lHOUASflJ Sf61

FOREWORD
This manual includes procedures involved in disassembly and assembly
of major components of 1978 Chevrolet, Malibu, Monte Carlo, Nova,
Camaro, Corvette and Light Duty Trucks. Information on diagnosis, mainte­
nance and adjustments, minor service operations, and removal and installa­
tion for these components is contained in either the 1978 Passenger Car or
the Light Duty Truck Service Manuals.

The Section Index on this 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 recom­
mended item.

The manual should be kept in a handy place for ready reference. If prop­
erly used, it will enable the technician to better service the owners of
Chevrolet built vehicles.

All information, illustrations and specifications contained in this literature

are based on the latest product information available at the time 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 by Chevrolet 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 Warnings, and
Cautions 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 may damage the vehicle or render it unsafe.
It also is important to understand that these Warnings, and Cautions are not
exhaustive. Chevrolet 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, Chevrolet has
not undertaken any such broad evaluation. Accordingly, anyone who uses a
service procedure or tool which is not recommended by Chevrolet must first
satisfy himself thoroughly that neither his safety nor vehicle safety will be
jeopardized by the service method he selects.
 SECTION INDEX

1978
UNIT REPAIR (OVERHAUL) SECTION NAME

MANUAL
covering AIR CONDITIONING
ID
CHEVROLET, MALIBU, COMPRESSOR

MONTE CARLO, NOVA,

CAMARO, CORVETTE 3B STEERING |
and
LIGHT DUTY TRUCKS
(SERIES 10-35) 4B REAR AXLE |

4C 4-WHEEL DRIVE |

C AU TIO N
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
5 BRAKES |
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 7A AUTOMATIC TRANSMISSION |
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.

7B MANUAL TRANSMISSION |

7C CLUTCH |

7D TRANSFER CASES

© 1978 General M otors Corporation Printed In U.S.A.

 A/C COMPRESSOR OVERHAUL ID-1

AIR CONDITIONING COMPRESSOR

OVERHAUL
CONTENTS OF THIS SECTION
For Compressor REMOVAL AND INSTALLATION, DIS- ING PROCEDURES FOR C.C.O.T. A/C SYSTEMS, see the
CHARGING, ADDING OIL, EVALUATING AND CHARG - appropriate Service Manual.

INDEX
Minor Repair Procedures for the A-6 Compressor......................................... ID-2
A-6 Compressor Clutch Plate and Hub Assembly....................................... ID-2
A-6 Compressor Pulley and Bearing Assy................................................. ID-6
A-6 Compressor Pulley Bearing..................................................................... ID-7
A-6 Compressor Clutch Coil and Housing Assembly.................................. ID-8
Major A-6 Compressor Repair Procedures....................................................... ID-9
A-6 Compressor Shaft Seal.............................................................................. ID-9
Seal Leak Detection..................................................................................... ID-9
A-6 Compressor Pressure Relief Valve or Pressure Switch........................ ID-11
A-6 Compressor Cylinder and Shaft Assembly............................................ ID-12
Removal......................................................................................................... ID-12
Disassembly................................................................................................... ID-14
Gaging Operation......................................................................................... ID-15
A-6 Teflon Piston Ring Replacement........................................................ ID-19
Assembly........................................................................................................ ID-20
Re-Install........................................................................................................ ID-22
Minor Repair Procedures for the R-4 Compressor.......................................... ID-26
R-4 Compressor Clutch Plate and Hub Assy............................................... ID-26
R-4 Compressor Clutch Rotor and/or Bearing............................................ ID-29
Replace Rotor and Bearing Assembly (On Car)...................................... ID-31
Replace Rotor and Bearing Assembly (On Bench).................................. ID-31
R-4 Compressor Clutch Coil and /or Pulley Rim....................................... ID-32
R-4 Compressor Inertia Ring Installation.................................................... ID-33
Major R-4 Compressor Repair Procedures....................................................... ID-35
R-4 Compressor Shaft Seal.............................................................................. ID-35
Seal Leak Detection..................................................................................... ID-35
R-4 Compressor Shaft Seal Replacement (On Car)................................. ID-35
R-4 Compressor Shaft Seal Replacement (Off Car)................................. ID-37
R-4 Compressor Pressure Relief Valve or Pressure Switch........................ ID-37
R-4 Compressor Front Head and/or O-Ring............................................... ID-37
R-4 Compressor Thrust and Belleville Washers........................................... ID-39
R-4 Compressor Main Bearing....................................................................... ID-39
R-4 Compressor Shell and/or O-Rings.......................................................... ID-40
R-4 Compressor Discharge Valve Plate and/or Retainer........................... 1D41
R-4 Compressor Cylinder and Shaft Assy..................................................... ID-42
A-6 and R-4 Comp. Leak Testing (External and Internal)........................ ID-42
ID-2 A/C COMPRESSOR OVERHAUL

For all practical purposes, all vehicles make use of the these operations are covered later in this section as “Major
same air conditioning 4 and 6-cylinder compressors. Actual Repair Procedures” because the system MUST FIRST BE
differences between compressors are found in their PURGED of Refrigerant-12.
mounting brackets, pulleys, connector assemblies and Illustrations used in describing these operations show
compressor capacities, none of which will affect the the compressor removed from the vehicle only to more
following Overhaul Procedures. clearly illustrate the various operations.
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
the 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 trichlorethylene, naphtha, Stoddard solvent,
kerosene or equivalent 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 witn the compressor removed from the vehicle. Fig. 1D-1 A-6 Compressor
They have been prepared in sequence in order of
accessibility of the components. Pad fender/skirt and secure When servicing the compressor, remove only the
compressor near top of fender skirt with wire, rope, etc. necessary components that preliminary diagnosis indicates
when performing on-car service. are in need of service. Refer to the AIR CONDITIONING
W hen an A-6 or R-4 compressor is removed section and Fig. ID-2 and Fig. ID-3 for information relative
from the vehicle FOR SERVICING , the amount of
oil remaining in the compressor should be drained
to parts nomenclature and location.
and measured . This oil should then be discarded Removal and illustration of external compressor
and new 5 2 5 viscosity refrigerant oil added to the components and disassembly and assembly of internal
compressor (See Fig. ID-1, and “C.C.O.T. Refrigerant components must be performed on a clean workbench. The
Oil Distribution” in the AIR CONDITIONING section). w ork area, tools, and parts must be kept clean at
SHOULD AN A-6 COMPRESSOR, IT’S all times . Parts Tray J 9402 (Fig. ID-38) should be used
COMPRESSOR SHAFT SEAL OR ANY OTHER for all A-6 internal compressor parts being removed, as well
COMPONENT EVER BE REMOVED FOR as for replacement parts.
SERVICING BECAUSE IT WAS DETERMINED TO
BE THE CAUSE OF EXCESSIVE SIGNS OF OIL
LEAKAGE IN THE A/C SYSTEM, THEN THE OIL IN
A-6 COMPRESSOR CLUTCH PLATE
THE A-6 COMPRESSOR MUST BE DRAINED, AND HUB ASSEMBLY
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 Remove
SYSTEM THEN MUST ALSO be removed - oil drained 1. Place Holding Fixture J 9396 in a vise and clamp the
- measured, etc. according to same section. compressor in the Holding Fixture.
CAUTION: Do not kink or place excessive 2. Keep clutch hub from turning with Clutch Hub
tension on refrigerant lines or hoses. Holder J 25030 or J 9403, and remove locknut from end of
M INOR REPAIR PROCEDURES
shaft using Thin Wall Socket J 9399 (Fig. ID-4).
CAUTION: To avoid internal damage to the
FOR THE A-6 COMPRESSOR compressor, DO NO T DRIVE OR POUND on
THE FOLLOW ING OPERATIONS TO THE A-6 the Clutch Plate and Hub assembly OR on the
COMPRESSOR CLUTCH PLATE AND HUB, end o f the shaft. I f proper tools to remove and
PULLEY A N D BEARING, AND COIL AND replace clutch parts are not used, it is possible to
HOUSING ARE COVERED AS "M IN O R " disturb the position o f the axial plate (keyed to
BECAUSE THEY MAY BE PERFORMED the main shaft), resulting in compressor damage
W IT H O U T FIRST PURGING THE SYSTEM OR and seal leakage due to shifting o f the crankshaft.
REM O VING THE COMPRESSOR from the
vehicle. 3. Thread Clutch Plate and Hub assembly Remover J
The Compressor Shaft Seal assembly, Pressure Relief 9401 into hub. Hold body of Remover with a wrench and
Valve and Pressure Switch may also be serviced WITHOUT tighten center screw to remove Clutch Plate and Hub
REMOVING THE COMPRESSOR from the vehicle but assembly (Fig. ID-5).
 O-RING
FRONT H E £ 0
SHAFT SEAL ASSEMBLY
SEAL SEAT
SEAL SEAT RETAINER RING
O-RINGS ABSORBENT SLEEVE
SEAL RETAINER
|\ PRESSURE RELIEF

J \,Z.^
^
IV VA LVE / / CLUTCH COIL RETAINER RING

J
) O-RING O-RING* / / COMPRESSOR SHELL
o u , ^ y O-RING CLUTCH COIL AND HOUSING ASSEMBLY
^ I PULLEY
BEARING
Fig. 1D-2 Exploded View

BEARING RETAINER
\ PULLEY RETAINER RING
LOCK NUT CLUTCH PLATE AND
REAR HEAD HUB ASSEMBLY
OUTER OIL PUMP COVER RETAINER RING
REAR DISCHARGE VA LVE PLATE ASSEMBLY LOCK NUT
of A-6 Compressor

TEFLON PISTON RING

BALL'
SHOE DISC
TEFLON RING TYPE PISTON

A/C COMPRESSOR OVERHAUL

TEFLON PISTON RING
SHAFT
DISCHARGE CROSSOVER TUBE
THRUST RACES
BUSHING*
FRONT
SUCTION REED
FRONT DISCHARGE
^DISCHARGE CROSSOVER TUBE O-RING OR BUSHING VA LVE PLATE ASSEMBLY
4978

ID-3
ID-4 A/C COMPRESSOR OVERHAUL

FRONT
SUCTION REED DISCHARGE VALVE PLATE
SHAFT SEAL ASM.
TEFLON PISTON RING SHELL/ / / .p u L L E Y
PULLEY BEARING
SHAFT BALL A XIA L PLATE
PISTON __________ /
SHOE DISC
REAR HEAD CLUTCH PLATE
AND
HUB ASSEMBLY

OIL PUMP SEAL SEAT

GEARS
RETAINER RING

PRESSURE RELIEF
VALVE 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

4987

Fig. 1 D-3 A-6 Compressor Cross Section

CLUTCH A SS EM BLY CLUTCH PLATE

& HUB ASM
REMOVER
J-9401
TH IN W ALL
SOCKET
HOLDING 399
FIXTURE
J-9396

4970

Fig. 1D-4 Removing A-6 Shaft Lock Nut Fig. 1D-5 Removing A-6 Clutch Plate and Hub Asm.
 A/C COMPRESSOR OVERHAUL ID-5

4. Remove square drive key from shaft or drive plate 2. Line up the key in the hub with keyway in the
hub. shaft (Fig. ID-8).
5. Remove hub spacer retainer ring using Snap-Ring
Pliers J 5403 (#21), and then remove hub spacer (Fig. 1D- HOLDING FIXTURE
6). J-9396

KEYWAY
IN SHAFT

5073

Fig. 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
(Fig. ID-9).
Fig. 1D-6 Removing or Installing Retainer Ring in A-6
Clutch Drive Plate DRIVE PLATE
INSTALLER
6. Inspect driven plate for cracks or stresses in the drive J 9480-01

surface. Do not replace driven plate for a scoring condition

(Fig. ID-7). J 9396
HOLDING
DRIVE PLATE FIXTURE
DRIVEN PLATE DRIVE PLATE
INSTALLER BEARING

SCORING OF DRIVE A N D DRIVEN PLATES IS N O RM AL.

DO N O T REPLACE FOR THIS C O NDITIO N. 5038

Fig. 1 D-7 A-6 Clutch Driven Plate and Drive Plate

Fig. 1D-9 Installing A-6 Drive Plate

If the frictional surface shows signs of damage due to

excessive heat, the Clutch Plate and Hub and Pulley and 4. Press the driven plate onto the shaft until there is
Bearing should be replaced. Check , further for the approximately 3/32" space between the frictional faces of
underlying cause of the damage (i.e. low coil-voltage - coil the Clutch Drive Plate and Pulley.
should draw 3.2 amps at 12 volts - or binding of the CAUTION: Make certain key remains in place
compressor internal mechanism (cylinder and shaft when pressing hub on shaft.
assembly), clutch air gap too wide (see Fig. ID-11), broken
drive plate to hub asm. springs, etc.
A ZERO thrust race is approximately 3/32" thick and
may be used to roughly gage this operation. Use Clutch Hub
Replace Holder J 25030 or J 9403 to hold Clutch Plate and Hub if
necessary.
1. Insert the square drive key into the hub of driven 5. Install the hub spacer and, using Snap-Ring Pliers
plate; allow it to project approximately 3/16" out of the J 5403 (#21), install the retainer ring (see installed Retainer
keyway. Ring in Fig. ID-10), with convex side of ring facing spacer.
ID-6 A/C COMPRESSOR OVERHAUL

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 Asm.” Removal
procedure.
2. Remove pulley retainer ring, using Snap-Ring Pliers
J 6435 (#26), Fig. ID-12.

Compressor

6. Using Thin-Wall Socket J 9399 and Clutch Hub

Holder J 25030 or J 9403 to install a new shaft locknut w ith Fig. 1D-12 Removing A-6 Pulley Retainer Ring
shoulder or circular projection on the locknut
facing tow ards retainer ring. Tighten the nut to 14-26
lb.ft. torque. Air gap between the frictional faces should now 3. Pry out absorbent sleeve retainer, and remove
be .022" to .057" (Fig. ID-11). If not, check for absorbent sleeve from compressor neck.
mispositioned key or shaft. 4. Place Puller Pilot J 9395 over end of compressor
shaft.
CAUTION: 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 (Fig. ID-13).
Inspection
Check the appearance of the Pulley and Bearing
assembly (see Fig. ID-7). The frictional surfaces of the
Pulley and Bearing assembly should be cleaned with
trichlorethylene, naphtha, Stoddard solvent, kerosene or
4946
equivalent solvent before reinstallation.
Fig. 1D-1 1 Checking A-6 Air Gap
Replace

7. The pulley should now rotate freely. 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
8. Operate the refrigeration system in the MAX A/C due to overheating, the Pulley and Bearing assembly should
control selector (mode) lever position and warm engine (off be replaced.
fast idle) speed at 2000 RPM. Rapidly cycle the compressor 2. Check bearing for brinelling, excessive looseness,
clutch by turning the A/C control selector (mode) lever noise, and lubricant leakage. If any of these conditions exist,
from OFF-to-MAX at least 15 times at approximately one bearing should be replaced. See “A-6 Compressor Pulley
second intervals to burnish the mating parts of the clutch. Bearing” Replacement procedure.
 A/C COMPRESSOR OVERHAUL ID-7

A-6 COMPRESSOR PULLEY BEARING

Remove
1. Remove Clutch Plate and Hub assembly as described
PULLER in “A-6 Compressor Clutch Plate and Hub Asm.” Removal
J-8433 procedure.
2. Remove Pulley and Bearing assembly as described
in “A-6 Compressor Pulley and Bearing Asm.” Removal
procedure.
3. Remove pulley bearing retainer ring with a small
screwdriver or pointed tool (Fig. ID-15).
5066
LLEY AND
BEARING
BEARING
ASSEMBLY RETAINER
RING
PULLER PILOT
J-9395
Fig. 1D-13 Removing A-6 Pulley and Bearing Asm.

3. Press or tap Pulley and Bearing assembly on neck

of compressor until it seats, using Pulley and Bearing BEARING
Installer J 9481 with Universal Handle J 8092 (Fig. ID-14).
The Installer will apply force to inner race of bearing and
prevent damage to bearing.
Fig. 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
UNIVERSAL J 9398 with Universal Handle J 8092, drive Bearing
HANDLE assembly out of pulley (Fig. ID-16).
J-8092

UNIVERSAL HANDLE
J-8092

PULLEY & BEARING

INSTALLER J-9398

PULLEY AND PULLEY

ASSEMBl
BEARING
INSTALLER
J-9481

5039
5067
Fig. 1D-16 Removing Bearing From A-6 Pulley Asm.
Fig. 1D-14 Installing A-6 Pulley and Bearing Asm.

Replace
4. Check pulley for binding or roughness. Pulley should
rotate freely. 1. Install new bearing in pulley using Pulley and
Bearing Installer J 9481 with Universal Handle J 8092 (Fig.
5. Install retainer ring, using Snap Ring Pliers J 6435 ID-17). The Installer will apply the force to the outer race
(#26). of the bearing.
6. Install absorbent sleeve retainer in neck of CAUTION: DO NO T CLEAN N EW
compressor. Using sleeve from Seal Seat Remover-Installer BEARING ASSEM BLY W ITH A N Y TYPE
J 23128, install retainer so that outer edge is recessed 1/32" OF SOL VENT Bearing is supplied with correct
from compressor neck face. lubricant when assembled and requires no other
7. Install Clutch Plate and Hub assembly as described lubricant at any time.
in “A-6 Compressor Clutch Plate and Hub Asm.” 2. Install bearing retainer ring, making certain that it
Replacement procedure. is properly seated in ring groove.
ID-8 A/C COMPRESSOR OVERHAUL

CLUTCH COIL AND

HOUSING ASSEMBLY
SNAP RING PLIERS
J -6435 (#26)

UNIVERSAL RETAINER
HANDLE RING
J-8092

THIS RIDGE
OF TOOL
MUST BE
UP WHEN
INSTALLING
BEARING 5065

PULLEY AND Fig. 1D-18 Removing A-6 Coil Housing Retainer Ring
BEARING
INSTALLER
SUPPORT J-9481
BLOCK
J-21352 4952

Fig. 1D-17 Installing Bearing on A-6 Pulley

ELECTRICAL
3. Install Pulley and Bearing assembly as described in TERMI
“A-6 Compressor Pulley and Bearing Asm.” Replacement
procedure.
4. Install Clutch Plate and Hub assembly as described
in “A-6 Compressor Clutch Plate and Hub Asm.”
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 Asm.” Removal 4959
procedure. Fig. 1D-19 Installing A-6 Coil Housing
2. Remove Pulley and Bearing assembly as described
in “A-6 Compressor Pulley and Bearing Asm.” Removal 5. Install Clutch Plate and Hub assembly as described
procedure. Note position of terminals on coil in “A-6 Compressor Clutch Plate and Hub Asm.”
housing and scribe location on compressor front Replacement procedure.
head casting.
3. Remove coil housing retaining ring, using Snap-Ring
Pliers J 6435 (#26) (Fig. ID-18).
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 (Fig. ID-19).
2. Align locating extrusions on coil housing with holes
in front head casting.
3. Install coil housing retainer ring w ith fla t side of
ring facing coil, using Snap-Ring Pliers J 6435 (#26).
4. Install Pulley and Bearing assembly as described in
“A-6 Compressor Pulley and Bearing Asm.” Replacement
procedure.
 A/C COMPRESSOR OVERHAUL ID-9

MAJOR A-6 COMPRESSOR REPAIR PROCEDURES

Service repair procedures to the Compressor A-6 COMPRESSOR SHAFT SEAL
Shaft Seal, Pressure Relief Valve, Pressure
Sw itch or disassembly of the Internal Compressor
Cylinder and S haft Assembly are considered SEAL LEAK DETECTION
"M A JO R " SINCE THE REFRIGERATION SYSTEM
M U ST BE COMPLETELY PURGED OF A SHAFT SEAL SHOULD NOT BE CHANGED
REFRIGERANT before proceeding and/or because BECAUSE OF AN OIL-LINE ON THE HOOD
major internal operating and sealing components INSULATOR. The Seal is designed to seep some
of the compressor are being disassembled and oil for lubrication purposes. Only change a S haft
serviced. Seal when a leak is detected by evidence of oil
sprayed in LARGE A M O U N TS and then only after
SHOULD AN A-6 COMPRESSOR, IT’S actual refrigerant leakage is determined by test
COMPRESSOR SHAFT SEAL, OR ANY OTHER w ith Electronic Leak Detector J 2 3 4 0 0 .
COMPONENT EVER BE REMOVED FOR SHOULD AN A-6 COMPRESSOR SHAFT SEAL
SERVICING BECAUSE IT WAS DETERMINED TO EVER HAVE TO BE REPLACED BECAUSE IT WAS
BE THE CAUSE OF EXCESSIVE SIGNS OF OIL DETERMINED TO BE THE CAUSE OF EXCESSIVE
LEAKAGE IN THE A-6 A/C SYSTEM, THEN THE OIL SIGNS OF OIL LEAKAGE IN THE A/C SYSTEM,
IN THE COMPRESSOR MUST BE DRAINED, THEN THE OIL IN THE A-6 COMPRESSOR MUST BE
measured and replaced according to “C.C.O.T. Refrigerant DRAINED, measured and replaced according to
Oil Distribution” in the AIR CONDITIONING section to “C.C.O.T. Refrigerant Oil Distribution” in the AIR
determine oil loss. THE ACCUMULATOR IN THIS A-6 CONDITIONING section to determine oil loss. THE
SYSTEM MUST THEN ALSO be removed - oil drained ACCUMULATOR IN THIS A-6 SYSTEM MUST THEN
- measured, etc. according to same section. ALSO be removed - oil drained - measured, etc. according
WHEN REPLACING THE SHAFT SEAL to same section.
ASSEMBLY (see Fig. ID-20), PRESSURE RELIEF
VALVE (see Fig. ID-26) OR PRESSURE SWITCH (see
Figures ID-27 and 28), even if the compressor remains on
the vehicle during the operation, IT WILL BE S P E C IF IC A T IO N P A R T S

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
DISASSEMBLY OF THE INTERNAL A-6
COMPRESSOR CYLINDER AND SHAFT R E S IS T A N C E A N D

ASSEMBLY.
L IF E E X P E C T A N C Y .

