A 3 Install dial indicator J 8001 and plunger extension J 7057 Position extension against end of output shaft Set dial indicator to zero Fig 7A 95A 4 Move output shaft upward by turning the adjusting screw on J 25013 5 until the white or scribed line on sleeve J 25013 1 begins to disappear Fig 7A 94A and read end play Rear unit end play should be 0 10 0 64mm 004 025 The selective washer controlling this end play 1s located between the front internal gear thrust washer and output ROLLER THRUST BEARING ASSY Fig 7A 93A Installing Front Carrier and Roller Thrust Bearing OVERHAUL MANUAL 200 7A 24 AUTOMATIC TRANSMISSION J 25013 5 J 25013 1 Fig 7A 94A Installing Tools on Rear End of Case shaft snap ring If more or less washer thickness is required to bring end play within specifications select proper washer from the chart shown in Figure 7A 96A 5 Remove dial indicator and clamp assembly Fig 7A 95A 6 Loosen J 25013 5 adjusting screw on output shaft DIAL INDICATOR J 8001 LOCATION Fig 7A 95A Checking Rear Unit End Play REAR UNIT END PLAY CHART THICKNESS IDENTIFICATION Number and or Color 0 114 0 119 0 121 0 126 0 128 0 133 0 135 0 140 0 143 0 147 0 150 0 154 0 157 0 161 0 164 0 168
515. ut shaft housing bolts and remove housing and retainer assembly from case 3 Remove retaining nut and yoke from shaft then remove shaft assembly from housing 4 Remove snap ring using Tool J 23432 and discard 5 Remove thrust washer and washer pin 6 Remove tanged bronze washer Remove gear needle bearings 32 per row spacer and second row of needle bearings 7 Remove tanged bronze thrust washer from shaft IDLER SHAFT COVER FRONT OUTPUT SHAFT REAR BEARING RETAINER Fig 7D 1R Rear View of Transfer Case POPPET NUTS SHIFT RAIL ai ZA FRONT OUTPUT SHAFT ASSEMBLY B LA gt AE st FRONT INPUT SHAFT ASSEMBLY 5 Fig 7D 2R Front View of Transfer Case FRONT OUTPUT SHAFT REAR BEARING RETAINER Fig 7D 3R Removing Front Output Shaft Rear Bearing Retainer OVERHAUL MANUAL 70 2 TRANSFER CASES 789109811 1213 14 d keem LJ wem egen o 449 FS 45 44 43 414241 1 Input Shaft 18 Rear Bearing 32 Idler Gear Shaft Bearing 43 Sliding Clutch 2 O Aing Retainer Cup 44 Front Wheel Hi Gear 3 Snap Ring 19 Rear Yoke Assembly 33 Idler Shaft Bearing 45 Spacer 4 Bearing 20 Locknut Cone 46 Bearing 5 Snap Ring 21 Washer 34 Idler Shaft Cover 47 Snap Ring 6 Input Shaft Gear 22 Rear Output Shaft Bolts and 48 Seal 7 Sliding Clutch 23 Bearing Retainer Lockwasher 49 Front Output Shaft 8 Tanged Bronze Thrust Sea 35 Idler Shaft Gear 50 Washer Washer
516. uts of front housing and to seal in rear housing Assemble diaphragm and plate assembly into rear housing by carefully guiding rear plate hub through seal in rear housing Bosses on center plate must be aligned between lances in rear housing for reassembly Work outer rim of front diaphragm into rear housing with screwdriver blade so that it is under lances in housing 11 Attach base of Holding Fixture J 22805 to front housing with nuts and washers and draw down tight to eliminate bending or damage to studs 12 Secure front housing and Holding Fixture J 22805 on arbor press plate by a suitable means fig 5 4B 13 Place Spanner Wrench J 9504 over studs on rear housing Use three washers and nuts to attach wrench to housing Place a suitable piece of pipe approximately two inch I D and approximately three inches in length over plastic diaphragm plate hub Place a piece of flat stock steel over end of pipe 14 Install diaphragm return spring so that small end of spring is against front housing OVERHAUL MANUAL 5 10 BRAKES Fig 5 6B Removing Rear Seal 15 Place rear housing over front housing and align scribe marks 16 Rotate spanner wrench clockwise until housings are locked together Bend tabs of the four deep lances back to their original position 17 Remove three nuts and lock washers securing rear housing to spanner wrench 18 Remove Holding Fixture J 22805 from front housing by removing two nuts and washers