0858
If the A-6 Compressor Internal Cylinder and
S haft Assembly is to be serviced or replaced, then
Fig. 1D-20 Specification A-6 and R-4 Compressor Shaft
the oil in the compressor must be drained,
measured and replaced according to “C.C.O.T.
Seal Kit
Refrigerant Oil Distribution” in the AIR Remove
CONDITIONING section to determine addition of proper 1. “Discharge the Refrigerant System” according to the
oil quantity to new assembly. DISCHARGING, ADDING OIL, EVACUATING AND
A clean workbench, preferably covered with a sheet of CHARGING PROCEDURES FOR C.C.O.T. A/C
clean paper, orderliness in the work area and a place for all SYSTEMS in the AIR CONDITIONING section.
parts being removed and replaced is of great importance, as 2. Remove the Clutch Plate and Hub assembly and
is the use of the proper, clean service tools. Any attempt to shaft key as described in “A-6 Compressor Clutch Plate and
use make-shift or inadequate equipment may result in Hub Asm.” Removal procedure.
damage and/or improper compressor operation. 3. Pry out the sleeve retainer and remove the absorbent
These procedures are based on the use of the proper sleeve. Remove the shaft seal seat retaining ring, using Snap-
service tools and the condition that an adequate stock of Ring Pliers J 5403 (#21). See Figure ID-21.
service parts is available. All parts required for servicing the 4. Thoroughly clean inside of compressor neck area
internal compressor are protected by a preservation process surrounding the shaft, the exposed portion of the seal seat
and packaged in a manner which will eliminate the necessity and the shaft itself. This is absolutely necessary to
of cleaning, washing or flushing of the parts. The parts can prevent any dirt or foreign material from getting
be used in the internal assembly just as they are removed into compressor.
from the service package. 5. Place Seal Protector J 22974 over the end of the shaft
Piston shoe discs and shaft thrust races will be to prevent chipping the ceramic seat. Fully engage the
identified by “number” on the parts themselves for reference knurled tangs of Seal Seat Remover-Installer J 23128 into
to determine their size and dimension (see Fig. ID-38). the recessed portion of the seal seat by turning the handle
ID-10 A/C COMPRESSOR OVERHAUL

Fig. 1D-21 Removing or Installing A-6 Shaft Seal Seat

Retaining Ring
clockwise . Remove the Seal Seat from the compressor
with a rotary-pulling motion (Fig. ID-22). Discard the Seat.
Fig. 1D-23 Replacing A-6 Seal and O-Ring

Inspection
SEALS SHOULD NOT BE REUSED. A LW A Y S
USE A NEW SEAL KIT ON REBUILD (see Fig. ID -
20). Be extrem ely careful th a t the face of the Seal
to be installed is not scratched or damaged in any
way. M ake sure th a t the Seal Seat and Seal are
free of lint and dirt th a t could damage the seal
surface or prevent sealing.

Replace
1. Coat the new seal seat O-ring in clean 525 viscosity
refrigerant oil and assemble onto O-Ring Installer J 21508
(see Fig. IB-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 seal
retainer ring). Rotate the Installer to seat the O-ring and
Fig. 1D-22 Removing A-6 Shaft Seal Seat and O-Ring
remove Installer (See Fig. ID-24).
3. Coat the O-ring and seal face of the new Seal
CAUTIO N: DO NO T tighten the handle with assembly with clean 525 viscosity refrigerant oil. Carefully
a wrench or pliers; however, the handle must be mount the Seal assembly to Seal Installer J 9392 by engaging
hand-tightened securely to remove the Seat. the tabs of the Seal with the tangs of the Installer (Fig.
ID-23).
6. With Seal Protector J 2291A still'over the end of the 4. Place Seal Protector J 22974 (Fig. ID-23) over end
shaft, set Seal Remover-Installer J 9392 down over shaft of compressor shaft and carefully slide the new Seal
end, turning clockwise, w hile pressing down, to assembly down onto the shaft. Gently tw is t the
engage Remover tangs with the tabs on the Seal assembly. Installer J 9 3 9 2 CLOCK-WISE, w hile pushing the
Then lift the Shaft Seal assembly out (see Fig. ID-23). seal assembly down the shaft until the Seal
Discard the Seal. assembly engages the flats on the shaft and is
seated in place. Disengage the Installer by pressing
7. Remove and discard the seal seat O-ring from the downward and twisting counter-clockwise.
compressor neck, using O-Ring Remover J 9533 (see Fig. 5. Attach the ceramic Seal Seat to the Seal Seat
ID-22). Remover and Installer J 23128 and dip the ceramic Seat in
8. Recheck the shaft and inside of the compressor neck clean 525 viscosity refrigerant oil to coat the seal face and
for dirt or neck foreign material and be sure these areas are outer surface. Carefully install the Seat over the compressor
perfectly clean before installing new parts. shaft end and Seal Protector J 22974 and push the Seat into
 A/C COMPRESSOR OVERHAUL 1D-l 1

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
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 the front end of the sleeve. Pulley
Puller Pilot J 9395 (see Fig. 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 Fig. ID-24).
11. Reinstall the Clutch Plate and Hub assembly as
described in “A-6 Compressor Clutch Plate and Hub Asm.”
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
place with a rotary motion. Take care not to dislodge the the compressor. If the axial plate is mispositioned, the
seat O-ring. However, be sure Seal Seat makes a good seal carbon face of the shaft seal assembly may not contact the
with O-ring. Remove Installer J 23128 and Seal Protector seal seat and the rear thrust races and bearing may be
J 22974 (Fig. ID-22). damaged.
6. Install the new seal seat retainer ring w ith its fla t To check for proper positioning of the axial plate on
side against the Seal Seat, using Snap-Ring Pliers J the shaft, rempve the clutch driven plate and measure the
5403 (#21). See Fig. ID-21. Use the sleeve from Seal Seat distance between the front head extension and the flat
Remover-Installer J 23128 (Fig. ID-22) to press in on the shoulder on the shaft as shown in Fig. ID-24. To measure
seal seat retainer ring so that it snaps into its groove. this distance, use a wire gage ( the clearance should be
7. Install Compressor Leak Test Fixture J 9625 (Fig. between .026" and .0 7 5 " ). If the shaft has been pushed
ID-25) on rear head of compressor and connect gage back in the axial plate (measurement greater than .075"),
charging lines or pressurize SUCTION SIDE (low-pressure disassemble the compressor and replace the shaft and axial
side) of compressor on vehicle with Refrigerant-12 vapor to plate assembly rear thrust races and thrust bearing.
equalize pressure to the drum pressure. Temporarily install If there also appears to be too much or insufficient air
the shaft nut and, with compressor in horizontal position gap between the drive and driven plates, dislocation of the
and oil sump down, rotate the compressor shaft in normal shaft should be suspected. If the carbon seal is not seating
direction of rotation several times by hand. Leak test the against the seal seat, it will not be possible to completely
Seal with Electronic Leak Detector J 23400. Correct any “Evacuate the System” as outlined under
leak found. Remove, discard and later replace the shaft nut. DISCHARGING, ADDING OIL, EVACUATING AND
CHARGING PROCEDURES FOR C.C.O.T. A/C
SYSTEMS in the AIR CONDITIONING section.
LEAK TEST
12. “Add Oil, Evacuate and Charge System” (see
ADAPTER
J-9625 DISCHARGING, ADDING OIL, EVACUATING AND
CHARGING PROCEDURES FOR C.C.O.T. A/C
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 (Fig. ID-26 and Figures ID-27 and 28),
the valve/switch assembly should be removed after
PURGING THE SYSTEM OF REFRIGERANT. A new
OIL FITTING 5Q41 valve/switch and O-ring coated with 525 viscosity
refrigerant oil should be installed (see DISCHARGING,
Fig. 1D-25 Leak Testing A-6 Compressor ADDING OIL, EVACUATING AND CHARGING
PROCEDURES FOR C.C.O.T. A/C SYSTEMS in the
AIR CONDITIONING section).
ID-12 A/C COMPRESSOR OVERHAUL

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.
DISCHARGE SYSTEM BEFORE An inspection should be made of the Internal
REMOVING HIGH PRESSURE Mechanism (Cylinder and Shaft) assembly to determine if
RELIEF VALVE
any service operations should be performed. A detailed
inspection of parts should be made to determine if it is
feasible to replace them.
Removal

f 1. Before proceeding with disassembly, wipe exterior

HI PRESS. surface of compressor clean.
RELIEF 2. All oil in compressor should be drained and
VALVE REAR HEAD measured. Assist draining by positioning compressor with
5040 oil drain plug down. Record the amount of oil drained
from the compressor (See " C.C.O.T. Refrigerant
Fig. 1D-26 A-6 High Pressure Relief Valve Oil Distribution" in the AIR CO ND ITIO N IN G
section).
3. Invert compressor and Holding Fixture J 9396, with
front end of compressor shaft now facing downward (Fig.
O-RING COMPRESSOR ID-29).
PRESSURE SWITCH
SNAP RING
REAR
HEAD

SHELL
6363
HOLDING
Fig. 1D-27 Compressor Pressure Switch FIXTURE
J-9396

4974

Fig. 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).
Fig. 1D-28 A-6 Compressor Pressure Switch on A, B, A liquid measuring cup may be used for this purpose.
Series Drained oil should then be discarded.
A-6 COMPRESSOR INTERNAL 4. Remove four locknuts from threaded studs on
MECHANISM (CYLINDER AND SHAFT compressor shell and remove rear head. Tap uniformly
ASM.) around rear head if head is binding (Fig. ID-29).
Service operations to the A-6 compressor Rear Head 5. Wipe excess oil from all sealing surfaces on rear head
or Internal Mechanism (Cylinder and Shaft) of the casting webs, and examine sealing surfaces (Fig. ID-30). If
compressor should be performed with the system PURGED any damage is observed, the Rear Head should be replaced.
OF REFRIGERANT according to the DISCHARGING, 6. Remove Suction Screen and examine for any damage
ADDING OIL, EVACUATING AND CHARGING or contamination. Clean or replace if necessary.
PROCEDURES FOR C.C.O.T. A/C SYSTEMS in the
AIR CONDITIONING section. The compressor must also 7. Paint an identifying mark on exposed face of inner
be removed from the vehicle to insure that the necessary and outer Oil Pump Gears and then remove gears.
degree of cleanliness may be maintained. Additionally, Identifying marks are to assure that gears, if re-used, will
’’Compressor Clutch Plate and Hub, Pulley and Bearing, be installed on identical position.
 A/C COMPRESSOR OVERHAUL ID-13

SUCTION SCREEN SEALING Fig. 1D-32 Removing A-6 Rear Suction Reed
SURFACES
REAR HEAD
SHELL TO HEAD
OIL PICK-UP TUBE
" 0 " RING
REMOVER J-5139

OIL PUMP
ROTORS

5042

Fig. 1D-30 A-6 Rear Head Removal

8. Remove and discard rear head to shell O-ring.

9. Carefully remove Rear Discharge Valve Plate Fig. 1D-33 Removing A-6 Oil Pick-Up Tube
assembly. Use two small screwdrivers under reed retainers
to pry up on assembly (Fig. ID-31). Do not position Support Block in position with one hand, lift compressor
screwdrivers between reeds and reed seats.
from Holding Fixture with other hand. Invert compressor
(shaft will now be facing upward) and position on bench
REED RETAINERS 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.
CAUTION: To prevent damage to shaft, DO
NO T TAP ON END OF COMPRESSOR
SHAFT to remove Internal Cylinder and Shaft
Assembly. I f Internal Assembly will not slide out
o f compressor shell, tap on Front Head with a
■ 'd is c h a r g e reeds plastic hammer.
REAR DISCHARGE
VALVE PLATE
A S S E M B LY 16. Rest compressor shell on its side and push Front
4969
Head assembly through Compressor Shell, being careful
not to damage sealing areas on inner side of front
Fig. 1D-31 Removing A-6 Rear Discharge Valve Plate head. Discard O-ring.
It may be necessary to tap on outside of front head,
10. Examine Valve Reeds and Seats. Replace entire using a plastic hammer, to overcome friction of O-ring seal
assembly if any reeds or seats are damaged. between front head and compressor shell.
11. Using two small screwdrivers, carefully remove 17. Wipe excess oil from sealing surfaces on front head
Rear Suction Reed (Fig. ID-32). Do not pry up on casting webs and examine sealing surface. If any surface
horseshoe-shaped reed valves. damage is observed, the head should be replaced.
12. Examine reeds for damage, and replace if necessary.
13. Using Oil Pick-Up Tube Remover J 5139 (Fig. 1D- 18. Remove Front Discharge Valve Plate assembly and
33), remove Oil Pick-Up Tube. Remove O-ring from oil Front Suction Reed Plate. Examine reeds and seats. Replace
inlet. necessary parts.
14. Loosen compressor from Holding Fixture J 9396, 19. Remove Suction Cross-Over Cover by prying with
place Internal Cylinder and Shaft Assembly Support Block screwdriver between cylinder casting and cover (Fig. 1D-
J 21352 over oil pump end of shaft and, while holding 34).
ID-14 A/C COMPRESSOR OVERHAUL

3. Separate cylinder halves, using a wood block and

mallet (Fig. ID-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).

SUCTiON
PASS
COVER

CYLINDER
ASSEMBLY
4958

Fig. 1D-34 Removing A-6 Suction Cross-Over Cover

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 4964
necessary to use the Service Internal Cylinder and Shaft
Assembly rather than replace individual parts.
Fig. 1D-36 Separating A-6 Cylinder Halves

CAUTION: UNDER NO CIRCUMSTANCES

A-6 COMPRESSOR INTERNAL SHOULD SHAFT BE STRUCK A T EITHER
CYLINDER AND SHAFT ASM END in an effort to separate upper and lower
cylinder halves because the shaft and the axial
Disassembly plate could be damaged.
Use Parts Tray J 9402 (Fig. ID-38) to retain
compressor parts during disassembly. 4. Carefully remove the Rear Half of the cylinder from
1. Remove Internal Cylinder and Shaft Assembly from the pistons and set the Front Cylinder Half, with the piston,
compressor as described in “A-6 Compressor Internal shaft and axial plate in Compressing Fixture J 9397.
Mechanism (Cylinder and Shaft Asm.)” Removal 5. Pull up on compressor shaft and remove piston
procedure. previously identified as No. 1, with balls and shoe discs,
2. Identify by pencil mark, or some other suitable from axial plate.
means, each piston numbering them as 1, 2 and 3 (Fig. 1D- a. Inspect the Teflon piston rings for nicks, cuts
35). 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.
FRONT 7. Remove and examine piston balls, and if satisfactory
CYLINDER for re-use, place balls in No. 1 compartment of Parts Tray
HALF J 9402 (Fig. ID-38).
8. Place piston in No. 1 compartment of Parts Tray J
PISTON 9402, w ith notch in casting w eb at front end of
piston (Fig. 1 D-37) into the dimpled groove of Parts
Tray compartment.
9. Repeat Steps 5 through 9 for Pistons No. 2 and No.
SUPPORT
3.
BLOCK J-213 10. Remove rear combination of thrust races and thrust
bearing from shaft. Discard races and bearing.
4956
11. Remove shaft assembly from front cylinder half. If
Fig. 1D-35 Numbering A-6 Piston and Cylinder Bores the Discharge Cross-Over Tube remained in the front
cylinder half, it may be necessary to bend discharge cross­
Number the piston bores in the front cylinder half in over tube slightly in order to remove shaft.
like manner, so that pistons can be replaced in their original 12. Remove front combination of thrust races and
locations. bearing from shaft. Discard races and bearing (Fig. ID-39).
13. Examine surface of Axial Plate and Shaft. Replace
as an assembly , if necessary.
 A/C COMPRESSOR OVERHAUL 1D-l 5

This is necessary only on original factory

TEFLON equipment, as ends of the 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 END of the tube, and
can be easily removed by hand (see Fig. ID-58).
15. Examine piston bores and needle bearings in front
and rear cylinder halves. Replace Front and Rear Cylinder
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.
1 Insert socket in hub end (inner side) of cylinder head and
drive bearing out.
(PISTON FRONT I 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
Fig. 1D-37 Notch Identifying Front End of A-6 Piston (Fig. ID-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".

4982

Fig. 1D-38 A-6 Parts Tray

NEEDLE BEARING
INSTALLER J-9432

THRUST RACE NEEDLE BEARING

THRUST CYLINDER
BEARIN HEAD

SUPPORT
THRUST BLOCK J-21352
4975

Fig. 1D-40 Installing A-6 Needle Bearing

SUPPORT BLOCK
J-21352
17. Wash all parts to be re-used with trichlorethylene,
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
5074
by referring to Fig. ID-2 and Fig. ID-3.
Fig. 1D-39 Removing A-6 Front Thrust Races and
Bearings A-6 COMRESSOR INTERNAL
CYLINDER AND SHAFT ASM
A certain amount of shoe disc wear on axial plate is
normal, as well as some markings indicating load of needle
bearings on shaft. Gaging Operation
1. Install Compressing Fixture J 9397 on Holding
14. Remove Discharge Cross-Over Tube from cylinder Fixture J 9396 in vise. PLACE FRONT CYLINDER
half, using self-clamping pliers. HALF in Compressing Fixture, flat side down. Front
ID-16 A/C COMPRESSOR OVERHAUL

cylinder half has long slot extending out from

shaft hole. “Legs” of front cylinder half will be pointed
upward .
2. Secure from Service parts stock four ZERO thrust SHOE DISC
races, tw o thrust bearings and three ZERO shoe discs.
3. Now install a 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 TEFLON RING
bearing assembly (race-bearing-race) to rest on hub of
cylinder.
5. Now install a ZERO THRUST RACE ON REAR
END of compressor axial shaft (Fig. ID-41), so that it rests
on hub of axial plate. Then add one thrust bearing and a 4979
SECOND ZER6 THRUST RACE onto shaft. Lubricate
races and bearing with petrolatum. Fig. 1D-42 Installing A-6 Front Shoe Disc

At this point, BOTH front end and rear end of axial

shaft will have a stack-up of one ZERO race-one bearing- 9. Lift the axial shaft assembly up a little out of front
one ZERO race. cylinder half and hold front thrust race and bearing
assembly (“zero” race-bearing-“zero” race) against axial
’■""trS plate hub.
THRUST BEARING 10. Position No. 1 Piston over No. 1 cylinder bore
THRUST RACE (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 (Fig. ID-43).
THRUST RACE
REAR NEEDLE PISTON DRIVE
COMPRESSING THRUST BEARING BALL ONLY
FIXTURE AND "ZERO” THRUST AT REAR
J-9397 ------------ FRONT RACES
CYLINDER
HOLDING FIXTU HALF
J-9396

FRO NT CYLINDER
5070

Fig. 1D-41 Installing A-6 Rear Thrust Races and

Bearings

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. 4951
7. Lubricate cavity of a ZERO SHOE disc with 525 Fig. 1D-43 Installing A-6 Piston During Gaging
viscosity refrigerant oil and place shoe disc OVER BALL Operation
IN FRONT END of piston (Fig. ID-42). Front end of
piston has an identifying notch in casting web 11. Repeat Steps 6 through 10 for Pistons No. 2 and
(Fig. ID-37). No. 3.
CAUTION: Exercise care in handling the Piston 12. NOW INSTALL REAR CYLINDER HALF
and Ring Assembly, particularly during assembly ONTO PISTONS, aligning cylinder with discharge cross­
into and removal from the cylinder bores to over tube hole in front cylinder half.
prevent damage to the Teflon piston rings. Tap into place using a plastic mallet or piece of clean
wood and hammer (Fig. ID-44).
13. Position discharge cross-over tube opening between
SHOE DISCS SHOULD NOT BE INSTALLED a pair of Compressing Fixture J 9397 bolts to permit access
ON REAR of piston during following "Gaging" for feeler gage.
operation.
14. Install top plate on Compressing Fixture J 9397.
8. Rotate shaft and axial plate until high point of axial Tighten nuts to 15 lb. ft. (20 N-m)torque using a 0-25 lb.
plate is over the No. 1 Piston cylinder bore. ft. (0-60 N*m) torque wrench.
 A/C COMPRESSOR OVERHAUL ID-17

4963

Fig. 1D-44 Assembling A-6 Cylinder Halves Fig. 1D-45 Gaging A-6 Rear Piston Ball

Gaging Procedure (Steps 15 thru 18) d. If reading in Step “c” above is under 4 OR over 8
The gaging operations which follow have been worked ounces, reduce or increase thickness of Feeler Gage leaves
out on a simple basis to establish and provide necessary and repeat Steps a. through c. above until a reading of 4 to
running tolerances. Two gaging procedures are necessary. 8 ounces is obtained. Record the clearance between ball and
axial plate that results in the desired 4 to 8 ounce pull on
The first is made to choose the proper size Spring Scale.
shoe discs to provide, at each piston, a .0016" to .0024" 16. Now rotate shaft 120° and repeat Step 15 between
total preload between the seats and the axial plate at the this same No. 1 Piston Rear Ball and axial plate. Record
tightest place through the 360-degree rotation of the axial this measurement.
plate. The bronze shoe discs are provided in .0005" If shaft is hard to rotate, install shaft nut onto shaft and
variations, including a basic ZERO shoe. turn shaft with wrench.
The second, performed at the rear shaft thrust race
and bearing stack-up, is designed to obtain .0025" to 17. Rotate shaft another 120° and again repeat Step 15
.0030" preload between the hub surfaces of the
between these same parts and record measurements.
axial plate and the front and rear hubs of the cylinder. A 18. Select a “NUMBERED” SHOE disc corresponding
total of 14 steel thrust races, including a basic ZERO race, to minimum feeler gage reading recorded in the three
are provided in increments of .0005" thickness to provide checks just made above. (See example in Fig. ID-47). Place
the required fit. the selected shoe discs in Parts Tray J 9402 compartment
Feeler and Tension Gage Set J 9564-01 or J 9661-01 corresponding to Piston No. 1 and Rear Ball pocket
may be used for gaging proper shoe disc size. Feeler Gage position.
Set J 9564-01 or Dial Indicator Set J 8001 may be used to Shoe discs are provided in .0005" (one-half
determine proper thrust race size. thousandths) variations. There are a total of 11 sizes
PROPER SELECTION OF THRUST RACES AND available for field servicing. All shoe discs are marked with
BALL SEATS IS OF EXTREME IMPORTANCE. the shoe size, which corresponds to the last three digits of
the piece part number. (See Shoe Disc Size Chart in Fig.
15. Measure clearance between REAR BALL of No. ID-46).
1 Piston AND AXIAL PLATE, in following manner: Once a proper selection of the shoe has been
a. Select a suitable combination of well-oiled Feeler made, the M A TC H ED C O M B IN A TIO N OF SHOE
Gage leaves to fit snugly between ball and axial plate. DISC TO REAR BALL AND SPHERICAL C A V ITY
b. Attach Tension Gage J 9661-3 to the feeler gage. A IN PISTON M U S T BE KEPT IN PROPER
distribution point checking scale or Spring Scale J 544 may RELATIONSHIP during disassembly after Gaging
be used. operation, and during final assembly into the
c. Pull on Spring Scale to slide Feeler Gage stock out Internal Cylinder and S haft Assembly.
from between ball and axial plate, and note reading on 19. Repeat in detail the same Gaging Procedure
Spring Scale as Feeler Gage is removed (Fig. ID-45). outlined in Steps 15 through 18 for Piston No. 2 and No.
Reading should be between 4 and 8 ounces. 3.
ID-18 A/C COMPRESSOR OVERHAUL

SHOE DISC THRUST BEARING RACE

PART NO. IDENTIFICATION MIN.FEELER PART NO. IDENTIFICATION DIAL INDICATOR
ENDING IN STAMP GAGE READING ENDING IN STAMP READING
000 0 .0000 000 0 .0000
175 17-1/2 .0175 050 5 .0050
180 18 .0180 055 5-1/2 .0055
185 18-1/2 .0185 060 6 .0060
190 19 .0190 065 6-1/2 .0065
195 19-1/2 .0195 070 7 .0070
200 20 .0200 075 7-1/2 .0075
205 20-1/2 .0205 080 8 .0080
210 21 .0210 085 8-1/2 .0085
215 21-1/2 .0215 090 9 .0090
220 22 .0220 095 9-1/2 .0095
100 10 .0100
105 10-1/2 .0105
110 11 .0110
115 11-1/2 .0115
120 12 .0120
-------------------------------------------------------- ------------------------ 0913
Fig. 1D-46 Available A-6 Service Shoes and Thrust Races

DIAL INDICATOR SLEEVE CLAMP

SELECT J -8001-3 J-8001-2 J-8001-1
POSITION POSITION POSITION
AND USE
1 2 3
SHOE NO.
PISTON NO. 1 .019'' .0195" .019" 19

PISTON NO. 2 .020" .020" .020" 20

PISTON NO. 3 .021" .021" .022" 21

0914

Fig. 1D-47 Selection of Proper A-6 Shoe Disc

REAR THRUST
20A. Mount Dial Indicator J 8001 on edge of BEARING & RACES
Compressing Fixture J 9397 with Clamp J 8001-1 and Sleeve
J 8001-2 (Fig. ID-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 Fig. 1D-48 Gaging A-6 Rear Thrust Race
again and record measurement. Dial Indicator increments
are .001"; therefore, reading must be estimated to nearest Fifteen (15) thrust races are provided in increments of
.0005". .0005" (one-half thousandths) thickness and one ZERO
20B. An alternate method of selecting a proper race is gage thickness, providing a total of 16 sizes available for
to use Gage Set J 9661-01 selecting a suitable feeler gage leaf field service. The thrust race “number” also corresponds to
until the result is a 4 to 8 ounce pull on the scale between the last three digits of the piece part number. See Thrust
the rear thrust bearing and upper (which also happens to Race Size Chart in Fig. ID-46.
be the outer rear) thrust race (Fig. lD-49).If the pull is just 22. Remove nuts from top plate of Compressing Fixture
less than 4 ounces, add .0005" to the thickness of the feeler J 9397, and remove top plate.
stock used to measure the clearance. If the pull on the scale 23. Separate cylinder halves while unit is in Fixture. It
reads just over 8 ounces, then subtract .0005" from the may be necessary to use a wooden block and mallet.
thickness of the feeler stock. 24. Remove Rear Cylinder Half and carefully
21. For either method used, select a thrust remove one piston at a tim e from axial plate and
race w ith a "number" corresponding to TW O (2) front cylinder half. DO NOT LOSE THE
FULL SIZES LARGER than Dial Indicator or Feeler RELATIONSHIP of the front ball and shoe disc
Gage m easurement of the amount of end play and rear ball. Transfer each piston, ball and shoe
shown. (If measurement is .007", select a No.9 or 090 disc to its proper place in Parts Tray J 9 4 0 2 .
race.) 25. Now remove REAR OUTER ZERO thrust race (it
PLACE THRUST RACE IN RIGHT-HAND SLOT will be on top) from shaft AND INSTALL THE THRUST
AT BOTTOM CENTER OF PARTS TRAY J 9402. RACE JUST SELECTED in Steps 20 and 21 that is
 A/C COMPRESSOR OVERHAUL ID-19

CHECKING FOR W A R N IN G : EXERCISE PERSONAL

REAR CARE IN CUTTING THE PISTON RING
THRUST FOR R E M O V A L
AND RACE
THICKNESS
2. Clean the piston and piston ring grooves with
trichlorethylene, 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 (Fig. ID-51).
FRONT THRUST 4. Install a Teflon ring on the Ring Installer Guide J
GIVES PROPER
CHECKING FOR SHOE 24605-2 as shown in Fig. ID-51, w ith the dished or dull-
THICKNESS “X” side down and glossy-side up.
HEAD CLEARANCE
5. Push the Ring Installer J 24608-5 down over the
Installer Guide J 24608-2 to install the Teflon ring in the
4980 piston ring groove (Fig. ID-52). If the Teflon ring is slightly
off position m the ring groove, it can be positioned into place
Fig. 1D-49 Checking A-6 Piston and Shaft End Play
by fingernail or blunt-edged tool that will not damage the
piston.
presently setting in the right-hand slot at bottom center of The Ring Installer J 24608-5 will retain the Installer
Parts Tray J 9402. Guide J 24608-2 internally when the Teflon ring is installed
The removed ZERO thrust race may be put aside for on the piston. Remove the Installer Guide from the Ring
re-use in additional Gaging or rebuilding operations. Installer and DO NOT STORE THE INSTALLER
26. Repeat for each piston. GUIDE IN THE RING INSTALLER, as the Ring
Installer Segment Retainer O-Ring J 2 4 6 0 8 -3 w ill
A-6 COMPRESSOR CYLINDER AND be stretched and possibly weakened during
SHAFT ASSEMBLY storage. This could result in the O-Ring J 24608-3 not
holding the Ring Installer segments tight enough to the
Installer Guide J 24608-2 to properly install the Teflon ring
A-6 Teflon Piston Ring Replacement
on the piston.
The Teflon piston ring installing, sizing and gaging 6. Lubricate the piston ring area with 525 viscosity
tools are shown in Fig. ID-50. refrigerant oil and rotate the Piston and Ring Assembly into
the Ring Sizer J 24608-6 a t a slight angle (Fig. ID-53).
1. Remove the old piston rings by CAREFULLY Rotate the piston, while pushing inward, until the piston is
slicing through the ring with a knife or sharp instrument, inserted against the center stop of the Ring Sizer J 23608-6.
holding the blade almost flat with the piston surface. Be CAUTION: DO N O T push the Piston and Ring
careful not to damage the aluminum piston OR piston Assembly into the Ring Sizer J 24608-6 without
proper positioning and rotating as described
above, as the ends o f the needle bearings o f the
Ring Sizer may damage the end o f the piston.

J-24608-2 >J-24608-5
RING INSTALLER * RING INSTALLER
GUIDE J-24608-6
RING SIZING TOOL
J-24608-1
PISTON RING GAGE

J-24608-3 O-RING 7

Fig. ID -5 0 A-6 Teflon Piston Ring Installing, Sizing and Gaging Tools
ID-20 A/C COMPRESSOR OVERHAUL

T E F L O N PISTON R IN G
w j

J-24608-2 R IN G
IN S T A L L E R
G U ID E

0918

Fig. 1D-51 A-6 Teflon Piston Ring Positioned on Ring Fig. 1D-52 Installing A-6 Teflon Piston Ring
installer Guide

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 (Fig. 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
(Fig. ID-54). The piston should go through the Ring Gage
with a 6-lb. force or less without lubrication. If not, repeat
Steps 6 and 7.
9. Repeat the procedure for the opposite end of the
piston (Fig. ID-55).
CAUTIO N: DO NO T lay the piston down on a
dirty surface where dirt or metal chips might Fig. 1D-53 Turning A-6 Piston and Ring Asm. Into Ring
come into contact and become imbedded in the Sizing Tool
Teflon ring surface. A-6 COMPRESSOR INTERNAL
10. Lubricate BOTH ENDS of the piston with 525 CYLINDER AND SHAFT ASM.
viscosity refrigerant oil before inserting the piston into the
cylinder bore. Assembly
CAUTIO N: Reasonable care should be exercised After properly performing the “Gaging Procedure”,
in installing the piston into the cylinder bore to choosing the correct shoe discs and thrust races, and
prevent damage to the Teflon ring. installing any needed Teflon piston rings, the cylinder
 A/C COMPRESSOR OVERHAUL 1D-21

'SELECTED" REAR SHOE DISC "SELECTED"

REAR THRUST RACE
PISTON AND RING ASSEMBLY

THRUST BEARING

NOTCHED END

"ZERO"THRUST
RACES LIFT
"ZERO"FRONT SHAFT UPWARD
SHOE DISC AND HOLD THE
THRUST RACES
AND BEARING
J -24608-1 PISTON RING GAGE
4986: AGAINST HUB

Fig. 1D-54 Gaging A-6 Piston Ring Size

THRUST BEARING 0920

Fig. 1D-56 Installing 1st A-6 Piston Assembly Into Front
Cylinder Half

REAR THRUST RACES

AND BEARING

0919

Fig. 1D-55 A-6 Teflon Piston Ring Installed in Piston

Groove.

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. BALL AND
FRONT AND
Assembly procedure is as follows:
1. Support the FRONT half of the cylinder assembly
on Compressing Fixture J 9397. Install the shaft and axial A X IA L PLATE
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 FRONT THRUST RACES AND BEARINGS
piston assembly. 0921
3. Rotate the axial plate so that the high point is above
cylinder bore No. 1. Fig. 1D-57 Installing 2nd A-6 Piston

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 (Fig. ID-56).
4. Repeat this operation for Pistons No. 2 and No. 3
(Fig. ID-57).
5. Without installing any O-rings or bushings, assemble 6. Now rotate the shaft to position the pistons in a
one end of the new Service Discharge Cross-Over Tube into stair-step arrangement; then carefully place the Rear
the hole in the front cylinder half (Fig. ID-58 and ID-59). Cylinder Half over the shaft and start the pistons into the
Be sure the flattened portion of this tube cylinder bore (Fig. ID-60).
faces the inside of the compressor to allow for axial plate
clearance (Fig. ID-59).
ID-22 A/C COMPRESSOR OVERHAUL

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 (Fig. 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.

Fig. 1D-59 Installing A-6 Discharge Cross-over Tube

4965

Fig. 1D-61 Installing A-6 Suction Cross-over Cover

PISTONS IN "STAIR STEP" POSITION
A-6 COMPRESSOR INTERNAL
CYLINDER AND SHAFT ASM
REAR THRUST Re-Install
RACES AND
BEARING 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 (Fig. ID-62). The O-ring and
bushing are Service parts only for Internal Cylinder and
Shaft Assemblies that have been disassembled in the field
(Also see Fig. ID-58).

BUSHING

FRONT
CYLINDER HALF

COMPRESSING FIXTURE 0924

Fig. 1D-60 A-6 Pistons Positioned in Stair-Step

Arrangement

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 cylinder.
5077
8. When all parts are in proper alignment, tap with a
clean wooden block and mallet to seat the rear half of the Fig. 1D-62 Installing O-Ring On A-6 Discharge Cross-
cylinder over the locating dowel pins. If necessary, clamp Over Tube
the cylinder in Compressing Fixture J 9397, to complete
drawing the cylinder halves together.
 A/C COMPRESSOR OVERHAUL ID-23

3. Install new dowel pins in front cylinder half, if

previously removed. SUCTION
4. Install Front Suction Reed Plate on front cylinder >^REED
half. Align with dowel pins, suction ports, oil return slot,
and discharge cross-over tube (Fig. ID-63). LARGER
5. Install Front Discharge Valve Plate assembly (it has DIA. HOLE
a large diameter hole in the center), aligning holes with
dowel pins and proper openings in front suction reed plate
(Fig. ID-64 and Fig. ID-65.)
6. Coat sealing surfaces on webs of compressor front
head casting with clean 525 viscosity refrigerant oil.
OIL RETURN DISCHARGE
SLOT CROSSOVER TUBE REAR DISCHARGE FRONT DISCHARGE
VALVE PLATE VALVE PLATE
4953

Fig. 1D-65 Front and Rear A-6 Discharge Valve Plates

DOWEL PINS DOWEL PINS

casting into position (Fig. ID-66), making certain th a t

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.

5062

FRONT SUCTION SUPPORT BLOCK

REED PLATE J-21352
Fig. 1D-63 Installing A-6 Front Suction Reed
FRONT HEAD
CASTING
FRONT
DISCHARGE FRONT
DOWEL PINS VALVE PLATE DISCHARGE
ASSEMBLY VALVE PLATE
ASSEMBLY

4967

DOWEL PINS
SUPPORT BLOCK
J-21352
Fig. 1D-66 Installing A-6 Front Head Casting

SUPPORT BLOCK 8. Generously lubricate new O-ring and angled groove

J-21352
5075 at lower edge of front head casting with 525 viscosity
refrigerant oil and install new O-ring into groove (Fig. 1D-
Fig. 1D-64 Installing A-6 Front Discharge Valve Plate
67).
7. Determine exact position of Front Head casting in
relation to dowel pins on Internal Cylinder and Shaft 9. Coat inside machined surfaces of compressor shell
Assembly. Mark position of dowel pins on sides of Front with 525 viscosity refrigerant oil and position shell on
Head assembly and on sides of Internal Cylinder and Shaft Internal Cylinder and Shaft Assembly, resting on O-ring
Assembly with a grease pencil. Carefully lower Front Head seal.
ID-24 A/C COMPRESSOR OVERHAUL

13. Install new O-ring in 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 (Fig. 1D-
69).

FRONT OIL PICK-UP TUB

HEAD
O-RING
OIL PUMP

4950

SUPPORT
BLOCK J-21351

Fig. 1D-67 A-6 Front Head O-Ring Installed

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
Fig. 1D-69 Installing A-6 Oil Pick-up Tube

slides down, line up oil sump with oil intake tube hole (Fig.
ID-68). 15. Now install new O-ring and bushing on rear-end
of discharge cross-over tube (See Fig. ID-58).
16. Install Rear Suction Reed over dowel pins, w ith
slot TO W A R D S sump.
17. Install Rear Discharge Valve Plate assembly over
dowel pins, w ith reed retainers UP.
COMPRESSOR 18. Position Inner Oil Pump Gear over shaft with
SHELL previously applied identification mark UP.
OIL SUMP 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
meshes with inner gear at the 9-o’clock position. The
resulting cavity between gear teeth is then at 3-o’clock
position (Fig. ID-70).
20. Generously oil Rear Discharge Valve Plate
assembly with 525 viscosity refrigerant oil around outer
RING
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.
SUPPORT
4957
21. Using the 525 oil, lubricate new head to-shell O-ring
BLOCK J-21352 and install on rear discharge valve plate, in contact with
OIL INTAKE
TUBE HOLE shell (Fig. ID-71).
22. Install Suction Screen in rear head casting, using
Fig. 1D-68 Installing A-6 Compressor Shell care not to damage screen.
23. Coat sealing surface on webs of compressor rear
11. Holding Support Block J 21352 with one hand, head casting with 525 viscosity refrigerant oil.
invert Internal Cylinder and Shaft Assembly and place back 24. Install Rear Head assembly over studs on
into Holding Fixture J9396 with front end of shaft now compressor shell. The tw o lower threaded
facing downward. Remove Support Block. compressor mounting holes should be in
alignm ent w ith the compressor sump.
12. Install new dowel pins in rear cylinder half, if Make certain that suction screen does not drop out of
previously removed. place when lowering rear head into position (Fig. ID-72).
 A/C COMPRESSOR OVERHAUL ID-25

CAVITY BETWEEN 26. Invert compressor in Holding Fixture and install

GEAR TEETH compressor Shaft Seal as described in “A-6 Compressor
(3 O'CLOCK) Shaft Seal” Replacement procedure.
27. Install compressor Clutch Coil and Housing
assembly as described in “A-6 Compressor Clutch Coil and
Housing Asm.” Replacement procedure.
28. Install compressor Pulley and Bearing assembly as
described in “A-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
OIL SUMP Asm.” Replacement procedure.
6 O'CLOCK) 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 “A-6 Compressor Leak Testing” procedure
found at the end of this OVER-HAUL section.
OIL DRAIN 32. “Evacuate and Charge the Refrigerant System”
PLUG according to the DISCHARGING, ADDING OIL,
EVACUATING AND CHARGING PROCEDURES
4972
FOR C.C.O.T. A/C SYSTEMS in the AIR
Fig. 1D-70 Positioning A-6 Oil Pump Gears C O N D IT IO N IN G section.

FRONT
HEAD

SHELL T(
HEAD O-l

CYLINDER
ASSEMBLY

4955

Fig. 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 on threaded shell studs and tighten
evenly to 25 lb. ft. (34 N*m) torque using a 0-50 lb. ft. (0-60
N-m) torque wrench. Fig. 1D-72 Installing A-6 Rear Head
ID-26 A/C COMPRESSOR OVERHAUL

MINOR REPAIR PROCEDURES FOR THE R-4

COMPRESSOR
THE FOLLOWING OPERATIONS TO THE R-4
COMPRESSOR CLUTCH PLATE AND HUB,
ROTOR A N D BEARING, A N D COIL & PULLEY
RIM ARE COVERED AS "M IN O R " BECAUSE
THEY M A Y BE PERFORMED W IT H O U T FIRST
PURGING THE SYSTEM OR REM O VING 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 Fig. 1D-73 R-4 Compressor
clearly illustrate the various operations.
R-4 COMPRESSOR CLUTCH PLATE
When servicing the compressor, remove only the AND HUB ASM.
necessary components that preliminary diagnosis indicates
are in need of service. Refer to the AIR CONDITIONING Remove
section and Fig. ID-74 and Fig. ID-75 for information 1. If compressor is not removed from the car, loosen
relative to parts nomenclature and location. compressor mounting brackets, disconnect the compressor
Removal and installation of external compressor drive belt and reposition the compressor for access, if
components and disassembly and assembly of internal necessary.
components must be performed on a clean workbench. The If compressor has been removed from the car, attach
w ork area, tools and parts must be kept clean at the compressor to Holding Fixture J 25008-1, and clamp the
all times. Holding Fixture in a vise (Fig. ID-76).
 SPECIAL WASHER-PULLEY RIM PULLEY RIM
MOUNTING SCREW LOCKING
O-RING, PRESSURF COIL AND HOUSING ASSEMBLY
RELIEF VALVE
PRESSURE RELIEF ROTOR BEARING
VALVE
SCREW ROTOR

RETAINER RING
Fig. 1D-74

SHIPPING
PLATE

O-RING,
Exploded View

SUCTION-DISCHARGE
PORTS

C CLUTCH HUB KEY SHAFT NUT

N * , i ,E I
of R-4 Compressor

RETAINER RING PLATE / .

CYLINDER AND SHAFT ASSEMBLY

A/C COMPRESSOR OVERHAUL

O-RING, CYLINDER TO SHELL O-RING, SEAL SEAT

SHAFT SEAL
SHELL
SEAL SEAT
RING SEAL, FRONT HEAL FRONT HEAD-
TO CYLINDER U

SCREW AND WASHER ASSEMBLY-

FRONT HEAD MOUNTING
SHAFT SEAL KIT / *
RETAINER RING

ID-27
1607
ID-28 A/C COMPRESSOR OVERHAUL

THRUST AND BELLEVILLE

WASHERS

COMPRESSOR SHELL MAIN BEARING — FRONT

PULLEY RIM
/ MTG. SCREW

PULLEY RIM MTG.

DISCHARGE PORT SCREW LOCKWASHER

ROTOR BEARING
ROTOR
BEARING
SUCTION PORT RETAINER
SEAL SEAT
RETAINER
SHAFT KEY
SHAFT NUT
MAIN BEARING — REAR
SHAFT SEAL
SEAL SEAT
SEAL SEAT
PISTON ASSEMBLY O-RING
lii^CLUTCH DRIVE
ASSEMBLY
ROTOR AND HUB
FRONT HEAD ASSEMBLY
SHELL RETAINER CLUTCH COIL AND HOUSING ASSEMBLY

VALVE PLATE RETAINER RING VALVE PLATE

ASSEMBLY

5140
Fig. 1D-75 R-4 Compressor Cross Section

DISCHARGE
PORT
J 25030
SUCTION CLUTCH HUB
PORT H O LD IN G TOOL
J 9399
SHAFT NU T
SOCKET

CLUTCH
ASSEMBLY

J-25008 1 J 25008-1
HOLDING HIGH PRESSURE H O LD IN G
FIXTURE RELIEF VALVE F IX T U R E

Fig. 1D-76 R-4 In Holding Fixture

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, Fig. Fig. 1D-77 Removing R-4 Shaft Nut
ID-77.
 A/C COMPRESSOR OVERHAUL 1D-29

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 CLUTCH PLATE
Remover body to remove the Clutch Plate and Hub AND HUB ASSY.
assembly (Fig. ID-78).

J 9401
HUB AND CLUTCH
DRIVE PLATE
ASM.REMOVER

SHAFT
KEY
CLUTCH PLATE
AND HUB ASM.

J 25008 1
HOLDING
Fig. 1D-79 Installing R-4 Shaft Key
FIXTURE

D R IV E PLA TE
Fig. 1D-78 R-4 Clutch Plate & Hub Asm. Removal IN S T A L L E R
J 9480-1

4. Remove the shaft key.

D R IV E P LA TE
Replace IN S T A L L E R

1. Install the shaft key into the hub key groove (Fig. B E A R IN G

ID-79). Allow the key to project approximately 3/16" out

of the keyway.
The shaft key is curved slightly to provide an
CLUTCH
A IR GAP
A N D HUB ASM.

interference fit in the shaft key groove to permit the key

.0 2 0 " .0 4 0 " !

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.
CAUTIO N: To avoid internal damage to the
Fig. 1D-80 Installing R-4 Clutch Plate & Hub Asm.

compressor, do not drive or pound on the clutch

hub or shaft. N*m) torque wrench.
7. If operation is performed with compressor on car,
4. Install the Clutch Plate and Hub Installer J 9480-01 connect drive belt,
as illustrated in Fig. ID-80. tighten mounting brackets and adjust belt tension.
5. Hold the hex portion of the Installer Body J 9480-1
with a wrench and tighten the center screw to press the hub R-4 COMPRESSOR CLUTCH ROTOR
onto the shaft until there is a .020-.040 inch air gap between AND/OR BEARING
the frictional 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 Remove
Socket J 9399. Hold the Clutch Plate and Hub assembly 1. Remove the Clutch Plate and Hub assembly as
with Clutch Hub Holding Tool J 25030, and tighten to 8-12 described in “R-4 Compressor Clutch Plate & Hub Asm.”
foot pounds (ll-16N*m) torque, using a 0-25 pounds (0-60 Removal procedure.
ID-30 A/C COMPRESSOR OVERHAUL

2. Remove Rotor and Bearing assembly retaining ring,

using Snap Ring Pliers J 6083 (#24), Fig. ID-81. Mark the
location of the clutch coil terminals.