517. ve Plate to be sure they are still in good condition Replace as required 7 Assemble a new Pulley Rim over the Clutch Coil and mount the Pulley Rim to the Rotor and Bearing assembly using the short notch mounting locations Figure 1D 91 The mounting notches are located 120 apart radially around the Pulley Rim 8 Assemble three new lockwashers on the three new 1 4 28 X 5 16 mounting screws and apply Loctite 601 or equivalent sealer to the entire thread surface of the mounting screws into the short notch mounting hole locations and tighten finger tight 9 Align the Pulley Rim so that the bottom of the rim notches touch the mounting screws at all three mounting locations Also center the drilled holes in the Pulley Rim with the remaining mounting holes in the Rotor When the rim is positioned properly tighten the three mounting screws to 100 in Ibs torque 10 Temporarily make a trial fit of the Inertia Ring to the Pulley Rim If any portion of the sheer edge of the Pulley Rim prevents the installation of the Inertia Ring the raised edge may be filed off to remove the excess metal and facilitate installation DO NOT use undue force or cock the ring in assembling the Inertia Ring in place over the Pulley Rim that could cause ring distortion or stress 1D 34 AIR CONDITIONING COMPRESSOR OVERHAUL CLEARANCE NOTCH LOCK WASHER TO SIDES OF SCREW HEAD AND DOWN OVER NOTCH IN RING 3 MOUNTING HOLE LOCATIONS INERTIA R
518. ve identical inside and outside diameters It is possible to reverse the pistons during reassembly therefore care should be exercised to make certain the proper piston be installed in the clutch assemblies as shown in Figure 7A 102C 1 Install a new inner clutch piston seal on piston with lip facing away from spring pockets Fig 7A 96C 2 Install a new outer clutch piston seal with lip facing away from spring pockets Fig 7A 97C 3 Install a new center seal on clutch housing with lip of seal facing up Fig 7A 98C Apply automatic transmission oil to all seals and clutch plates before installation CLUTCH OUTER SEAL NOTICE The direct clutch housing for models CB Fig 7A 97C Installing Direct Clutch Outer Seal CD and CL use the 6 plate clutch assembly This housing can be identified by the elimination of the inside diameter chamfer on the clutch plate end and or CLUTCH INNER SEAL CLUTCH CENTER SEAL Fig 7A 96C Installing Direct Clutch Inner Seal Fig 7A 98C Installing Direct Clutch Center Seal AUTOMATIC TRANSMISSIONS 400 7A 33 CHAMFER FOR x FOR IDENTIFICATION IDENTIFICATION NO CHAMFER AND OR GROOVE DIRECT CLUTCH HOUSING DIRECT CLUTCH HOUSING FOR 4 OR 5 PLATE PACK FOR 6 PLATE CLUTCH PACK J 21409 Fig 7A 99C Direct Clutch Housing Identification Fig 7A 101C Installing Direct Clutch Piston a groove in the face at the base of the tower Fig 7 CHECK BALL 99C Should replacement of the direc
519. ve plate hub 5 Remove hub spacer retainer ring using Snap Ring Pliers J 5403 3 21 and then remove hub spacer Figure 1D 6 6 Inspect driven plate for cracks or stresses in the drive surface Do not replace driven plate for a scoring condition Figure 1D 7 If the frictional surface shows signs of damage due to excessive heat the Clutch Plate Hub Pulley and Bearing should be replaced Check further for the underlying cause of the damage i e low coil voltage coil should draw 3 2 amps at 12 volts or binding of the compressor internal mechanism cylinder and shaft assembly clutch air gap too wide see Figure 1D 11 broken drive plate to hub assembly sprints etc Replace 1 Insert the square drive