J 6083
PLIERS

CLUTCH
ROTOR

RETAINER
RING

JIONS

Fig. 1D-82 Installing R-4 Rotor & Bearing Puller Guide

Fig. 1D-81 Removing R-4 Rotor & Bearing Asm. Retainer

Ring / J-25031-2
ROTOR AND
If the Clutch Rotor and/or Rotor Bearing only are to BEARING PULLl
be replaced, bend the lockwashers away from the pulley rim
mounting screws (see Fig. ID-79), and remove the six
mounting screws and special lock washers before proceeding J-25031
with Step 3. Discard the lock washers. GUIDE

3. Install Rotor and Bearing Puller J 25031-2 down into

the rotor until the Puller arms engage the recessed edge of
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 (Fig. ID-82 and ID-83),
being careful not to drop the Puller Guide.
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 Fig. 1D-83 Removing R-4 Clutch Rotor Asm.
Assembly.
5. Place the Rotor and Bearing assembly on blocks as 2. Align the new bearing squarely with the hub bore
shown in Fig. ID-84. Drive the bearing out of the rotor hub and using Pulley and Bearing Installer J 9481 with Universal
with Rotor Bearing Remover J 25029. Handle J 8092, drive the bearing fully into the hub (Fig.
It is not necessary to remove the staking at the rear of ID -86). The Installer will apply force to the outer race of
the rotor hub to remove the bearing (see Fig. ID-85). the bearing.
Replace 3. Using a center punch with a 45° angle point, stake
deep) the bearing in three places 120° apart as
(0.45 "-.055"
1. Place the Rotor and Hub assembly face down on a shown in Fig. ID -85, but do not stake too deeply to avoid
clean, flat and firm surface. distorting the outer race of the bearing.
 A/C COMPRESSOR OVERHAUL ID-31

J 8092
DRIVER
LE
J8092
DRIVER
HANDLE

#J25029
ROTOR
BEARING
REMOVER J 9481
PULLEY BEARING
AND PULLEY
INSTALLER

ROTOR
BEARING

5134
ROTOR AND
Fig. 1D-84 R-4 Clutch Rotor Bearing Removal HUB ASM.
4694

Fig. 1D-86 Installing R-4 Clutch Rotor Bearing

BEARIN
STAKE
LOCATIONS 4695

Fig. 1D-85 R-4 Rotor & Bearing Asm.

4. REPLACE ROTOR & BEARING ASM. (ON

CAR)
NOTE: Rotor and Bearing assembly removal and 5078
installation may be completed on the car without
“Discharging” the A/C system. Fig. 1D-87 Installing R-4 Rotor and Bearing Asm. (On
Car)

A. Position the Rotor and Bearing assembly on the G. Install shaft lock nut. Torque to 12 ft. lbs.
front head. 4. REPLACE ROTOR & BEARING ASM. (ON
B. With Rotor & Bearing Installer J 26271 (without BENCH)
driver handle) in position and Rotor and Bearing assembly Reassemble the Rotor and Bearing assembly to the
aligned with the Front Head as illustrated, drive the front head of the compressor using Rotor & Bearing
assembly part way onto the head (Fig. ID-87). Installer J 26271. With Installer assembled to the Universal
C. Plug clutch coil connector onto Clutch Coil. Handle J 8092, as shown in Fig. ID-88, force will be applied
to the inner race of the bearing when installing the assembly
D. Position the Clutch Coil so the 3 locating tabs will onto the front head of the compressor.
align with the holes in the head and continue to drive the 5. Install rotor and bearing assembly retainer ring,
Rotor and Bearing assembly onto the front head. using Snap Ring Pliers J 6083 (#24) (see Fig. ID-81).
E. Install the retainer ring (Fig. ID-81). 6. Apply sealer (Loctite RC-75, Loctite 601 or
F. Reassemble the Clutch Plate and Hub with the shaft equivalent) to threads of pulley rim mounting screws. Install
key onto the shaft with Installer J 9480-1 until .020" to .040" screws and new special lock washers but do not torque the
air gap is obtained. screws.
ID-32 A/C COMPRESSOR OVERHAUL

FRONT SURFACE

J 8092
DRIVER
HANDLE

4703

Fig. 1D-89 R-4 Clutch Coil Asm.

Replace
1. Assemble the Clutch Coil, Pulley Rim and the
Clutch Rotor and Bearing assembly as shown in Fig. ID-90.
Use new special lock washers and apply sealer (Loctite RC-
75, Loctite 601, or equivalent) to screw threads but do not
J 25008-1
lock the screws in place.
HOLDING
FIXTURE

0942
Fig. 1D-88 Installing R-4 Rotor & Bearing Asm. (On
Bench)

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 (Fig. ID-88).
9. Reinstall Clutch Plate and Hub assembly as
described in “R-4 Compressor Clutch Plate and Hub”
Replacement procedures. Fig. 1D-90 Assembling R-4 Clutch Coil, Pulley Rim and
Rotor & Bearing

R-4 COMPRESSOR CLUTCH COIL 2. Place the assembly on the neck of the Front Head
and seat into place using Rotor & Bearing Installer J 26271
AND/OR PULLEY RIM (Fig. ID-88).
NOTE: If original pulley rim was equipped with an
inertia ring, either bolted or welded on, or if a ring is Before fully seating the assembly on the Front Head,
to be added, refer to INERTIA RING be sure the clutch coil terminals are in the proper location
INSTALLATION following. in relation to the compressor and that the three protrusions
on the rear of the clutch coil align with the locator holes
Remove in the Front Head.
1. Perform Steps 1 through 4 of “R-4 Compressor 3. Install the rotor and bearing assembly retaining ring
Clutch Rotor and/or Bearing” Removal procedure but do and reassemble the Clutch Plate and Hub assembly as
not loosen or remove the pulley rim mounting described in “R-4 Compressor Clutch Plate and Hub Asm.”
screws until the Clutch Rotor, Coil and Pulley Rim Replacement procedure. Check to see that the clutch plate
assembly have been removed from the Front to clutch rotor air gap is .020 - .040 inches.
Head. Be careful not to drop the Puller Guide J 25031-1
when removing the assembly. Rotate the Pulley Rim and Rotor to be sure the Pulley
2. Remove the pulley rim mounting screws and special Rim is rotating“in-line” and adjust or replace as required.
lock washers. Discard the lock washers.
3. Slide the pulley rim off the Rotor and Hub assembly. 4. Tighten the pulley rim mounting screws to 100 inch-
The Pulley Rim and the Clutch Coil (Fig. ID-89) are pounds torque and lock the screw heads in place by bending
replaceable at this point. lock washers (Fig. ID-88).
 A/C COMPRESSOR OVERHAUL ID-33

R-4 COMPRESSOR INERTIA RING

INSTALLATION MOUNTING HOLES (3)
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) A welded - on Inertia Ring is installed - replace using
Procedure II.
Procedure I
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 ID-91, rather than a “mounting notch” screw
location. DO NOT remove the drive belt unless necessary.
NOTE: 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” 6197
screw location. Fig. 1D-91 R-4 Pulley Rim Mounting Location Detail

2. Remove the three mounting screws and lockwashers 9. Retighten the compressor drive belt to proper belt
at the pulley rim “mounting hole” locations. (The pulley rim tension.
"mounting holes” are located 120° apart radially around the 10. Check compressor and system operation.
rim or every other mounting screw location.) Do not remove
the screws in the “mounting notches”. NOTE: If “mounting notch” screws must be replaced
3. Temporarily make a trial fit of the Inertia Ring to for any reason, the screws should be torqued into place
the Pulley Rim. If any portion of the sheer edge of the Pulley (100 in. lbs. torque) using Loctite 601 (or equivalent
Rim prevents the installation of the Inertia Ring, the raised sealer) on the threads and locked into place similar to
edge may be filed off to remove the excess metal and the original locking method.
facilitate installation. DO NOT use undue force or cock the
ring in assembling the Inertia Ring in place over the Pulley Procedure II
Rim that could cause ring distortion or stress. INERTIA RING A N D PULLEY RIM W ELDED
4. Assemble the Inertia Ring onto the Pulley Rim, ASSEM BLY ~ REPLACEMENT
being careful to align the inertia ring mounting holes with (NEW PULLEY RIM AND INERTIA RING KIT
the mounting holes in the pulley rim. If the Inertia Ring REQUIRED)
must be rotated on the Pulley Rim for centering the 1. Loosen the compressor mounting bracket and
mounting holes and cannot be shifted by hand, use a drift remove the compressor drive belt.
punch or blunt tool and a hammer to carefully tap the 2. Remove the Clutch Hub and Drive Plate assembly
Inertia Ring at a clearance notch, Figure ID-92, to move as described in “R-4 Compressor Clutch Plate and Hub
the ring into position. Asm.” Removal procedure.
5. Install a special lockwasher onto each 1/4-28 X 17/ 3. To remove as an assembly, perform Steps 1 through
32" mounting screw. 4 of “R-4 Compressor Clutch Rotor and/or Bearing”
6. Apply Loctite 601 (or equivalent sealer) to the screw Removal procedures but do not loosen or remove the
threads of each mounting screw and threads of the mounting pulley rim mounting screws, so as to remove the
holes in the Clutch Rotor. Wet the threads thoroughly to Clutch Rotor and Bearing, Clutch Coil, Pulley Rim and
ensure complete thread coverage. Inertia Ring as a TOTAL assembly. Be careful not to drop
7. Install the screws into the mounting holes and the Puller Guide J 25031 when removing the assembly.
tighten finger-tight. Torque each screw to 100 in. lbs. 4. Remove all six pulley rim mounting screws and
torque. lockwashers from the assembly and discard.
8. Lock the three screws in place by flattening the 5. Separate the Pulley Rim and Inertia Ring assembly
special washer against two sides of the hex head screw using away from the Rotor and Bearing assembly.
vise grip pliers and one portion of the lockwasher bent down 6. Inspect the drive surfaces of the Rotor and Drive
over the edge of the inertia ring slot, Fig. ID-92. DO NOT Plate to be sure they are still in good condition. Replace as
move the screw heads from the torqued position. Locking required.
of the screws must be similar to the production forming of 7. Assemble a new Pulley Rim over the Clutch Coil and
the lockwasher in order to effectively retain the screw. mount the Pulley Rim to the Rotor and Bearing assembly,
ID-34 A/C COMPRESSOR OVERHAUL

“ LOCK" WASHER TO SIDES OF SCREW

HEAD AND DOWN OVER NOTCH IN RING.
(3 "MOUNTING HOLE" LOCATIONS)

INERTIA RING

"LOCK" WASHER TO SIDES OF SCREW

HEAD AND DOWN OVER EDGE OF PULLEY
RIM. (3 "MOUNTING NOTCH" LOCATIONS)

PULLEY RIM
6198

Fig. 1D-92 R-4 Pulley Rim and Inertia Ring Mounting Detail

using the short notch mounting locations, Figure ID-91. 12. Install the special lock washers onto the 1/2-28 X
The mounting notches are located 120° apart radially 17/32" mounting screws and apply Loctite 601 (or
around the Pulley Rim. equivalent sealer) to the total screw thread and the threads
8. Assemble three new lockwashers on the three new of the mounting holes in the rotor.
1/4-28 X 5/16" mounting screws and apply Loctite 601 (or 13. Install the screw and washers into the rotor
equivalent sealer) to the entire thread surface of the mounting holes and tighten finger tight. When all screws
mounting screws and the mounting hole threads in the are in place, torque each screw to 100 in. lbs. torque.
Rotor. Assemble the three screws into the short notch 14. Using Rotor and Bearing assembly Installer J-
mounting hole locations and tighten finger tight. 26271 and Universal Handle J-8092, install the Pulley,
9. Align the Pulley Rim so that the bottom of the rim Clutch Coil, Rotor and Bearing assembly onto the Front
notches touch the mounting screws at all three mounting Head of the compressor. Be sure to locate the clutch coil
locations. Also center the drilled holes in the Pulley Rim terminals in the proper position.
with the remaining mounting holes in the Rotor. When the 15. Spin the Rotor and Pulley assembly to ascertain
rim is positioned properly, tighten the three mounting that the pulley runs “in line”. If not, the mounting screws
screws to 100 in. lbs. torque. will have to be loosened and the parts aligned.
10. Temporarily make a trail fit of the Inertia Ring to 16. When all screws are torqued in place, lock all
the Pulley Rim. If any portion of the sheer edge of the Pulley mounting screws in position by flattening the special washer
Rim prevents the installation of the Inertia Ring, the raised against two opposite sides of the hex head screw, using vise-
edge may be filed off to remove the excess metal and grip pliers. Form a portion of the lock washer down over
facilitate installation. DO NOT use undue force or cock the the pulley rim or over the Inertia Ring slot to secure the
ring in assembling the Inertia Ring in place over the Pulley screws in place. DO NOT move the screw heads from the
Rim that could cause ring distortion or stress. torqued position. See Fig. ID-92.
11. Assemble the Inertia Ring onto the Pulley Rim 17. Install the Clutch Hub and Drive Plate as described
being careful to align the Inertia Ring mounting holes with in “R-4 Compressor Clutch Plate and Hub Asm.”
the mounting holes in the Pulley Rim. If the Inertia Ring Replacement procedures.
cannot be moved by hand and must be rotated for centering 18. Install the compressor drive belt and adjust for
the mounting holes, use a drift punch or blunt tool and a proper tension.
hammer to carefully tap at one of the large clearance 19. Operate the air conditioning system to check for
notches in the inertia ring to rotate the ring into position, proper operation.
Fig. ID-92.
 A/C COMPRESSOR OVERHAUL ID-35

MAJOR R-4 COMPRESSOR REPAIR PROCEDURES

Service repair procedures to the Compressor THEN THE A C C U M U LA TO R IN THIS R-4
S haft Seal, Pressure Relief Valve, Pressure SYSTEM M U S T ALSO BE REMOVED FROM THE
Sw itch or disassembly of the Internal Compressor VEHICLE; THE OIL IN THE ACCUMULATOR THEN
Cylinder and S haft Assembly are considered MUST BE DRAINED, measured and replaced according
"M A JO R " SINCE THE REFRIGERATION SYSTEM to “C.C.O.T. Refrigerant Oil Distribution” in the AIR
MUST BE COMPLETELY PURGED OF CONDITIONING section to determine oil loss.
REFRIGERANT before proceeding and/or because
major internal operating and sealing components R-4 COMPRESSOR SHAFT SEAL
of the compressor are being disassembled and
serviced.
REPLACEMENT
WHEN REPLACING THE SHAFT SEAL
ASSEMBLY (see Fig. ID-20), PRESSURE RELIEF Remove (On Car)
VALVE (see Fig. ID-102) or PRESSURE SWITCH (see 1. “Discharge the Refrigerant System” according to the
Figures ID-27 and ID-102), even if the compressor remains DISCHARGING, ADDING OIL, EVACUATING AND
on the vehicle during the operation, IT WILL BE CHARGING PROCEDURES FOR C.C.O.T. A/C
NECESSARY TO PURGE THE SYSTEM OF SYSTEMS in the AIR CONDITIONING section.
REFRIGERANT as outlined in the AIR 2. Loosen and reposition compressor in mounting
CONDITIONING section (see “Discharging, Adding Oil, brackets.
Evacuating and Charging Procedures for C.C.O.T. A/C 3. Remove Clutch Plate and Hub assembly from
Systems”). THE SAME HOLDS TRUE FOR ANY compressor as described in “R-4 Compressor Clutch Plate
DISASSEMBLY OF THE INTERNAL R-4 & Hub Asm.” Removal procedure.
COMPRESSOR CYLINDER AND SHAFT ASM. 4. Remove the shaft seal seat retainer ring, using Snap
IF THE R-4 COMPRESSOR INTERNAL Ring Pliers J 5403 (#21). See Fig. ID-21.
CYLINDER AND SHAFT ASSEMBLY IS TO BE 5. Thoroughly clean inside of compressor neck area
SERVICED OR REPLACED, THEN THE OIL IN THE surrounding the shaft, the exposed portion of the seal seat
R-4 COMPRESSOR MUST BE DRAINED, measured and and the shaft itself. This is absolutely necessary to
replaced according to “C.C.O.T. Refrigerant Oil prevent any dirt or foreign material from getting
Distribution” in the AIR CONDITIONING section to into compressor.
determine addition of proper oil quantity to new assembly. 6. Place Seal Protector J 22974 over the end of the shaft
A clean workbench, preferably covered with a sheet of to prevent chipping the ceramic seat. Fully engage the
clean paper, orderliness in the work area and a place for all knurled tangs of Seal Seat Remover-Installer J 23128 into
parts being removed and replaced is of great importance, as the recessed portion of the seal seat by turning the handle
is the use of the proper, clean service tools. Any attempt to clockwise. Remove the Seal Seat from the compressor
use make-shift or inadequate equipment may result in with a rotary-pulling motion (Fig. IB-93). Discard the Seat.
damage and/or improper compressor operation. CAUTION: DO N O T tighten the handle with
These procedures are based on the use of the proper a wrench or pliers; however; the handle must be
service tools and the condition that an adequate stock of hand-tightened securely to remove the Seat.
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

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 S haft
Seal when a leak is detected by evidence of oil
Fig.1D-93 Removing R-4 Ceramic Seal Seat (On Car)
sprayed in large amounts and then only after
actual refrigerant leakage is determined by test
w ith Electronic Leak Detector J 2 3 4 0 0 . 7. With Seal Protector J 22974 still over the end of the
SHOULD AN R-4 COMPRESSOR SHAFT SEAL shaft, set Seal Remover-Installer J 9392 down onto shaft
EVER HAVE TO BE REPLACED BECAUSE IT WAS end, turning clockwise, w hile pressing down to
DETERMINED TO BE THE CAUSE OF EXCESSIVE engage Remover tangs with the tabs on the Seal assembly.
SIGNS OF OIL LEAKAGE IN THE A/C SYSTEM, Then lift the Shaft Seal assembly out (see Fig. IB-94).
ID-36 A/C COMPRESSOR OVERHAUL

Discard the Seal.

Fig. 1D-96 Installing R-4 O-Ring (On Car)

Fig.1D-94 Removing R-4 Seal (On Car)

ring and remove the Installer. (See Fig. ID-24.)
3. Coat the O-Ring and seal face of the new Seal
8. Remove and discard the seal seat O-ring from the assembly with clean 525 viscosity refrigerant oil. Carefully
compressor, neck using O-Ring Remover 9553 (Fig. ID-95). mount the Seal assembly to Seal Installer J 9392 by engaging
the tabs of the seal with the tangs of the Installer (Fig.
ID-97).

Fig. 1D-95 Removing R-4 O-Ring (On Car)

9. Recheck the shaft and inside of the compressor neck Fig. 1D-97 Installing R-4 Seal (On Car)
for dirt or neck foreign material and be sure these areas are
perfectly clean before installing new parts. 4. Place Seal Protector J 22974 over end of compressor
shaft and carefully slide the new Seal assembly
Inspection onto the shaft. Gently tw is t the Installer J 9 3 9 2
SEALS SHOULD NOT BE RE-USED. A LW A YS CLOCK-WISE, w hile pushing the Seal assembly
USE A NEW SPECIFICATIO N SERVICE SEAL KIT down the shaft until the Seal assembly engages
ON REBUILD (see Fig. 1 D-20). Be extremely the flats on the shaft and is seated in place.
careful th a t the face of the Seal to be installed is Disengage the Installer by pressing downward and twisting
not scratched or damaged in any way. M ake sure counterclockwise.
th a t the Seal Seat and Seal are free of lint and dirt 5. Attach the ceramic Seal Seat to the Seal Seat
th a t could damage the seal surface or prevent Remover and Installer J 23128 and dip the ceramic Seat in
sealing. clean 525 viscosity oil refrigerant to coat the seal face and
outer surface. Carefully install the Seat over the compressor
Replace (On Car) shaft and J 22974 Seal Protector and push the Seat into place
1. Coat the new seal seat O-ring in clean 525 viscosity with a rotary motion (Fig. ID-98). Take care not to dislodge
refrigerant oil and assemble onto O-Ring Installer J 21508 the seat O-ring. However, be sure Seal Seat makes a good
(see Fig. ID-96). seal with O-ring. Remove Installer J 23128 and Seal
2. Insert the O-Ring Installer J 21508 completely Protector J 22974.
down into the compressor neck until the Installer 6. Install the new seal seat retainer ring w ith its fla t
“bottoms”. Lower the moveable slide of the O-Ring side against the Seal Seat, using Snap-Ring Pliers J
Installer to release the O-Ring into the seal seat O-ring 5403 (#21). See Fig. ID-21. Use the sleeve from Seal Seat
lower groove. (The compressor neck top groove is for the Remover-Installer J 23128 to press in on the seal seat
shaft seal retainer ring). Rotate the Installer to seat the O- retainer ring so that it snaps into its groove.
 A/C COMPRESSOR OVERHAUL 1D-37

-I 23128
SEAL SEAT
REMOVER AND
INSTALLER

CERAMIC
SEAL
SEAT

J 22974
SHAFT SEAL PROTECTOR

Fig. 1D-98 Installing R-4 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 with Electronic Leak Detector J 23400. Correct any Fig. 1D-99 Removing & Installing R-4 Seal Seat (Off Car)
leak found. Remove, discard and later reaplace 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 & Hub Asm.”
Replacement procedure.
10. Re-install compressor belt and tighten bracketry.
11. “Evacuate and Charge 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.
R-4 COMPRESSOR SHAFT SEAL
REPLACEMENT (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 ID-99, ID-100 and ID-101.
R-4 COMPRESSOR PRESSURE RELIEF
VALVE OR PRESSURE SWITCH Fig. 1D-100 Removing & Installing R-4 Seal (Off Car)

When necessary to replace the Pressure Relief Valve (or

Pressure Switch if so located), located in the compressor R-4 COMPRESSOR FRONT HEAD
rear head casting (Figures ID-27 and 102), the valve/switch AND/OR O-RING
assembly should be removed after PURGING THE
SYSTEM OF REFRIGERANT. A new valve/switch and
O-ring coated with 525 viscosity refrigerant oil should be Remove
installed (see DISCHARGING, ADDING OIL, 1. “Discharge the Refrigerant System” according to the
EVACUATING AND CHARGING PROCEDURES “DISCHARGING, ADDING OIL, EVACUATING
FOR C.C.O.T. A/C SYSTEMS in the AIR AND CHARGING PROCEDURES FOR C.C.O.T. A/C
CONDITIONING section). SYSTEM” in the AIR CONDITIONING section.
ID-38 A/C COMPRESSOR OVERHAUL

FRONT
HEAD

MOUNTING

4705

Fig. 1D-103 Removing R-4 Front Head Mounting Screws

OIL HOLE TO FRONT HEAD

SHAFT SEAL AREA cc M IN G RING

Fig. 1D-101 Installing R-4 Seal Seat 0-Ring(0ff Car)

MAIN
BEARING

COMPRESSOR
PRESSURE SWITCH

THRUST WASHERS
AND BELLEVILLE
WASHER

Fig. 1D-104 Removing R-4 Front Head Asm.

5. Remove and discard the front head O-ring.

Fig. 1D-102 R-4 Compressor Pressure Relief Valve and
Pressure Switch on A, B, Series Replace
2. Perform steps 1 through 4 of “R-4 Compressor 1. Check the Front Head and compressor cylinder area
Clutch Rotor and/or Bearing” Removal procedure but do for any dirt, lint, etc. and clean, if necessary. Install a new
not loosen or remove the pulley rim mounting Service thrust washer kit, if required, as described in “R-4
screws so as to remove the Clutch Rotor and Bearing, Compressor Thrust and Belleville Washers ’’Removal and
Clutch Coil and Pulley Rim as a TOTAL assembly. Be Replacement procedures.
careful not to drop the Puller Guide J 25031, when 2. Coat the new front head O-ring in clean 525 viscosity
removing the assembly. refrigerant oil and install in the seal groove on the front head
3. Remove and discard the Shaft Seal parts as described (Fig. ID-104).
in “R-4 Compressor Shaft Seal” Removal procedure. 3. Position the oil hole in the Front Head to be “up”
when assembled to the compressor cylinder to correspond
4. Remove the four front head mounting screws (Fig. with the “up” position of the compressor. Install the Front
ID-103) and remove the Front Head assembly (Fig. 1D- Head and tighten the front head mounting screws to an 20
104). lb. ft. (27 N*m) torque.
 A/C COMPRESSOR OVERHAUL ID-39

4. Install new specification Service Shaft Seal kit (Fig.

ID-20) as described in “R-4 Compressor Shaft Seal”
Replacement procedure.
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 (Fig. ID-88).
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 C.C.O.T. A/C SYSTEMS in the AIR
CONDITIONING section.
Fig. 1D-105 Replacing R-4 Thrust and Belleville
Washers
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
“R-4 Compressor Front Head” Removal procedure.
Remove and 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” (Fig. ID-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” (Fig. ID-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 Fig. 1D-106 Removing R-4 Main Bearing
Head” Replacement procedure.
Replace
R-4 COMPRESSOR MAIN BEARING 1. Place the Front Head “with neck-end down” on a
flat, solid surface.
Remove 2. Align the new Main Bearing and the Bearing
1. “Discharge the Refrigerant System” according to the Installer J 24895 squarely with the bearing bore of the Front
DISCHARGING, ADDING OIL, EVACUATING AND Head and drive the bearing into the Front Head. The
CHARGING PROCEDURES FOR C.C.O.T. A/C Installer J 24895 must seat against the Front Head to insert
SYSTEMS in the AIR CONDITIONING section. the bearing to the proper clearance depth (see Fig. ID-107).
2. Remove the Front Head assembly as described in 3. Assemble the Front Head to the cylinder, using a
“R-4 Compressor Front Head” Removal procedure. new O-ring as described in “R-4 Compressor Front Head”
Discard front head O-ring. Replacement procedure.
3. Place the Front Head assembly on two blocks, as 4. “Evacuate and Charge the Refrigerant System”
shown in Fig. ID-106, and use Main Bearing Remover J according to the DISCHARGING, ADDING OIL,
24896 to drive the Main Bearing out of the Front Head. EVACUATING AND CHARGING PROCEDURES
ID-40 A/C COMPRESSOR OVERHAUL

J 24895
BEARING
IN STALLER R E T A IN IN G
STRAP
M AIN
BEARING

FRONT
HEAD
4699

Fig. 1D-107 Installing R-4 Main Bearing

FOR C.C.O.T. A/C SYSTEMS in the AIR

CONDITIONING section. Fig. 1D-108 Releasing R-4 Shell Retaining Strap

R-4 COMPRESSOR SHELL AND/OR O-

J 25008-1
RINGS HOLDING FIXTURE SHELL TO
CYLINDER
Remove O-RING
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. 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 Co il and Pulley Rim as a TOTAL assembly. Be
careful not to drop the Puller Guide J 25031 when removing STEP CONTACTS
the assembly. [COMPRESSOR SHELL
5. Pry the shell retaining strap away from the cylinder Fig. 1D-109 Removing R-4 Shell
and position the strap high enough to clear the cylinder as
the Shell is removed (Fig. ID-108). soon as the Shell is free of the shell to cylinder O-rings. Do
6. Remove Compressor Holding Fixture J 25008-1, and not turn the screws any further than necessary to release the
reverse Holding Fixture with step block protrusions Shell.
engaging the compressor Shell. Install the medium-length
bolts through the Holding Fixture and thread them finger- 8. Remove the compressor Shell and remove the
tight on both sides into the compressor cylinder until the Holding Fixture J 25008-1 from the compressor. Reverse
step of the fixture protrusions contact the compressor the Holding Fixture to again hold the compressor by the
Shell.(Fig. ID-109). With compressor at room temperature, opposite side, using the short-length screws.
check to be sure the step protrusions do not overlap the 9. Remove and discard both cylinder to Shell O-rings.
cylinder but will pass both sides.
7. Using a wrench, alternately tighten each bolt Replace
approximately 1/4 turn to push the Shell free of the O-rings
on the cylinder. 1. Check the compressor cylinder assembly and interior
If one screw appears to require more force to turn than of the compressor Shell to be sure they are free of lint, dirt,
the other, immediately turn the other screw to bring the etc.
screw threading sequence in-step or the Shell will be cocked 2. Dip a new cylinder-to-shell O-ring in clean 525
and made more difficult to remove. Normal removal does viscosity refrigerant oil and install in the rear O-ring groove
not require much force on the wrench if the screws are kept of the cylinder. Be careful in moving the O-ring across the
in-step while turning. The Shell can be removed by hand as cylinder surface to prevent damaging the O-ring.
 A/C COMPRESSOR OVERHAUL ID-41

3. Dip the remaining cylinder-to-shell O-ring in the 525 FOR C.C.O.T. A/C SYSTEMS IN THE AIR
oil and install it in the front O-ring groove of the cylinder. CONDITIONING section.
4. Also coat inner surface of compressor Shell with the
oil and swab oil onto shell-to-cylinder O-rings. Place the R-4 COMPRESSOR DISCHARGE
compressor Shell on the cylinder and rotate the retaining VALVE PLATE AND/OR RETAINER
strap to its original location.
5. Attach the Shell Installing Fixture J 25008-2 to the
Holding Fixture J 25008-1, using the long-bolts and plate Remove and Replace
washers of the set. Align the step projections of the 1 . “Discharge the Refrigerant System ” according to
Installing Fixture J 25008-2, to contact the compressor Shell the DISCHARGING, ADDING OIL, EVACUATING
evenly on both sides. AND CHARGING PROCEDURES FOR C.C.O.T. A/C
6. Push the compressor shell as close to the O-ring, Fig. SYSTEMS in the AIR CONDITIONING section.
ID-110, as possible by hand and check for equal alignment 2 . Perform Steps 1 through 9 of “R-4 Compressor
of the shell around the cylinder. Tighten the Fixture screws Shell and/or O-Rings” Removal procedure.
finger tight. 3 . Remove valve plate retainer ring, using Internal
Snap Ring Pliers J 4245 (#23), Fig. ID-111. Remove
A L T E R N A T E L Y TIG H TEN Compressor Discharge Valve Plate (Fig. ID-112) for valve
SCREWS APPROX. plate replacement and/or piston inspection.
1/4 TURN
J 25008-1 Repeat this operation for additional valve plates and
HOLDING retainer rings. If all four valve plates and retainers are to
FIXTURE 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.

J 4245
PLIERS

VALVE PLATE
RETAINER RING

< J 25008-2
COMPRESSOR
y SHELL
IN STALLER
4701

Fig. 1D-1 10 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 Fig. 1D-11 1 Replacing R-4 Valve Plate Retainer
and made more difficult to install. Normal installation does
not require much force on the wrench if the screws are kept 4 . Install Discharge Valve Plates and/or Retainers as
in-step while turning. shown in Figs. 1D-111 and ID-112. Reposition compressor
8. When the Shell is seated against the stops, bend the and Holding Fixture in vise as necessary for access.
shell retaining strap down into place by tapping gently with
a hammer. Remove the Shell Installing Fixture J 25008-2. 5 . Re-install compressor Shell as described in “R-4
9. Re-install Clutch Rotor and Bearing Asm., Clutch Compressor Shell and/or O-Rings “Replacement
Coil and Pulley Rim as an assembly with Installer J 26271 procedures.
(Fig. ID-88), and the Clutch Plate and Hub Assembly with 6 . “Evacuate and Charge the Refrigerant System”
Installer J 9480-01 (Fig. ID-80). according to the DISCHARGING, ADDING OIL,
10. “EvaQuate and Charge the Refrigerant System” EVACUATING AND CHARGING PROCEDURES
according to the DISCHARGING, ADDING OIL, FOR C.C.O.T. A/C SYSTEMS in the AIR
EVACUATING AND CHARGING PROCEDURES CONDITIONING section.
ID-42 A/C COMPRESSOR OVERHAUL

2. “Evacuate and Charge the Refrigerant System”

according to the DISCHARGING, ADDING OIL,
VALVE
EVACUATING AND CHARGING PROCEDURES
PLATE
FOR C.C.O.T. A/C SYSTEMS in the AIR
CONDITIONING section.
A-6 AND R-4 COMPRESSOR LEAK
TESTING (EXTERNAL AND INTERNAL)
PISTON AND
REED ASSY. Bench-Check Procedure
1. Install Test Plate J 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.
NOTE: Suction port (low-side) of compressor has large
1662 internal opening. Discharge port (hi-side) has smaller
internal opening into compressor.
Fig. 1D-1 12 Replacing R-4 Discharge Valve Plate
4. Open LOW pressure control, HIGH pressure control
R-4 COMPRESSOR CYLINDER AND and REFRIGERANT control on Charging Station to allow
SHAFT ASM. refrigerant vapor to flow into compressor.
5. Using Electronic Leak Detector J 23400, check for
Remove leaks at Pressure Relief Valve, Pressure Switch (if so
1. “Discharge the Refrigerant System” according to the located) on compressor, compressor Shell to cylinder,
DISCHARGING, ADDING OIL, EVACUATING AND compressor front head seal (and also rear head seal and oil
CHARGING PROCEDURES FOR C.C.O.T. A/C charge port on A-6 compressor), and compressor Shaft Seal.
SYSTEMS in the AIR CONDITIONING section. After checking, shut off LOW pressure control and HIGH
pressure control on Charging Station.
2. Remove the Clutch Plate and Hub assembly as 6. If an external leak is present, perform the necessary
described in “R-4 Compressor Clutch Plate and Hub” corrective measures and recheck for leaks to make certain
Removal procedure. the leak has been corrected.
3. Perform Steps 1 through 4 of “R-4 Compressor 7. Loosen the Manifold Gage hose connections to the
Clutch Rotor and/or Bearing” Removal procedure but do Gage Adapters J 5420 connected to the LOW and HIGH
not loosen or remove the pulley rim mounting sides and allow the vapor pressure to release from the
screws, so as to remove the Clutch Rotor and Bearing, compressor.
Clutch Coil and Pulley Rim as a TOTAL assembly. Be 8. Disconnect both Gage Adapters J 5420 from the Test
careful not to drop the Puller Guide J 25031, when Plate J 9625.
removing the assembly. 9. Rotate the COMPLETE compressor assembly ( not
4. Remove the Shaft Seal as described in “R-4 the crankshaft or drive plate hub) slowly several
Compressor Shaft Seal” Removal procedure. turns to distribute oil to all cylinder and piston areas.
5. Remove the Front Head as described in “R-4 10. Install a shaft nut on the compressor crankshaft if
Compressor Front Head” Removal procedure. the drive plate and clutch assembly are not installed.
6. Remove the Thrust and Belville Washers as 11. Using a box-end wrench or socket and handle,
described in “R-4 Compressor Thrust and Bellville rotate the compressor crankshaft or clutch drive plate on
Washers” Removal procedures. the crankshaft several turns to ensure piston assembly to
7. Remove the compressor Shell as described in “R-4 cylinder wall lubrication.
Compressor Shell” Removal procedure. 12. Connect the Charging Station HIGH pressure line
8. Remove the Discharge Valve Plate and Retainer as or a HIGH pressure gage and Gage Adapter J 5420 to the
described in “R-4 Compressor Discharge Valve Plate and/ Test Plate J 9625 HIGH side connector.
or Retainer” Removal procedure. 13. Attach an Adapter J 5420 to the suction or LOW
9. Remove the High Pressure Relief Valve and Pressure pressure port of the Test Plate J 9625 to open the schrader-
Switch (if so equipped) as described in “R-4 Compressor type valve.
High Pressure Relief Valve or Pressure Switch” Removal NOTE: Oil will drain out of the compressor suction
procedure. port adapter if the compressor is positioned with the
suction port downward.
Replace
1. Replace above parts in opposite order.
 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.
NOTE: 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
COMPRESSOR SHOULD BE 50 P.S.I. OR ABOVE FOR
THE R-4 AND 60 P.S.I. OR ABOVE FOR THE A-6
COMPRESSOR. A pressure reading of less than 45
p.s.i. for the R-4 or 50 p.s.l. 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 be disassembled
and checked for cause of leak. Repair as needed,
reassemble and repeat the pump-up test. Externally leak test
with Electronic Leak Detector J 23400.
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.
NOTE: 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 Gears................................................................... ..3B-1
Power Steering Pump..................................................................... ..3B-8
Integral Power Steering Gear...........................................................3B-12
Control Valve and Power Cylinder - Corvette...............................3B-25
Special Tools......................................................................................3B-30
MANUAL STEERING G EARS
INDEX
Overhaul Operations............................................... ... 3B-1 Side Cover Bushing Replacement.................... 3B-3
Disassembly.......................................................... ... 3B-1 Wormshaft Bearing Race Replacement...... .... 3B-3
Inspection............................................................. ... 3B-2 Ball Nut Servicing............................ . ........... 3B-3
Repairs.................................................................. ... 3B-3 Assembly........................................................... .... 3B-5
Pitman Shaft/Wormshaft Seal Replacement.... ....3B-3 Adjustment on Bench........................... .......... .... 3B-7
Pitman Shaft Bushing Replacement................. 3B-3

OVERHAUL OPERATIONS
Disassembly (Figs. 3B-1A through 3B-4A) 3. Place a pan under the assembly to catch the lubricant
As with any ball bearing unit the steering gear parts and remove the three self locking bolts attaching the side
must be kept free of dirt. Clean paper or rags should be cover to the housing.
spread on the workbench before starting disassembly of the 4. Tap lightly on the end of the pitman shaft with a
steering gear. plastic hammer and lift the side cover and pitman shaft
1. Place the steering gear in a vise, clamping onto one assembly from the gear housing (fig. 3B-5A).
of the mounting tabs. The wormshaft should be in a NOTE: If the pitman shaft sector does not clear the
horizontal position. opening in the housing easily, turn the wormshaft by
2. Rotate the wormshaft from stop to stop, counting hand until the sector will pass through the opening in
the total number of turns. Then turn back exactly half way, the housing.
placing the gear on center (the wormshaft flat should be at 5. Remove the adjuster plug and locknut assembly
the 12 o’clock position). Loosen locknut. (incorporates the lower wormshaft bearing and race on all

ADJUSTER PLUG
LOCK NUT
/

W O RM
BEARING
WORM BEARING
(UPPER)
(LOWER)
BALL NUT PITMAN SHAFT
SECTOR

Fig. 3B-2A~Steering Gear (Except Corvette and G 10-30

Fig. 3 B -1A--Steering Gear (Except Corvette) Series Trucks)
3B-2 STEERING

PITMAN
SHAFT
WORM BEARING SECTOR BALL NUT BALL
(LOWER)
WORMSHAFT
WORM BEARING
(UPPER)
ADJUSTER
PLUG
SEAL

BEARING SECTOR
CUP

EXPANSION BEARING CLAMP BALL B A ll LOCK NUT

PLUG CUP GUIDE BEARINGS

Fig. 3B-5A--Removing Pitman Shaft Assembly-Typical

Fig. 3B-3A--Steering Gear-Corvette

screw and shim out of the slot in the end of the pitman shaft.
except Corvette - upper wormshaft bearing race on 10. Pry out and discard both the pitman shaft and
Corvette). wormshaft seals.
6. Draw the wormshaft and ball nut assembly from the
housing (fig. 3B-6A). Inspection
CAUTION: Use care that the ball nut does not run
down to either end o f the worm. Damage will be With the steering gear completely disassembled, wash
done to the ends o f the ball guides if the nut is all parts in cleaning solvent. Dry them thoroughly with air.
allowed to rotate until stopped at the end o f the With a magnifying glass inspect the bearings and bearing
worm. races for signs of indentation. Also check for any signs of
7. All Except Corvette-- Remove the upper bearing chipping or breakdown of the surface. Any parts that show
from the wormshaft. signs of damage should be replaced
Corvette-- Remove lower bearing from inside the gear Inspect all seals. Any seal that is worn or has been
housing. removed should be replaced.
8. All except C orvette- Using a suitable size screw
driver, pry the lower bearing retainer from the adjuster plug Inspect the fit of the pitman shaft in its bushing in the
housing and remove the bearing (fig. 3B-7A). side cover. If this bushing is worn, a new side cover and
9. Remove the locknut from the lash adjuster screw in bushing assembly should be installed.
the side cover. Remove the lash adjuster screw from the side
cover by turning the screw clockwise. Slide the adjuster Check steering gear wormshaft assembly for being bent
or damaged in any way. Never attempt to salvage steering
parts by welding or straightening.

HOLD ASSEMBLY
HORIZONTAL TO
PREVENT BALL NUT
RUNNING DO W N TO
END OF WORMSHAFT

LASH ADJUSTER PITMAN SHAFT SEAL

SCREW

Fig. 3B-4A~Steering Gear (Corvette and G 10-30 Series

Trucks) Fig. 3B-6~Removing the W ormshaft and Ball Nut--Typical
 STEERING 3B-3

Fig. 3B-7A--Removing Lower Bearing Retainer-Except

Corvette Fig. 3B-8A--Removing Pitman Shaft Bushing-Typical

Repairs HOUSING RACES

1. Corvette only- Using a drift or punch (inserted
Pitman Shaft and/or Wormshaft Seal into the housing from the adjuster plug end) drive the sheet
Replacement metal expansion plug out of the lower end of the housing.
The double lipped pitman shaft and wormshaft seals 2. All Series - Using a drift or punch, drive the bearing
should be replaced each time a defective seal is indicated race out of the housing.
or the steering gear is disassembled. 3. Press the new bearing race into position using Tool
1. If the seals were not removed at disassembly, pry out J-5755 (fig. 3B-10A).
the old seals using a suitable size screw driver. 4. Corvette only- Install a new expansion plug into
CAUTION: Before installing new seals, check the the lower end of the housing. Press on the center of the plug
condition o f the pitman shaft bushing(s) and the to deform it inward and secure it in the housing. Make sure
upper wormshaft bearing race. the plug is tight or lubricant leakage could result.
2. A suitable size socket, pressing on the outer diameter
of the seal, may be used to install new seals. Ball Nut Servicing
As a rule, disassembly of the ball bearing nut will not
CAUTION: Care should be taken to insure that be necessary if it is perfectly free with no indication of
the new seals are not assembled in a cocked binding or tightness when rotated on the worm. However,
position. if there is any indication of binding or tightness, the unit
should be disassembled, cleaned and inspected as follows:
Pitman Shaft Bushing Replacement
1. Support the steering gear housing in an arbor press 1. Remove screws and clamp retaining the ball guides
and press the pitman shaft bushing (2 bushings on Corvette in nut. Draw guides out of nut.
and G 10-30 Series Trucks) from the housing using Tool 2. Turn the nut upside down and rotate the wormshaft
J-1614, inserted from the lower end of the housing (fig. 3B- back and forth until all the balls have dropped out of the
8). nut into a clean pan. With the balls removed, the nut can
2. Press the new bushing(s) into position using Tool be pulled endwise off the worm.
J-1614. Position the Corvette and G10-30 Series Truck
bushings as shown in Figure 3B-4A.
NOTE: Service bushings are diamond bored to size and
require no further reaming.
Side Cover Bushing Replacement
The entire side cover assembly, including bushing, is
serviced as a unit and should be replaced when it is desired
to replace the bushing.
Wormshaft Bearing Race Replacement
ADJUSTER PLUG RACES
1. All Except C orvette- Remove the wormshaft
bearing race using Tool J-5822 and a Slide Hammer as
shown in Figure 3B-9A.
Corvette-- Using a hammer and punch, drive the
bearing race out of the adjuster plug.
2. Press the new bearing race into position using Tool
J-5755. Fig. 3B-9A--Removing Adjuster Plug Bearing Race
3B-4 STEERING

J-5755

WORM
BEARING RACE

Fig. 3B-1 OA-lnstalling Wormshaft Bearing Race-Typical Fig. 3 B -12A—Filling Ball Circuits-Corvette

3. Wash all parts in cleaning solvent and dry them as described for the first circuit in Steps c and d above.
thoroughly with air. Using a magnifying glass inspect the S. Corvette only (figs. 3B-12A and 3B-13A):
worm and nut grooves and the surface of all balls for signs a. Place the wormshaft flat on the bench and slip the
of indentation. Check ball guides for damage at ends where nut over the worm with the ball guide holes up and the
they deflect or pick up the balls from the helical path. Any shallow end of the rack teeth to the left from the steering
parts that show signs of damage should be replaced. wheel position. Align the grooves in the worm and nut by
4. All Except Corvette (fig. 3B -11 A): sighting through the ball guide holes.
a. Place the wormshaft flat on the bench and slip the b. Count 27 balls into a suitable container. This is the
nut over the worm with the ball guide holes up and the proper number of balls for half the circuit. Place these balls
shallow end of the ball nut teeth to the left from the steering into one of the guide holes while turning the worm gradually
wheel position. Align the grooves in the worm and nut by away from that hole.
sighting through the ball guide holes. c. Lay one-half of the ball guide, groove up, on the
b. Place two ball guide halves together and insert them bench and place the remaining balls from the count
into the upper circuit in the ball nut. Place the remaining container in it.
two guides together and insert them in the lower circuit. d. Close this half of guide with the other half. Hold the
c. Count 24 balls into a suitable container. This is the two halves together and plug each open end with petroleum
proper number of balls for one circuit. jelly so that balls will not drop out while installing the guide.
d. Load the balls into one of the guide holes while e. Push the guide into the guide holes of the nut. This
turning the wormshaft gradually away from that hole. completes one circuit of balls. If the guide does not push
When all of the balls have been installed, the circuit is all the way down easily, tap it lightly into place with the
complete. wooden handle of a screw driver.
e. Fill the remaining ball circuit in the same manner f. Fill the second ball circuit in the same manner.