key into the hub of driven plate allow it to project approximately 3 16 out of the keyway 2 Line up the key in the hub with keyway in the shaft Figure 1D 8 1055 9 y pepojdx3 z ga e1n814 O RING FRONT HEAD SHAFT SEAL ASSEMBLY SEALSEAT SEAL SEAT RETAINER RING O RINGS I ABSORBENT SLEEVE PRESSURE RELIEF i SLEEVE RETAINER VALVE CLUTCH COIL RETAINER RING O RING 4 z COMPRESSOR SHELL a e O RING CLUTCH COIL AND HOUSING ASSEMBLY 4 SUCTION SCREEN AE PULLEY INNER OIL PUMP GEAR DRAIN PLUG BEARING OIL PICK UP TUBE O RING BEARING RETAINER PULLEY RETAINER RING CLUTCH PLATE AND HUB D er LOCK NUT REAR HEAD OUTER OIL PUMP COVER SHAFT REAR DISCHARGE VALVE PLATE G
520. ver Side Bearing Adjusting Shims Bearing Cap Bearing Cap Bolt Differential Spider Differential Side Gear Pinion Gear Cover Screw Drain Plug Fig 1F Dana Differential with 10 1 2 Ring Gear Exploded View GENERAL DESCRIPTION This Dana Spicer axle is similar in design to other Salisbury type axles with the following exceptions 1 In order to remove the differential case the carrier must be spread 2 The drive pinion assembly incorporates an inner and outer bearing shim The inner shim is used to maintain proper pinion depth The outer shim is used to maintain proper preload on the pinion bearing DIFFERENTIAL CASE Removal 1 Place vehicle on hoist with rear axle hanging free 2 Remove wheel and tire assemblies 3 The axle shafts are full floating type with flanged outer end of shaft attached to wheel hub by studs and nuts Wheel is supported by tapered roller bearings at outer end of axle housing OVERHAUL MANUAL a Remove axle shaft to hub attaching nuts b Rap on axle shaft to loosen shaft from hub and remove shafts 4 Remove plug in carrier and drain lubricant 5 Remove cap screws and lock washers attaching cover to carrier Remove cover and gasket 6 Mark one side of carrier and matching cap for reassembly in the same position Remove bearing caps 7 Using spreader tool J 24385 and a dial indicator as shown in figure 2F spread carrier a maximum of 015 inch NOTICE Do not exceed
521. vice Shaft Seal kit Figure 1D 20 as described in R 4 Compressor Shaft Seal Replacement procedure Figure 1D 102 R 4 Compressor Pressure Relief Valve and Pressure Switch on A B Series 5 Install the Clutch Rotor and Bearing assembly Clutch Coil and Pulley Rim assembly to the Front Head using Rotor and Bearing Installer J 26271 Figure 1D 88 AIR CONDITIONING COMPRESSOR OVERHAUL 10 39 Before fully seating the assembly onto the Front Head be sure the clutch coil terminals are in the proper location in relation to the compressor and that the three protrusions on the rear of the clutch coil align with the locator holes in the Front Head 6 Install the rotor and bearing assembly retainer ring and reassemble the Clutch Plate and Hub assembly as described in R 4 Compressor Clutch Plate and Hub Replacement procedure Check to see that the clutch plate to clutch rotor gap is 020 040 inches 7 Evacuate and Charge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR A C SYSTEMS in the AIR CONDITIONING section R 4 COMPRESSOR THRUST AND BELLEVILLE WASHERS Remove and Replace 1 Discharge the Refrigerant System according to the DISCHARGING ADDING OIL EVACUATING AND CHARGING PROCEDURES FOR C C O T A C SYSTEMS in the AIR CONDITIONING section 2 Remove the Front Head assembly as described in RA Compressor Front Head Removal procedure Remove an