Fig. 3B-1 1A—Filling Ball Circuits-Except Corvette Fig. 3B-1 3A —Filling Ball Guides-Corvette
 STEERING 3B-5

1. Worm Bearing Adjuster 9. Upper Worm Bearing Race 16. Lash Adjuster
Locknut 10. Pitman Shaft Seal 17. Lash Adjuster Shim
2. Worm Bearing Adjuster 11. Housing 18. Housing Side Cover and
3. Lower Worm Bearing Race 12. Wormshaft Seal Bushing Assembly
4. Lower Ball Bearing 13. Side Cover Gasket 19. Lash Adjuster Locknut
5. Lower Bearing Retainer 14. Pitman Shaft Bushing 20. Side Cover Bolts
6. Ball Nut (2 Bushings on G 10-30 Series 21. Ball Guide Clamp Screws
7. Wormshaft Trucks) 22. Ball Guide Clamp
8. Upper Ball Bearing 15. Pitman Shaft 23. Ball Guides
24. Balls

Fig. 3B-1 4A~Steering Gear--Except Corvette

Continue until the ball circuit is full from the bottom of one meeting GM Standard GM 4673M (or equivalent) should
guide hole to the bottom of the other or until stopped by be applied to the pitman shaft and bearings, wormshaft and
reaching the end of the worm. bearings and the ball nut teeth.
NOTE: In cases where the balls are stopped by the end 1. Place the steering gear housing in a vise with the
of the worm, hold down those balls already dropped wormshaft bore horizontal and the side cover opening up.
into the nut with the blunt end of a clean rod or punch 2. With the pitman shaft and wormshaft seals, pitman
(fig. 3B-12A) and turn the worm in the reverse shaft bushings and wormshaft bearing races installed, and
direction a few turns. The filling of the circuit can then the ball nut installed on the wormshaft, proceed to Step 3
be continued. It may be necessary to work the worm or 4.
back and forth, holding the balls down first in one hole 3. All Except Corvette--
and then the other, to close up the spaces between the a. Slip the upper ball bearing over the wormshaft and
balls and fill the circuit completely and solidly. insert the wormshaft and nut assembly into the housing,
6. Assemble the ball guide clamp to the ball nut and feeding the end of the shaft through the upper ball bearing
tighten the screws to specified torque. race and seal.
Check the assembly by rotating the nut on the worm b. Place a ball bearing in the adjuster race and press
to see that it moves freely. Do not rotate the nut to the end the stamped retainer into place with a suitable socket.
of the worm threads as this may damage the ball guides. If c. Install the adjuster and locknut into the lower end
there is any "stickiness" in the motion of the nut, some slight of the housing (being careful to guide the end of the
damage to the ends of the ball guides or to other gear wormshaft into the bearing) until nearly all end play has
components may have been overlooked. been removed from the wormshaft.
Assembly (Fig. 3B-14A and 3B-15A) 4. C orvette-
After a major service overhaul, steering gear lubricant a. Place a wormshaft bearing in the housing race. Slide
3B-6 STEERING

1. Side Cover Screws 9. Expansion Plug 17. Worm Bearing Race—Upper

2. Lash Adjuster Locknut 10. Steering Gear Housing 18. Adjuster Plug
3. Side Cover and Bushing 11. Pitman Shaft Seal 19. Wormshaft Seal
4. Lash Adjuster Shim 12. Worm Bearing Race—Lower 20. Adjuster Plug Locknut
5. Lash Adjuster Screw 13. Worm Bearing—Lower 21. Clamp Screw
6. Side Cover Gasket 14. Ball Nut 22. Ball Guide Clamp
7. Pitman Shaft 15. Wormshaft 23. Balls
8. Pitman Shaft Bushings 16. Worm Bearing—Upper 24 Ball Guides

Fig. 3B-15A-Steering Gear-Corvette

the other bearing and the adjuster plug assembly over the shaft sector and ball nut will engage properly, with the
upper end of the wormshaft. center tooth of the sector entering the center tooth space
b. Insert the wormshaft, nut and adjuster assembly into in the ball nut.
the housing, guiding the lower end of the wormshaft into
the housing bearing.
c. Thread the adjuster into the housing until nearly all
end play is removed from the wormshaft.
5. Position the lash adjuster (with shim) in the slotted
end of the pitman shaft. Check the end clearance, which
should not be greater than .002" (fig. 3B-16A). If clearance
is greater than .002", a steering gear lash adjuster shim unit
is available. It contains four shims-.063", .065", .067" and
.069" thick.
6. Lubricate the steering gear with 11 oz. of lubricant
meeting GM Specification GM 4673 (or equivalent). Rotate
the wormshaft until the ball nut is at the end of its travel
and then pack as much new lubricant into the housing as
possible without losing it out the pitman shaft opening.
Rotate the wormshaft until the ball nut is at the other end
of its travel and pack as much lubricant into the opposite
end as possible.
7. Rotate the wormshaft until the ball nut is about in
the center of travel. This is to make sure that the pitman Fig. 3B-1 6A~Checking Lash Adjuster End Clearance
 STEERING 3B-7

8. Insert the pitman shaft assembly (with lash adjuster Adjustm ent on Bench
1. Tighten the adjuster plug until all end play has been
screw and shim but without side cover) into the housing so removed and then loosen one-quarter turn.
that the center tooth of the pitman shaft sector enters the
center tooth space of the ball nut. 2. Using an 11/16" 12-point socket and an in. lb. torque
wrench, carefully turn the wormshaft all the way to the right
9. Pack the remaining portion of lubricant into the turn stop and then turn back about one-half turn.
housing. 3. Tighten the adjuster plug until the proper thrust
10. Place the side cover gasket on the housing. bearing preload is obtained. Tighten the adjuster plug
locknut to specifications.
11. Install the side cover onto the pitman shaft by 4. Turn the wormshaft from one stop all the way to the
reaching through the side cover with a screwdriver and other, counting the number of turns. Then turn the shaft
turning the lash adjuster screw counterclockwise until the back exactly half the number of turns to the center position.
screw bottoms; back the screw off one-half turn. Loosely 5. Turn the lash adjuster screw clockwise to remove all
install a new locknut onto the adjuster screw. lash between the ball nut and sector teeth. Tighten the
12. Install and tighten the side cover bolts to locknut.
specifications. 6. Again using the 11/16" 12-point socket and an in.
lb. torque wrench, observe the highest reading while the
CAUTION: I f new side cover bolts are used at gear is turned through center position. See the Specifications
installation, be sure to use specified bolts which Section for proper over-center adjustment.
are self locking. 7. If necessary, readjust lash adjuster screw to obtain
proper torque. Tighten the locknut to 23 ft. lb. torque and
again check torque reading through center of travel.
3B-8 STEERING

POWER STEERING PUMP

INDEX
Overhaul Operations....................................................................... .3B-8
Disassembly.......................................................................................3B-8
Inspection..........................................................................................3B-9
Assembly...........................................................................................3B-9
OVERHAUL OPERATIONS
CAUTION: I f when overhauling a power steering tapping lightly on the outer edge of the reservoir with a soft
gear or pump, broken components or foreign hammer. Remove the "O" ring seal from the pump housing
material are encountered, the remaining and discard seal.
components o f the entire hydraulic system should 5. Remove magnet from housing assembly.
be disassembled, inspected, thoroughly cleaned 6. Remove the mounting stud square ring seals and the
and flushed before servicing is completed. flow control valve square ring seal and discard.
7. On Corvette, remove filter and filter cage; discard
Disassembly (Fig. 3B-1B)
Clean the outside of the pump in a nontoxic solvent filter element.
before disassembly. 8. Remove the end plate retaining ring. Compress the
1. Remove pump pulley by using tool J-25034 as shown end plate retaining ring by inserting a small punch in the
in Figure 3B-2B. 1/8" diameter hole in the pump housing. When the ring is
in compressed position, remove with a screw driver as
2. Place the pump in a vise and remove the union and shown in Figure 3B-3B.
"O" ring seal assembly. 9. Remove the end plate. The end plate is spring loaded
CAUTION: In clamping pump in vise, be careful and will generally sit above the housing level. If sticking
not to exert excessive force on the pump front hub should occur, a slight rocking action or light tapping with
as this may distort the shaft bushing. a soft hammer will free the plate. Remove the end plate
3. Remove the pump reservoir retaining studs. spring.
4. Remove the reservoir from the pump housing by 10. With the pump still in a vise, remove the shaft

L-6 AND
SMALL V-8

MARK V-8

(]a5=Q Of

1 2 3 4 6 7 8 9 10 1 1 12 13 14 15 16 17 21 22 23 24 25 26 27 28
1. Union 10. Spring 20. Mounting Stud Square Ring Seals
2. Union " 0 " Ring Seal 11. Pressure Plate 21. Flow Control Valve
3. Mounting Studs 12.. Pump Ring 22. Flow Control Valve Spring
4. Reservoir Mark Engine & Truck 13. Vanes 23. Flow Control Valve Square
4A. Reservoir L-6 and Small V-8 Only 14. Drive Shaft Retaining Ring Ring Seal
5. Dip Stick and Cover 15. Rotor 24. Pump Housing
6. Element (Corvette only) 16. Thrust Plate 25. Magnet
7. Filter Assembly (Corvette only) 17. Dowel Pins 26. Reservoir " 0 " Ring Seal
8. End Plate Retaining Ring 18. End Plate “ O” Ring 27. Shaft Seal
9. End Plate 19. Pressure Plate "0"'R ing 28. Shaft

Fig. 3B-1B~Power Steering Pump--Exploded View

 STEERING 3B-9

Fig. 3B-4B--lmpeller Unit Removal

Fig. 3B-2B--Power Steering Pump Pulley-Removal

are flat and parallel with pump ring. Check all of these parts
woodruff key and tap end of shaft gently with a soft hammer for cracks and scoring.
until the shaft pressure plate, pump ring, rotor assembly and NOTE: A high polish is always present on rotor
thrust plate can be removed as a unit (fig. 3B-4B). pressure plate and thrust plate as a result of normal
11. Separate the parts removed in Step 9 above. If wear. Do not confuse this with scoring.
inspection shows the shaft to be defective, separate it from 4. Make certain vanes were installed with rounded edge
the rotor by removing the retainer snap ring. Discard the toward pump ring and see that they move freely in rotor
snap ring. slots.
12. Remove the end plate and pressure plate "O" rings 5. If the flow control plunger is determined to be faulty,
from the pump housing and discard "O" rings. install a new part. This part is serviced as a unit only and
13. Remove the dowel pins. is factory calibrated.
14. Remove the flow control valve and spring assembly. 6. Check drive shaft for worn splines, breaks, bushing
15. Pry the shaft seal out of the pump housing being material pickup, etc.
careful not to damage the housing bore, discard the shaft 7. Always replace all rubber seals and "O" rings when
seal. pump is dismantled.
Inspection 8. Check reservoir, studs, casting, etc. for burrs and
Clean all metal parts in a nontoxic solvent and inspect other faults which would impair proper operation.
as follows:
1. Flow control valve must slide freely in housing bore. Assembly (Fig. 3B-5B)
Be sure all parts are clean during reassembly.
If sticking is observed, check for dirt and burrs. NOTE: In the following text, power steering fluid is
2. Check cap screw in the end of the flow control valve noted for use in lubricating components upon
for looseness; if loose, tighten, being careful not to damage reassembly.
machined surfaces. 1. Install a new shaft seal in the pump housing, using
3. Be sure that pressure plate and pump plate surfaces Tool J-22670 as shown in Figure 3B-6B.
2. Install both dowel pins in the pump housing and
install a new pressure plate "O" ring lubricated with power
steering fluid.
CAUTION: Do not use a "C" ring to replace the
full diameter ring. Be sure the retaining ring is
firmly seated in the shaft groove before
proceeding.
3. Install the thrust plate on the shaft with the ported
face towards the splined end of the shaft (fig. 3B-7B).
4. Install the rotor, which must be free on the shaft
splines, with the countersunk side towards the thrust plate.
5. Install a new shaft retaining ring by placing the ring
on the end of the shaft and using first a drift and then a 3/8"
socket to tap the NEW ring into place (fig. 3B-8B).
6. Place pump housing in a vise and install shaft, thrust
plate and rotor assembly into housing, aligning the holes in
the thrust plate with the dowel pins as shown in Figure
3B-9B.
Fig. 3B-3B~Removing End Plate Ring 7. Install the pump ring onto the dowel pins with the
3B-10 STEERING

Fig. 3B-7B~lnstalling Thrust Plate

direction of rotation arrow to the rear of the housing (fig.

3B-10B). Rotation is clockwise as viewed from the pulley
end of the shaft.
8. Install the vanes into the rotor slots with the radius
edge towards the pump ring and the square edge towards
the rotor as shown in Figures 3B-11B and 3B-12.
9. Lubricate the outside diameter and chamfer of the
pressure plate with power steering fluid, to ensure against
damaging the pressure plate "O" ring, and install the
1. Shaft 12. End Plate Retaining Ring pressure plate onto the dowel pins with the ported face
2. W oodruff Key 13. Pressure Plate Spring
towards the pump ring. Seat the pressure plate by placing
a large socket on top of the plate and pressing down by hand
3. Shaft Seal 14. Pump In le t Tube
4. Pump Housing 15. R o to r-to -D riv e Shaft
5. Thrust Plate Retaining Ring
(pressure plate will travel approximately 1/16" to seat).
6.
7.
Vanes
Pump Ring
16.
17.
Pump O u tle t Union
Reservoir 10. Install the pressure plate spring in the center groove
8. Reservoir " O " Ring Seal 18. Flow Control V a lv e of the pressure plate (fig. 3B-13B).
9. Pressure Plate " O " Ring 19. Flow Control V a lv e
11. Lubricate a new end plate "O" ring with power
steering fluid and install in housing groove.
10. Pressure Plate Spring
11. End Plate 20. Rotor

12. Lubricate the outside diameter and chamfer of the

end plate with power steering fluid, to ensure against
damaging the "O" ring, and install into the housing using
Fig. 3B-5B--Power Steering Pump-Typical an arbor press as shown in Figure 3B-14B.
NOTE: Place the end of the ring so that it is near the
valve bore in the housing.
13. Install the flow control spring and flow control

Fig. 3B-6B-lnstalling Seal Using Tool J -2 2 6 7 0 Fig. 3B-8B--lnstalling Shaft Snap Ring
 STEERING 3B-11
---------

DOWEL
PINS

*iPi
__
Fig. 3B-9B~lnstalling Shaft, Thrust Plate, and Rotor Assembly Fig. 3B-1 1 B—InstalIing Vanes

plunger. Be sure the hex head screw goes into the bore first 20. Install pump pulley by inserting tool J-25033
(fig. 3B-15B). through pulley hub and threading the bolt into the power
14. On Corvette, install cage and a new filter. steering pulley shaft as shown in figure 3B-16B.
15. Place magnet into proper position on housing
assembly (Fig. 3B-1B). NOTE: Pulley must be flush with end of shaft.
16. Install new mounting stud and union square ring
seals. CAUTION: DO NO T hammer on pump shaft.
17. Install a new reservoir "O" ring seal, lubricated Use special tools to prevent possible damage to
with power steering fluid, onto housing. internal pump components.
18. Lubricate reservoir sealing edge with power
steering fluid and place reservoir onto housing in the normal
position. Press down on reservoir until it seats onto housing;
check position of stud and union seals.
19. Place a new "O" ring seal, lubricated with power DOW EL CRO SS-O VER HOLE PUMP

steering fluid, onto union and install union assembly and PIN R IN G

studs.
HOLE

PUMP
R OTOR

PUMP
VANES

Fig. 3B-10B--lnstalling Pump Ring Fig. 3B-1 2B -Correct Vane Assembly

3B-12 STEERING

Fig. 3 B -13B —Installing Pressure Plate S pring Fig. 3B-1 5 B—Installin g Flow C ontrol Valve

VALVE BORE

Fig. 3B-1 4B --lnstalling End Plate Retaining Ring Fig. 3 B -1 6 B -P o w e r S teering Pump Pulley - Installatio n

INTEGRAL POWER STEERING GEARS

Overhaul, 605 G ear........................................................................ 3B-13
Overhaul, 800 and 808 Gear.......................................................... 3B-18
OVERHAUL OPERATIONS
be disassembled, inspected, thoroughly cleaned
CAUTION: I f when overhauling a power steering an<^ Hushed before servicing is completed,
gear or pump, broken components or foreign
material are encountered, the remaining
components o f the entire hydraulic system should
 STEERING 3B-13

POWER STEERING GEAR (605 MODEL)

GENERAL DESCRIPTION
This Integral Power Steering Gear has a NOTE: Whenever a part which forms a
control valve which directs oil to either side sealing surface for an “ 0 ” ring seal is
of the rack piston. The rack piston converts removed, the “ O” 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 steering 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)

K ey N o . Port N o m e Key No P art N a m e

1 - H O U S I N G , STEERING GEAR 2 0 -S H A F T ASSY , STUB

2-R E T A IN E R , STRG C O U P L IN G SHIELD 2 1 -S E A L , " O " R IN G (SHAFT TO W O R M )
3 - B E A R IN G ASSY , NEEDLE (STUB SHAFT) 2 2 - W O R M ASSY., PIN & STRG (36)----------
4 -S E A L , STUB SHAFT 2 3 - R IN G , R E T A IN IN G (SHAFT TO W O R M )
5 -S E A L , STUB SHAFT DUST 2 4 - R IN G . RACK PISTON
6 - R I N G , R E T A IN IN G (STUB SHAFT SEAL) 2 5 -S E A L , " O " R IN G (RACK PISTO N)
7 - B E A R IN G A S S Y , NEEDLE (P IT M A N SHAFT) 2 6 -R A C K -P IS T O N -N U T
8 -S E A L P IT M A N SHAFT 2 7 -B E A R IN G A S S Y , SUPPORT & LWR THR
9 -W A S H E R , SEAL B A C K -U P (P IT M A N SHAFT) 2 8 -S E A L , " O " R IN G (ADJUSTER PLUG)
1 0 -S E A L , P IT M A N SHAFT DUST 2 9 -P L U G ADJUSTER
1 1 - R IN G , R E T A IN IN G (P IT M A N SHAFT SEAL) 3 0 -N U T , ADJUSTER LOCK
1 2 -W A S H E R , LOCK (P IT M A N SHAFT) 3 1 -S P R IN G , SIDE COVER
1 3 - N U T , P IT M A N ARM 3 2 -S E A L , " O " R IN G (ADJUSTER PLUG)
1 4 - B E A R IN G ASSY , RACE & UPPER 3 3 -G E A R ASSY , P ITM A N SHAFT
1 5 - R IN G , VALVE BODY (3) 3 4 -C O V E R , ASSY , H O U S IN G SIDE
1 6 -S E A L , "O '- R IN G (VALVE B O D Y ) (3) 3 5 - R IN G , R E T A IN IN G (SIDE COVER)
1 7 - BO D Y ASSY , VALVE 3 6 - N U T , PRELOAD ADJUSTER SEALIN G
1 8 -S E A L , " O " R IN G (D A M P N E R ) 3 7 -C O N N E C T O R , INVERTED FLARE (2)
1 9 -S P O O L , VALVE

© * -®
(LM©
0 —0
(3M0>
_ O * -©
0 —®

Fig. 3B-1 C--Overhaul 6 0 5 Gear, Chart A

3B-14 STEERING

REMOVE AND INSTALL PITMAN SHAFT 3. REMOVE AND INSTALL PITMAN SHAFT
SEALS IN CAR AND SIDE COVER
REMOVE INSTALL REMOVE INSTALL
1. Clean exposed end of 1 Install parts as shown 1. If pitman shaft and 1. Install parts as shown.
pitman shaft and end side cover are to be Use new retaining ring,
of housing after HOUSING ASSEMBLY separated, remove make sure that open
removing arm. Inspect for burrs preload adjuster nut. end of retaining ring
2 Remove retaining ring IT IS A LEFT HAND is approx. 13mm (V2 ")
THREAD. from access hole.
3. Start engine and turn
wheels fully to the 2. Rotate stub shaft 2. Side cover must be
right to force seals to center gear, then depressed to install
and washer out remove parts as shown retaining ring.
Tap on thread end of (SEE BELOW)*
4. Turn off engine pitman shaft with
5. Inspect housing plastic hammer SIDE COVER
and shaft RETAINING RING
PITMAN SHAFT — PRELOAD ADJ NUT -
Inspect seal surface for RETAINING RING Torque to 44 Newton
roughness and pitting Metres (32 Ft. lbs.)
PITMAN ARM PITMAN SHAFT GEAR
SIDE COVER O RING SEAL
PRELOAD ADJUSTER
SIDE COVER SPRING
SIDE COVER
Retaining ring access
LOCK WASHER hole (use punch)

NUT — torque to
250 Newton metres
(180 Ft Lbs

STUB SHAFT-1

HOUSING ASSY.
Remove Pitman Arm

1__ n _____I
Separate pitman shaft
from side cover if required. * Depress side cover
Install Seals
4. REMOVE AND INSTALL LOWER BEARING
2. REMOVE AND INSTALL STUB SHAFT AND ADJUSTER
SEALS WITHOUT DISASSEMBLING GEAR REMOVE INSTALL
REMOVE INSTALL 1. Loosen lock nut. 1. Install parts as shown
1. Remove retaining ring 1 Install stub shaft seal Use punch against 2. Adjust thrust bearing
and dust seal. Take care Liberally coat top of seal edge of one slot. preload (see adjustment
not to scratch shaft. with anhydrous calcium 2. Remove parts as shown. procedure) before
2. Wrap 0.1mm to 0.2mm grease. 3. Inspect lower thrust tightening lock nut.
(.005" to .008") shim 2. Install dust seal just deep bearing assembly.
stock around shaft and enough to clear retaining
insert between shaft ring groove, then install HOUSING ASSEMBLY
and sealing lip until retaining ring.
it bottoms. Pry seal out LOWER THRUST BEARING
ASSEMBLY — Inspect for
DUST SEAL smooth operation
RETAINING RING
LOCK NUT-y
STUB SHAFT
SHIM STOCK
OIL SEAL

ADJUSTER PLUG O'' RING SEAL

Screwdriver
ADJUSTER PLUG
HOUSING ASSEMBLY
Hexagon Driver (17mm)

Fig. 3B-2C--Overhaul 6 0 5 Gear, Chart B

 STEERING 3B-15

REMOVE AND INSTALL RACK PISTON AND 7. REMOVE AND INSTALL VALVE
VALVE ASSEMBLY ASSEMBLY FROM WORM ASSEMBLY
REMOVE INSTALL REMOVE INSTALL
1. Remove parts as 1. Install parts as 1 Remove parts as 1. Install parts as shown.
shown. Push on shown. Make sure shown. See below. _> » ■ ■
stub shaft. DO NOT rack piston teeth Retaining ring
remove upper bearing are positioned toward VALVE ASSEMBLY access hole
assembly (see stub side cover opening.
shaft seal removal) WORM
Side cover
HOUSING ASSEMBLY opening
•Rack piston teeth SHAFT TO WORM
"0 " RING SEAL
-SHAFT TO WORM RETAINING RING
T Assemble worm to valve
STUB SHAFT
VALVE ASSEMBLY RETAINING RING — Install with
^W ORM ASSEMBLY RACK-PISTON-NUT "curved in end" on same side as
access hole
6 . REMOVE AND INSTALL VALVE AND WORM WORM ASSEMBLY -
ASSEMBLY FROM RACK PISTON L. Retaining ring access hole

REMOVE INSTALL
8. DISASSEMBLE AND ASSEMBLE VALVE
Unscrew valve and worm Install "O' ring and
from rack. teflon ring as shown DISASSEMBLE ASSEMBLE
Remove teflon ring and Screw worm and valve 1 Disassemble parts 2 Assemble parts
rack piston "0 " ring from into rack piston. as shown. as shown.
rack piston See procedure below. VALVE BODY O RING
VALVE AND WORM ASSEMBLY VALVE BODY-
VALVE SPOOL-
STUB SHAFT-

VALVE BODY
RING (teflon)
RACK PISTON RING (TEFLON)
RACK PISTON 0 RING SEAL SPOOL TO BODY "O" RING
•Shaft cap
RACK-PISTON-NUT
A Assemble worm and valve to rack piston A Loosen shaft cap
T B‘ Remove and install stub shaft.
Hold rack teeth and worm
Turn worm and
drive pin in relation shown Pull cap out approx. 6 mm(1/4 ")
valve counterclockwise
with light pressure to
hold worm thread against piston. slowly until one Click
is felt.

Turn worm and valve clockwise -Tap lightly on

to complete assembly wood block Pin on shaft and hole in
-------------------------------+ ----------------- -------------L_
spool ( Disengage to remove)

Check relation of stub shaft and rack piston C. Remove and install spool D. Engage stub shaft
a. Screw worm and valve into Rotate while
rack piston until valve face removing or
and rack piston face are STUB SHAFT installing-----
flush

With rack piston in position shown, Lubricate spool and body -Notch must fully engage
flats on stub shaft and piston are to be with power steering fluid. pin and cap must seat
parallel. If not parallel, disassemble and repeat "A:1above- against shoulder.

Fig. 3B-3C--Overhaul 6 0 5 Gear, Chart C

3B-16 STEERING

9. REMOVE AND INSTALL STUB SHAFT 10. REMOVE AND INSTALL PITMAN SHAFT
SEALS AND BEARINGS SEALS AND BEARING
REMOVE INSTALL REMOVE INSTALL
Clean end of housing to If removed, install new 1. Remove parts as shown 1 Bottom oil seal in
prevent dirt from entering stub shaft needle bearing. CAUTION: Do not counterbore. Install
gear. Bottom tool on housing damage housing bore. washer. Coat seal lip and
counterbore. washer face with
Remove parts as shown, anhydrous calcium
being careful not to score NOTE: SERVICE thrust
bearing DOES NOT grease.
housing bore.
SNAP ON needle bearing. 2. Install remaining parts as
Remove stub shaft needle If removed, install as shown.
bearing and upper thrust shown below.
bearing if required.
Install stub shaft seal. HOUSING ASSEMBLY
Put a finger into the stub
shaft cavity and hook it Liberally coat top of seal Inspect for burrs
onto the upper thrust with anhydrous calcium
bearing race. Turn the grease.
race while pulling up. If Install dust seal just deep
bearing operation is enough to clear retaining
smooth, it does not need ring groove, then install
removal. Check the stub retaining ring.
shaft needle bearing for
smoothness. If O.K., do
not remove.

HOUSING ASSEMBLY NEEDLE BEARING

DUST SEAL Remove only if it
^-R E TA IN IN G RING needs replacing

.Tool J-8810
!
Install with lettered
STUB SHAFT SEAL
edge of bearing against
RETAINING RING
tool and flush with

A. Remove bearings
bottom of counterbore.
J
Remove and install bearing (not
necessary unless bearing is to
be replaced).

Tool J-8524-2
STUB SHAFT
11. REMOVE AND INSTALL CONNECTORS
REMOVE INSTALL
NEEDLE BEARING
1. Remove Parts As Shown 1 Install Parts As Shown
UPPER THRUST BEARING

B. Install bearings

STUB SHAFT NEEDLE BEARING

Install from small end of housing

HOUSING ASSEMBLY

UPPER THRUST BEARING — Center

on valve body.

RACK PISTON AND VALVE

ASSEMBLY — Hold in position
shown and slip housing
assembly on.

Fig. 3B-4C ~O verhaul 6 0 5 Gear, Chart D

 STEERING 3B-17

12. ADJUST WORM BEARING PRELOAD 13. ADJUST “OVER CENTER” PRELOAD
A. Tighten adjuster plug until it B. Measure 13mm (V2") coun­
bottoms (use 17mm hex. A Back off preload adjusterl B. Turn adjuster in until
terclockwise and mark
driver). Torque to approx. housing only (LEFT HAND THREAD) torque to turn stub shaft is
40 Newton metres (30 Ft. until it stops, then turn 0.6 to 1.2 Newton
it in one full turn metres (6 to 10 in. lbs.)
more than reading #1 ■

Mark housing and adjuster

in line
Turn adjuster back until D Tighten lock nut Use punch
mark lines up with second ■With gear at center ■Torque adjuster lock
of travel, check torque nut to 44 Newton
to turn stub shaft metres (32 Ft. lbs.)
(reading #1) Prevent adjuster screw
from turning while
torqueing lock nut.

RECOMMENDED TORQUE SPECIFICATIONS

NEWTON METRES FOOT-POUNDS

Gear to Frame Bolts .................................... .................... 95 70

High Pressure Line Fitting (At G e a r).......................... 54 40
Oil Return Line Fitting (At Gear) ................................ 54 40
Pitman Shaft
Adjusting Screw L o c k n u t................................................ 44 32
Adjuster Plug Locknut...................................................... 110 80
Pitman Shaft N u t.................................................................250 180
Coupling Flange B o lt........................................................ 42 30

SPECIAL TOOLS

J-4245 — Internal Snap Ring Pliers

J-6133-01 — Pitman Shaft Seal Installer
J-6217 — Connector Seat Installer
J-7754 — 0-5 Newton-metre Torque
Wrench (0-25 inch-pounds)
J-8058 — 0-125 Newton-metre Torque
Wrench (0-50 foot-pounds)
J-8810 — Pitman Shaft Bearing Remover
and Installer
J-25323 — Power Steering Analyzer

Fig. 3B-5C--Overhaul 6 0 5 Gear, Chart E

3B-18 STEERING

________ POWER STEERING GEAR (800 AND 808 MODELS)

GENERAL DESCRIPTION
These Integral Power Steering Gears have This is a large design steering gear.
a control valve which directs oil to ei­ To determine this gear from the
ther side of the rack piston. The rack small steering gear see difference
piston converts hydraulic power into in side cover below.
mechanical force. This force is trans­
mitted to the mating pitman shaft teeth,
Rectangular side cover held in
through the pitman shaft to the steering place with four bolts
linkage.

These gears incorporate a recirculating

ball system in which steel balls act as a
rolling thread between a steering worm­
shaft and the rack-piston. Two sizes
of these gears are used. One (model
800) uses a 70mm (2%") diameter cylin­
der bore and the other (model 808)
LARGE GEAR
uses a 79mm (3Va") diameter bore. Two (800-808 MODEL)
types of each gear are used, but they
are serviced exactly the same. Some
vehicles use a constant ratio gear and Round side cover held in
others use a variable ratio gear. place with retaining ring

The variable ratio type gear is generally

faster, and requires fewer turns of the
steering wheel. Variable ratio is accom­
plished by a pitman shaft sector incor­
porating a short tooth on either side
of a long outer tooth, rather than a
sector with three teeth of equal length
as in constant ratio gears. Similar SMALL GEAR
(605 MODEL)
changes are also made in the rack-
piston teeth (see below).

PITMAN SHAFT SECTOR

NOTE: Whenever a part which forms a

sealing surface for an "O" ring is
removed, the ”0 '' ring seal should also
be removed and replaced with a new
seal. Whenever one of the Pitman shaft
RACK PISTON or stub shaft seals are removed all
adjacent seals should be removed and
CONSTANT VARIABLE
replaced with new seals. Lubricate all
RATIO RATIO new seals with power steering fluid to
ease assembly.

Fig. 3 B -6C -O v e rh a ul 8 0 0 and 8 0 8 Gears, Chart A

 Key No. P o rt Mame Key No. P o rt Name Key No. P ort Nome
1 9 - PLUG, ADJUSTER 3 7 -S C R E W A SSY., LOCKWASHER & (2)
1 - H O U S IN G , STEERING GEAR
2 - R A C E , THRUST BEARING (W O R M ) 2 0 -B E A R IN G , NEEDLE 3 8 - P L U G , RACK PISTON
3 -B E A R IN G A SSY., ROLLER THRUST (W O R M ) 21 - SEAL, STUB SHAFT 3 9 -S E A L , " O " R IN G (RACK PISTON)
4 -R A C E , THRUST BEARING (W O R M ) 2 2 -S E A L , STUB SHAFT DUST 4 0 - R I N G , RACK PISTON
5 - W O R M , STEERING 2 3 - R I N G , R E TA IN IN G 41 -S E A L , " O " R IN G (H O U S IN G END PLUG)
6 - S E A L , " O " R IN G (STUB SHAFT) 24 - NUT, ADJUSTER PLUG LOCK 4 2 -P L U G , H O U S IN G END
2 5 -B E A R IN G ASSY., NEEDLE (P IT M A N SHAFT) 4 3 - R I N G , R E T A IN IN G (H O U S IN G END PLUG)
7 - S H A F T , STUB
2 6 -S E A L , P IT M A N SHAFT (SINGLE LIP) 4 4 - G E A R ASSY., P IT M A N SHAFT
8 - S P O O L , VALVE
2 7 -W A S H E R , SEAL BACK-UP (P IT M A N SHAFT) 4 5 - S E A L A S S Y , GASKET
9 - S E A L , " O " R IN G (SPOOL)
1 0 - B O D Y , VALVE 2 8 -S E A L , P IT M A N SHAFT (DOUBLE LIP) 4 6 - C O V E R ASSY., H O U S IN G SIDE
11 - R IN G , V A LVE BO D Y (3) 2 9 -W A S H E R , SEAL BACK-UP (P IT M A N SHAFT) 4 / - B O L T , HEX. HEAD (SIDE COVER) (4)
1 2 - S E A L , " O " R IN G (VALVE BODY) (3) 3 0 - R IN G , R E T A IN IN G (P IT M A N SHAFT SEAL) 4 8 - NU T, LASH ADJUSTER
1 3 -R E T A IN E R , B EARING (ADJUSTER) 3 1 -W A S H E R , P IT M A N SHAFT LOCK 4 9 - S P R IN G , CHECK VALVE
1 4 -S P A C E R , THRUST BEARING 3 2 - N U T , P IT M A N SHAFT 5 0 -P O P P E T , CHECK VALVE
1 5 - R A C E , UPPER THRUST B EARING (SMALL) 3 3 - N U T , RACK PISTON 51 -C O N N E C T O R , INVERTED FLARE
3 4 -B A L L 52 - C O N N E C TO R , INVERTED FLARE
Fig. 3B-7C--Overhaul 800

1 6 -B E A R IN G , UPPER THRUST
1 7 - RACE, UPPER THRUST BEARING (LARGE) 3 5 - G U ID E , BALL RETURN (2) 5 3 -B O L T , C O U P L IN G PIN CH
1 8 - SEAL, " O " R IN G (ADJUSTER) 3 6 -C L A M P , BALL RETURN GUIDE 5 4 - C O U P L IN G , STEERING SHAFT

I
® ~ jL ?-—@
® -
and 808 Gears, Chart B

®JMw) ®
® W
A s s e m b lie s a n d S e rv ic e K its
GEAR A SSY., STEERING
V A LV E A SSY., STEERING GEAR
-P L U G SERV. ASSY., ADJUSTER
-SEA L SERV. KIT, ADJUSTER PLUG
SEAL SERV. KIT, V A LV E R IN G &
- N U T SERV. KIT, R A C K -PISTO N
H O U S IN G SERV. KIT, STRG. GEAR
C O VER SERV KIT, H SG . SIDE
-G E A R SERV. KIT, P IT M A N SHAFT
THIS N U M B ER N O T USED
SEAL SERV. KIT, EN D PLUG
- SEAL SERV. KIT, H S G . SIDE C O VER
-S E A L SERV. KIT, M ASTER
SEAL SERV. KIT, R A C K -PISTO N
V A L V E SERV. KIT, CHECK

STEERING
SEAL SERV KIT, P IT M A N SHAFT
BALL SERV. KIT, R EC IR C U LA TIN G
B E A R IN G ASSY SERV. KIT, UPR. THR.
-B E A R IN G A SSY. SERV. KIT, LW R. THR.

POWER STEERING GEAR EXPLODED VIEW

3B-19
3B-20 STEERING

1. REMOVE AND INSTALL PITMAN SHAFT REMOVE AND INSTALL HOUSING END
SEALS IN CAR PLUG
REMOVE INSTALL REMOVE INSTALL
Remove parts Install parts as shown.
Clean exposed end Install parts
as shown. Open end of retaining
of pitman shaft and as shown.
ring to be approx. 25 mm
end of housing after
HOUSING ASSEMBLY (1 inch) from access hole.
removing arm.
Inspect for burrs
Remove retaining
Retaining ring
ring with snap
access hole
ring pliers J-4245.
Start engine and SEAL (SINGLE LIP)
turn wheels fully
to the left to WASHER
force seals and SEAL ( DOUBLE LIP)
washer out.
WASHER
Turn off engine.
RETAINING RING
Inspect housing
and shaft. ------PITMAN ARM
LOCK WASHER
PITMAN SHAFT
Inspect seal surface NUT-Torque
for roughness and pitting to 250 N m
(180 Ft. Lbs.)

2. REMOVE AND INSTALL PITMAN SHAFT 4. REMOVE AND INSTALL RACK PISTON
AND SIDE COVER
REMOVE INSTALL REMOVE INSTALL

If pitman shaft and If removed, install 1 Remove parts 1 Install parts

side cover are to be gasket seal by as shown as shown
separated, remove bending tabs around
preload adjuster nut. cover edges When installing rack,
Rotate stub shaft to I Install parts care should be taken not
center gear, then as shown to cut teflon seal, J-7576
remove parts as shown. or J-8947 rack piston sea
-SIDE COVER BOLTS compressor may be used
Torque to 60 N-m to compress seal
(40 Ft. Lbs )

Insert ball retainer

J-21552. Hold tool tightly
against worm while
turning stub shaft
counter-clockwise. The
■RACK PISTON PLUG rack-piston will be forced
must be removegi onto the tool. Remove the
before removing rack-piston and ball
Separate pitman retainer from the gear
shaft and gasket rack.
housing together.
seal from side
cover if required.

Fig. 3B-8C ~O verhaul 8 0 0 and 8 0 8 Gears, Chart C

 STEERING 3B-21

5. REMOVE AND INSTALL ADJUSTER PLUG 7. REMOVE AND INSTALL BEARING, WORM,
ASSEMBLY AND VALVE ASSEMBLY
REMOVE INSTALL REMOVE INSTALL
Loosen lock nut. Install parts Grasp stub shaft and .1. Install parts as
Use punch against as shown remove valve and worm shown
edge of slots. assembly as a unit
ADJUSTER PLUG
Remove adjuster Separate the valve from the
plug using spanner worm Note how the pin in
wrench J-7624. ( LOCK NUT the worm fits the
slot in the valves
THRUST BEARING
AND RACES-*,

Use J-6222 stub shaft

seal protector when VALVE ASSEMBLY
installing adjuster plug.

DISASSEMBLE AND ASSEMBLE ADJUSTER WORM ASSEMBLY

PLUG ASSEMBLY
NOTE When reassembling
DISASSEMBLE ASSEMBLE gear make sure angle
Disassemble parts 1. Assemble parts of thrust races are as
as shown. as shown ^ shown

8. DISASSEMBLE AND ASSEMBLE VALVE

DISASSEMBLE ASSEMBLE
1. Disassemble parts 2 Assemble parts
as shown as shown

/ / / /^ R E T A IN IN G RING VALVE BODY O R IN G -------------- r ---------r --------- y _

/ / ^ — STUB SHAFT
DUST SEAL
------STUB SHAFT SEAL STUB SHAFT-7 \ n iV J x
I — NEEDLE BEARING
( “-ADJUSTER PLUG ^ V A L V E BODY
L "0 " RING SEAL RING (teflon)
UPPER BEARING RACE (LARGE) SPOOL TO BODY O RING
UPPER THR U ST BEARING Shaft cap
UPPER BEARING RACE (SMALL)
THRUST BEARING SPACER
'BEARING RETAINER A. Loosen shaft cap B. Remove and install stub shaft

RETAINER Pull cap out approx 6 m m (V )

Screwdriver

Remove bearing retainer

-Tap lightly on
wood block ^ P in on shaft and hole in
J-7079-2 Driver
spool ( Disengage to remove)
J-7079-2
J-8524-1 Installer
Driver C. Remove and install spool D. Engage stub shaft
Also use for seal
installation after Rotate while
bearing is in place removing or
Drive bearing 1 installing —
and seals I
from adjuster |
Bearing with
J -8524-2 identification
Bearing toward tool
remover

ADJUSTER PLUG ADJUSTER PLUG

Lubricate spool and body Notch must fully engage
with power steering fluid. pin and cap must seat
Remove bearing and seals. Install bearing and seals against shoulder.

Fig. 3B-9C--Overhaul 8 0 0 and 8 0 8 Gears, Chart D

3B-22 STEERING

9. DISASSEMBLE AND ASSEMBLE RACK 10 . REMOVE AND INSTALL PITMAN SHAFT

PISTON SEALS AND BEARING
DISASSEMBLE ASSEMBLE REMOVE INSTALL
Clean end of Install parts as
1. Disassemble parts Assemble parts
housing thoroughly shown.
as shown. as shown
to prevent dirt from
entering and be
Clean and inspect extremely careful not
all parts for NOTE: The black balls to score the housing
excessive wear are smaller than the bore.
silver balls. The black HOUSING ASSEMBLY
and silver balls must be Remove retaining ring Inspect for burrs.—
installed alternately into with snap ring pliers
the rack-piston and J-4245.
return guide to maintain
rack piston to worm gear Using screw driver,
preload. pry seals and washers
from bore.

TEFLON SEAL AND "O" RING — PITMAN SHAFT S E A L "^ / V

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 ■NEEDLE BEARING
is aligned with the lower SEAL BACK UP WASHER
ball return guide hole Remove only if it
-j needs replacing.
J-6278
WORM—Slide all the way
into the rack-piston.—

I_Removing
_»__________
bearing
.J
r
Lubricate balls with
power steering fluid

-Before assembling rack

in housing, ball retainer Install balls, through
J-21552 must be inserted ball return guide hole,
into rack to allow while rotating worm J-8092
removal of worm. counterclockwise -J-6219

GUIDE—Alternately
install remainder of
balls and retain with J-22407
grease at each
end of guide.

CLAMP

When tool bottoms on

housing bearing is
fully installed.------------
SCREW-Tighten
to 5 N-m
(4 Ft. Lbs.)
1______________________ I_______________ J
Install Pitman shaft Install Pitman shaft seals
bearing

Fig. 3B-1QC--Overhaul 8 0 0 and 8 0 8 Gears, Chart E

 STEERING 3B-23

11. REMOVE AND INSTALL CONNECTORS PITMAN SHAFT "OVER-CENTER

& CHECK VALVE SECTOR ADJUSTMENT
REMOVE INSTALL

1. Remove parts as shown 1. Install parts as shown

Installer J-6217-

Remover No. 4
Screw Extractor
Tangs on check When gear is on center
valve to be pointing i flat on stub shaft is
down.---------------------- normally on same side as,
•INVERTED
FLARE and parallel with, side cover.
CONNECTORS
Spring should be
seated in counter;
bore of port.— ' CHECK VALVE

SPRING

HOUSING ASSEMBLY

12. ADJUST WORM BEARING PRELOAD

The block tooth on the Pitman
Using spanner wrench shaft is in line with the
J-7624, tighten adjuster over-center preload adjuster.—
plug until thrust
bearing is firmly
bottomed 27 N-m
(20 ft. lbs.) Back off preload adjuster Turn adjuster in until
until it stops, then turn torque to turn stub shaft
it in one full turn.-. is 0.6 to 1.2 N-m
(6 to 10 in. lbs.)
more than reading #1,—
but not to exceed 2 N-m
(18 in. lbs.)

Measure back
Mark housing and counterclockwise
face of adjuster 13 mm (%") and place a
plug.------------------ second mark on housing

With gear at center Torque adjuster lock

of travel, check torque nut to 27 N-m
to turn stub shaft (20 Ft. lbs.)-------------
Turn adjuster Using punch in notch (reading #1)
Prevent adjuster screw
counterclockwise until tighten lock nut securely. from turning while
mark on face of adjuster Hold adjuster plug to torqueing lock nut.
lines up with second maintain alignment of
mark on housing.---------- the marks.