522. xcessive wear Replace parts as needed 2 Inspect all differential components for excessive wear and breakage Replace parts as needed The following are serviceable components for this differential e Governor assembly and latching bracket with spring and stop pin e Cam plate e Clutch disc pack with guides and guide clip e Pinion cross shaft e Pinion gears e Pinion thrust washers e Reaction block 4 sizes e Thrust ring e Flange end shim 4 sizes NOTICE Attempts to service other components may disturb critical clearances and could result in differential complaints If reaction block or flange end shim must be replaced the original pieces must be carefully measured for thickness and replaced with a piece of the same size CAM CLUTCH SERVICE Disassembly If cam plate or clutch discs must be replaced the cam gear sub assembly must be serviced as follows 1 Measure and record overall length of gear assembly front face of gear to back side of thrust ring include shim This dimension will be needed to reassembly unit if thrust ring is replaced DO NOT REPLACE THRUST RING UNLESS NECESSARY If ring is excessively worn or scored check bore in case for scoring If bore is scored replace entire differential 2 With gear hub end up compress disc pack and install jaws of split ring bearing remover J 22912 between the thrust ring and the top eared disc Bevel side of bearing remover should face up toward thrus
523. y from pin Finally install snap ring using Tool J 23423 and J 23423 1 and check end play which should be within 002 027 inch 4 Grease pilot bore or rear output shaft and install needle bearings 15 Install thrust washer and new snap ring in bore 5 Clean grease and install new bearing in retainer housing using Tool J 23431 Fig 7D 17R 6 Install housing onto output shaft assembly install spacer and speedometer gear then install bearing Fig 7D 18R SPEEDOMETER GEAR SPACER REAR OUTPUT LOW GEAR CLUTCH GEAR Fig 7D 18R Installing Rear Output Shaft Spacer and Speedometer Gear OVERHAUL MANUAL 70 8 TRANSFER CASES 7 Install rear bearing retainer seal using Tool J 21359 or J 22834 2 Fig 7D 19R 8 Install bearing retainer assembly onto housing with one or two gaskets depending on clearance Torque bolts to 30 ft Ibs 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 Miscellaneous 1 Install P T O cover and gasket Torque bolts to 15 ft Ibs 2 Install and seal cup plugs at rail pin holes if not previously done 3 Install drain and filler plugs and torque to 30 ft Ibs 4 Install shift rail cross link clevis pins and lock pins J 21359 Fig 7D 19R Installing Rear Bearing Retainer Seal MODEL 203 FULL TIME TRANSFER CASE INDEX
524. ylinder piston rod with approximately a 40 50 pound load to be sure it is properly seated 5 Place Gage J 22647 over the piston rod in a position which will allow the gage to be slipped to the left or right without contacting the studs fig 5 12 6 The center section of the gage has two levels The piston rod should always contact the longer section lower level of the gage The piston rod should never contact the J 22733 J 22839 Fig 5 9B Seal Protector J 22733 Installed AIR VALVE PLUNGER 5 SPRING x Fig 5 10B Installing Air Valve Plunger E REAR PLATE REAR DIAPHRAGM Fig 5 11B Installing Rear Diaphragm Retainer BRAKES 5 11 Fig 5 12B Gaging Piston Rod shorter section higher level of the gage Move gage from side to side to check piston rod height 7 Any variation beyond these two limits must be compensated for by obtaining the service adjustable piston rod and adjusting the self locking screw to meet the gaging specifications 8 Wipe a thin film of silicone lubricant on the 1 0 of the front housing seal and position seal in the depression in the housing DELCO SINGLE DIAPHRAGM POWER BRAKE UNIT UNIT REPAIR Disassembly 1 Scribe a mark on bottom center of front and rear housings to facilitate reassembly Mark staked interlocks so they will not be restaked Then straighten staked interlocks NOTICE If all interlocks have been used a new unit must be installed 2

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