Fig. 3B-1 1C--Overhaul 8 0 0 and 8 0 8 Gears, Chart F

3B-24 STEERING

RECOMMENDED TORQUE SPECIFICATIONS

FOOT-POUNDS NEWTON METRES

Gear to Frame Bolts ....................................................... 7 0 ............................................................. 95
High Pressure Line Fitting (At G ea r)............................ 4 0 ............................................................. 54
Oil Return Line Fitting (At Gear) ................................. 4 0 ............................................................. 54
Pitman Shaft
Adjusting Screw L ocknut................................................. 3 5 ............................................................. 48
Side Cover B o lts................................................................. 4 5 ............................................................. 61
Adjuster Plug Locknut....................................................... 8 0 ............................................................. 108
Coupling Flange N u ts ....................................................... 2 0 ............................................................. 27
Return Guide Clamp Screws ......................................... 4 ............................................................. 5
Rack-Piston P lu g ................................................................. 7 5 ............................................................. 102
Pitman Shaft N u t................................................................. 180 ............................................................. 244
Coupling Flange B olt......................................................... 3 0 ............................................................. 41

SPECIAL TOOLS

J-21552 — Ball Retainer J-6219 — Pitman Shaft Seal Installer

J-7624 — Spanner Wrench J-6222 — Stub Shaft Seal Protector
J-7079-2 — Handle J-8947 — Rack Piston Seal Compressor
J-8524-2 — Adjuster Plug Bearing Remover (70mm [2%"] Piston Bore)
J-8524-1 — Adjuster Plug Bearing Installer J-8058 — 0-50 Ft-Lb Torque Wrench
J-6217 — Connector Seat Installer J-7754 — 0-25 In-Lb Torque Wrench
J-8092 — Handle J-25323 — Power Steering Analyzer
J-22407 — Pitman Shaft Bearing Installer J-7576 — Rack Piston Seal Compressor
J-6278 — Pitman Shaft Bearing Remover (79mm [3%"] Piston Bore)

Fig. 3 B - 1 2C--Overhaul 8 0 0 and 8 0 8 Gears, Chart G

 STEERING 3B-25

CONTROL VALVE AND POWER C YLIN D ER -C O R V ETTE

INDEX
Overhaul Control Valve.............. ............................................3B-25
Disassembly............................. .............................................3B-25
Inspection............................ . ............................................3B-25
Repairs...................................... ........................................... .3B-25
Assembly................................... ........................................... .3B-25
Valve Balancing....................... ........................................... .3B-26
Overhaul Power Cylinder........... ........................................... .3B-27
OVERHAUL CONTROL VALVE including mating parts when necessary.
3. Replace all seals, gaskets, covers with approved
service parts.
Disassembly
1. Place the valve in a vise as shown and remove dust Repairs
The Corvette valve incorporates a 40 lb.
cover (fig. 3B-1D). NOTE:
centering spring. The Corvette valve incorporating this
2. Remove adjusting nut (fig. 3B-2D). spring is identified by an "C" stamped on the dust
3. Remove valve to adapter bolts and remove valve cover.
housing and spool from adapter. In case a connector seat becomes damaged, proceed as
4. Remove spool from the housing (fig. 3B-3D). follows:
5. Remove spring, reaction spool, washer reaction To remove connector seat, tap threads in center hole
spring, spring retainer, and seal (fig. 3B-4D). "O" ring may using a 5/16-18 tap. Thread a bolt with nut and flat washer
now be removed from the reaction spool. attached into tapped hole so that the washer rides against
6. Remove the annulus spacer valve shaft washer and the face of the port boss and the nut rides against the washer.
plug to sleeve key (See Figure 3B-5D). Hold the bolt from rotating while turning the nut off the
7. Remove clamp by removing nut, bolt and spacer or, bolt. This will force the washer against the port boss face
if crimped type clamp is used, straighten clamp end and pull and will back out the bolt thus drawing the connector seat
clamp and seal off end of stud (fig. 3B-6D). from the top cover housing (fig. 3B-8D). Discard the
8. Carefully, so as not to nick the top surface, turn connector seat. Clean the housing out thoroughly to remove
adjuster plug out of sleeve (fig. 3B-7D). any tapping chips.
9. Remove the adapter from the vise and invert, Drive new connector seat against housing seat, using
permitting the spring and one of the two ball seats to fall Tool J-6217, being careful not to damage either the
free. connector seat or the housing seat (fig. 3B-9D).
10. Remove the ball stud and the other ball seat and
the sleeve will fall free. Assembly (Fig. 3 B -1 1 D)
1. Replace the sleeve and ball seat in the adapter, then
Inspection the ball stud, and finally the other ball seat and the spring,
1. Wash all metal parts in nontoxic solvent and blow small coil down.
dry with compressed air. 2. Clamp the adapter in vise, put the shaft through the
2. Inspect all parts for scratches, burrs, distortion, seat in the adjuster plug and screw adjuster plug in sleeve
evidence of wear and replace all worn or damaged parts, (fig. 3B-10D).

Fig. 3B-1D--Dust Cap Removal Fig. 3B-2D ~R em ovin g Adjusting Nut

3B-26 STEERING

Fig. 3B-3D--Removing Spool from Housing Fig. 3B-5D--Removing Plug-to-Sleeve Key

10. Depress the valve spool and turn the locknut onto
3. Turn the plug in until it is tight, then back it off until the shaft about four turns with a clean wrench or socket.
the slot lines up with notches in the sleeve. NOTE: Always use a new nut.
4. Install new seal and clamp over stud so lips on seal Valve Balancing (Fig. 3B-13D)
mate with clamp. (A nut and bolt attachment type clamp The control valve must be adjusted, after being
replaces the crimped type for service fig. 3B-6D). disassembled, as outlined in the following procedure. The
5. Center the ball stud, seal and clamp at opening in same procedure may be followed to correct a complaint of
adapter housing, then install spacer, bolt and nut. harder steering effort required in one direction than the
6. Insert the key, making sure that the small tangs on other. See Figure 3B-13D.
the ends of the key fit into the notches in the sleeve (fig. 1. Install valve in vehicle. Connect all hoses and fill the
3B-12D). pump reservoir with oil. Do not connect the piston rod to
7. Install the valve shaft washer, annulus spacer, and the frame bracket. If the vehicle is already in operation, it
the reaction seal (lip up), spring retainer, reaction spring and will be necessary to detach the piston rod from the frame
spool, washer and adjustment spring. (Install "O" ring seal bracket.
on reaction spool before installing spool on shaft.) Install 2. With the car on a hoist, start the engine. One of the
the washer with the chamfer "up". following two conditions will exist.
8. Install the seal on the valve spool (lip down), then a. If the piston rod remains retracted, turn the adjusting
install spool in housing being careful not to jam spool in nut clockwise until the rod begins to move out. Then turn
housing. the nut counter-clockwise until the rod just begins to move
9. Install housing and spool onto adapter. The side in. Now turn the nut clockwise to exactly one-half the
ports should be on the same side as the ball stud. Bolt the rotation needed to change the direction of the piston rod
housing to the adapter. movement.

Fig. 3B-4D --Removing Valve Parts from Shaft Fig. 3B-6D --Seal with Clamp Attachment
 STEERING 3B-27

Fig. 3B-7D~Turning Adjuster Plug out of Sleeve Fig. 3B-9D--lnstalling Connector Seat

b. If the rod extends upon starting the pump, move the OVERHAUL POWER CYLINDER
nut counter-clockwise until the rod begins to move in. Now
position the nut exactly one-half the rotation needed to Disassembly (Fig. 3B-14D)
change the direction of the piston rod movement. 1. To remove the piston rod seal, remove the snap ring;
then pull out on rod, being careful not to spray oil.
CAUTION: Do not turn the nut back and forth 2. Remove the piston rod scraper and scraper element,
more than is absolutely necessary to balance the back up washer and piston rod seal from the rod.
valve. 3. At the ball stud end of the cylinder, remove the ball
stud seal.
3. With the valve balanced it should be possible to move 4. Remove the snap ring retaining the end plug and
the rod in and out manually. lube fitting.
5. Push on the end of the ball stud and remove the end
4. Turn off the engine and connect the cylinder rod to plug, spring, spring seat and ball stud.
the frame bracket. 6. Remove the "O" ring seal from the top lip of the
power cylinder ball stud opening.
5. Restart the engine. If the front wheels (still on the 7. If the ball seat is to be replaced, it must be pressed
hoist) do not turn in either direction from center, the valve out using Tool J-8937.
has been properly balanced. Correct the valve adjustment
if necessary. Assembly
1. Reassemble the piston rod seal components by
6. When the valve is properly adjusted, grease end of reversing the disassembly procedure. Apply power steering
valve and install dust cap. fluid on the inner surfaces of the seal and scraper before
assembly.

Fig. 3B-8D--Removing Connector Seat Fig. 3 B - 1 0 D - R e p la c i n g A djuster Plug and Shaft

3B-28 STEERING

Qjgj£|
a a w e

J 4
3 2 1
1. Dust Cover 1 1. Spring Thrust Washer 21. Valve Shaft
2. Adjusting Nut 12. Valve Spring 22 Ball Seat Spring
3. Vee Block Seal 13. Spring Retainer 23. Ball Seat
4. Valve Spool 14. Annulus Seal 24. Ball Seat
5. Valve Mounting Bolts 15. Annulus Spacer 25. Sleeve Bearing
6. Lock Washer 16. Gasket 26 Adapter Housing
7. Valve Housing 17. Valve Shaft Washer 27. Lubrication Fitting
8 Valve Adjustment Spring 18. "0" Ring Seal 28. Ball Stud
9. 'O'' Ring Seal 19. Plug to Sleeve Key 29. Seal
10. Valve Reaction Spool 20. Ball Adjuster Nut 30. Clamp

Fig. 3B-1 1D~Power Steering Control Valve and Adapter-Exploded

2. Reverse the disassembly procedure when

reassembling the ball stud.
3. In each case be sure that the snap ring is securely NOTE: Be sure to use new seals and "O" rings when
seated in the ring groove. re-assembling cylinder.

Fig. 3B-1 2 D - P r o p e r Key Installation Fig. 3 B -13D--Balan cing Valve

 STEERING 3B-29

1. Snap Ring 6. Ball Stud 11. Backup Washer

2. End Plug and Lube Fitting 7. Ball Seat 12. Scraper Element
3. "0" Ring 8. Ball Stud Seal 13. Piston Rod Scraper
4. Spring 9. Piston Body 14. Snap Ring
5. Spring Seat 10. Piston Rod Seal 15. Piston Rod

Fig. 3B-14D~Power Steering Power Cylinder Exploded

3B-30 STEERING

SPECIA L TOOLS

:!
14
13

21

T3r
20 22 24

o
35

25 27 28 30 31 32 33 34 36
1. J-6632 Pitman Arm Puller 18. J-7539 Ball Retainer
2. J-5504 Pitman Arm Puller 19. J-7624 Spanner Wrench
3. J-23073 Shift Tube Installer 20. J-4245 No. 23 Internal Pliers
4. J-23072 Shift Tube Remover 21. J-22670 Pump Shaft Seal Installer
5. J-5176 Oil Pressure Gauge 22. J-6222 Shaft Seal Protector
6. J-9226 Pitman Shaft Bushing Replacer (Truck) 23. J-8947 Rack-Piston Seal Compressor
7. J-7576 Rack-Piston Seal Compressor (Truck) 24. J-5755 Wormshaft Bearing Race
8. J-23600 Belt Tension Gauge Installer
9. J-2927 Steering Wheel Puller 25. J-8092 Handle
10. J-21239 Pump Pulley Remover (Stamped 26. J-6278 Pitman Shaft Bearing Remover
Pulley) 27. J-6278-2 Pitman Shaft Seal Installer
11. J-21854 Column Pivot Pin Remover 28. J-7979-2 Handle
12. J-23653 Lock Plate Compressor 29. J-8524-1 Adjuster Plug Bearing Installer
13. J-5421 Thermometer 30. J-8524-2 Adjuster Plug Bearing Remover
14. J-5860 Torque Wrench Adapter 31. J-6219 Pitman Shaft Seal Installer
15. J-5822 Wormshaft Bearing Race 32. J-22407 Pitman Shaft Bearing Installer
Remover 33. J-6217 Connector Seat Installer
16. J-8433 Pump Pulley Remover (Cast 35. Torque Wrenches
Pulley) 36. J-2619 Slide Hammer
17. J-1614 Pitman Shaft Bushing Remover

Fig. 3B-ST~Manual and Power Steering Special Tools

 REAR AXLE DIFFERENTIAL 4B-1

SECTION 4B
REAR AXLE DIFFERENTIAL CARRIER
CONTENTS OF THIS SECTION

General Information..................................................... 4B-1 Truck - Chevrolet 10-1/2" .... 4B-35

Alternate Pinion Setting Depth Setting Procedure.. . 4B-1 Truck - Dana 10-1/2" and 9-3/4" Ring Gear..... .... 4B-41
7-1/2", 8-1/2 and 8-3/4" Ring G ear........................ . 4B-3 Truck - Chevrolet 12-1/4" Ring Gear.................. .... 4B-54
Truck 8-7/8 Ring Gear.............................................. 4B-15 Limited Slip Units............. 4B-59
Corvette......................................................................... . 4B-25 .... 4B-77

GENERAL INFORMATION

AXLE IDENTIFICATIO N
It is important to know which axle is being serviced, gears, on Corvette, and on truck models with 8-7/8 inch
in order to use the correct overhaul procedure. The ring gears.
manufacturing code number on Passenger Car axles may be However, if J-21777-01 is not used in determining
found on the axle tube close to the carrier. It is the third pinion depth shim requirements, the following tools and
letter of the axle code. For example, if an axle had this axle procedures are recommended. Only the steps of the
number: 2HD B 8 218 1, the manufacturer could be procedures that differ from the J-21777-01 method are
determined from the third letter, B. Truck axles are mentioned.
identified in this section by ring gear size. 8 -1 /2 " Ring Gear - Passenger Car
The following chart lists pertinent information needed 1. Set up the tools as shown in figure 4B-3A.
on Passenger Car and Series 10-30 Truck axles. 2. Preload the dial indicator one half revolution, with
ALTERNATE PINION DEPTH SETTING the plunger off the gauge plate, and tighten in this position.
PROCEDURE 3. Rest the plunger on the low gauging surface, marked
A new pinion depth coding system facilitates the use Y.
of Pinion Setting Gauge J-21777-01, as outlined in later 4. "Zero" the indicator on the highest spot of the
portions of this section. The coding system is used on gauging surface.
passenger car differentials with 8-1/2 inch and 8-7/8 ring 5. Swing the plunger off the plate and read the dial
indicator. This reading is the required shim thickness for
a nominal pinion.
R ING GE AR SI2:e 6. If a pinion is coded+ 2, + 1, -1, or -2, alter the shim
VEH IC LE SERIES thickness that many thousandths of an inch.
8 -1 /2 8 -3 /4 7 -1 /2 8 -3 /8 For example, if the indicator reading was .028, and the
pinion code is -1, the required shim would be .028-.001
CHEVROLET X X X = .027 inch.
Corvette and 8 -7 /8 " Ring Gear - Truck
MALIBU
X 1. Set up the tools as shown in figures 4B-4A, and
EL CAMINO 4B-5A.
MONTE CARLO X 2. "Zero" the dial indicator off the gauge plate.
3. Swing the plunger across the plate until the highest
CAMARO X reading is obtained. Record the result.
4. Combine the pinion code number with "45", which
X represents a nominal pinion. From that number, subtract
NOVA the dial indicator reading. The result is the required shim
thickness.
CORVETTE X For example, if the reading was .016, and the pinion
code was +2, the correct shim could be determined as
Fig. 4 B -1 A -A xle Useage Passenger Car follows: 45 + 2 = 47; .047 -.016 = .031 inch.
4B-2 REAR AXLE DIFFERENTIAL

R IN G G E A R
MODEL SO U R CE T Y P E /C A P A C IT Y
SIZE

C 10 C hevrolet S a lis b u ry /3 7 5 0 # 8 -7 /8 "

C10 C hevrolet S a lisb u ry/3 7 5 0 # 8 -1 /2 "

K 10 C hevrolet S a lis b u ry /3 7 5 0 # 8 -7 /8 "

K 10 C hevrolet S a lis b u ry /4 0 0 0 # 8 -7 /8 "

P10 C hevrolet S a lis b u ry /3 5 0 0 # 8 -7 /8 "

G 10 C hevrolet S a lis b u ry /3 5 0 0 # 8 -7 /8 "

G 10 C hevrolet S a lis b u ry /3 1 0 0 # 8 -1 /2 ”

(Except
C20 Crew C hevrolet S a lis b u ry /5 7 0 0 # 10 1 /2 "
Cab)

C20 (Crew Cab) C hevrolet S a lis b u ry /7 5 0 0 # 1 0 -1 /2 "

K20 C hevrolet S a lis b u ry /5 7 0 0 # 1 0 -1 /2 "

P20 C hevrolet S a lis b u ry /5 7 0 0 # 1 0 -1 /2 " Fig. 4B -3 A -P in io n G auging Tools - 8 1 /2 " Ring Gear

G20 C hevrolet S a lis b u ry /3 5 0 0 # 8 -7 /8 "

G20 C hevrolet S alisbury /3 5 0 0 # 8 -1 /2 "

(Except
C30 Dual
K 30 Wheel C hevrolet S a lis b u ry /7 5 0 0 # 1 0 -1 /2 "
Camper)

C 30 (Dual
K 30 ™heel , Dana S a lis b u ry /7 5 0 0 # 1 0 -1 /2 "
Camper)

P30 C hevrolet S a lis b u ry /7 9 0 0 # 1 0 -1 /2 "

P (With
C hevrolet B a n jo /1 1 ,0 0 0 # 1 2 -1 /4 "
r ju H 2 2 /H 2 3 )

G 30 C hevrolet S a lis b u ry /5 7 0 0 # 1 0 -1 /2 "

„„n (Dual Dana S a lis b u ry /6 2 0 0 # 9 -3 /4 "

G 30 Wheel)
_ _ r, (Dual
Dana Sal is b u ry /7 5 0 0 # 10 1 /2 "
G3C Wheel)

Fig. 4B-2A~Axle Usage Truck

Fig. 4B -4 A -P in io n G auging Tools - Corvette

 REAR AXLE DIFFERENTIAL 4B-3

Fig. 4B-5A~Pinion G auging Tools - 8 -7 /8 " Truck

7-1/2", 8-1/2" and 8-3/4" RING GEAR

INDEX

Differential Case............................................................4B-3 2. Remove rear axle shaft.

Removal and Disassembly..........................................4B-3 3. Roll out the differenital pinions and thrust washers;
Inspection.................................................................... .4B-3 then remove side gears and thrust washers. Mark the
Side Bearing Replacement..........................................4B-4 pinions and side gears so they can be reassembled in their
Ring Gear Replacement............................................ .4B-4 original positions.
Installation and Adjustment.......................................4B-5 4. Mark side bearing caps for installation in same
Drive Pinion...................................................................4B-6 position during reassembly. Loosen bolts holding
Removal........................................................................4B-6 differential side bearing caps to housing.
Bearing Replacement................................................. .4B-7
Setting Pinion Depth................................................. .4B-9 CAUTION: Do not attempt to pry caps o ff as this
Installation and Adjustment.......................................4B-10 may damage machined face o f caps.
Checks and Adjustments............................................. .4B-13 5. Using a pry bar as shown in figure 4B-2, pry
Pinion Bearing Preload............................................... ..4B-13 differential case out of carrier. Exercise caution in prying
Side Bearing Preload................................................. ..4B-13 on carrier so that gasket sealing surface is not damaged. If
Pinion Depth and Backlash.........................................4B-13 the bearings are preloaded, the case will suddenly fall free
Gear Tooth Contact Pattern Check......................... ..4B-13 when it is pried past a certain point; therefore, make sure
case is properly supported to prevent damage. The bearing
DIFFERENTIAL CASE cups may be loosely installed, as shown in figure 4B-2, to
prevent case from falling.
Removal and Disassembly 6. Place right and left bearing outer races and shims
in sets with marked bearing caps so that they can be
NOTE: Before preoceeding with following steps, it is reinstalled in their original positions.
advisable to check the existing ring gear to pinion
backlash as described under "Checks and Inspection
Adjustments". This will indicate gear or bearing wear 1. Clean all parts in cleaning solvent; inspect all bearing
or an error in backlash or pinion depth setting which cups, races and rollers for scoring, chipping or evidence of
will help in determining cause of axle noise. Backlash excessive wear.
should be recorded so that if same gears are reused, 2. Inspect axle shaft and side gear for evidence of
they may be reinstalled at original lash to avoid excessive wear.
changing gear tooth contact. 3. Inspect hypoid ring gear and pinion teeth for possible
1. Remove screw that retains differential pinion shaft scoring, cracking or chipping.
and remove pinion shaft. 4. Inspect differential case, pinions, side gears, thrust
4B-4 REAR AXLE DIFFERENTIAL

9
10
1 1- 'N O T O N B O TYPE AXLES;

1. Companion Flange 7. Differential Case 13. Cover 19. Thrust Washer

2. Deflector 8. Shim 14. Pinion Shaft 20. Differential Pinion
3. Pinion O il Seal 9. Gasket 15. Ring Gear 21 . Shim
4. Pinion Front Bearing 10. Differential Bearing 16. Side Gear 22. Pinion Rear Bearing
5. Pinion Bearing Spacer 11. "C" Lock 17. Bearing Cap 23. Drive Pinion
6. Differential Carrier 12. Pinion Shaft Lock Screw 18. Axle Shaft

Fig. 4B-1--Cross Section of T ypical D iffere ntia l

washers and pinion shaft for cracks scoring, spalling or cage. Install other bearing as done in Step 3.
excessive wear.
5. Check fit of differential side gears in case. Ring Gear or D ifferential Case Replacement
1. Remove the ring gear screws (L.H. thread) and,
Differential Bearing Replacement using a soft drift and a hammer, tap ring gear off the case.
1. Install side bearing remover and proper adapter plug
tool J-22888 shown in figure 4B-3. Make sure that the puller NOTE: Do not attempt to pry ring gear from case. To
legs are fitted securely in case notches, against inner race. do so may damage machined surfaces.
2. Tighten puller screw to remove bearing. 2. Remove any nicks or imbedded dirt from case flange
3. Place new bearing onto hub, with the thick side of surface which mates with ring gear. Clean all surfaces.
the inner race toward the case. Drive the bearing into place, 3. Liberally coat the differential case pilot with hypoid
using J-22761 for 8-1/2" ring gear, J-22175 for the 8-3/4" lubricant. Pre-align ring gear and differential case bolt holes
ring gear, or J-25299 for 7-1/2" ring gear, as shown in figure and press against proper adapter plug to initially start ring
4B-4. gear on case pilot, as shown in figure 4B-5.
4. Before bearing installation on opposite hub, support 4. Start all ring gear bolts during initial assembly to
differential case on proper adapter plug. This allows maintain bolt hole alignment. Draw up all bolts evenly,
differential case to rest on adapter plug instead of bearing using a criss-cross pattern to avoid cocking the gear on the
 REAR AXLE DIFFERENTIAL 4B-5

J—8092

SIDE BEARING
INSTALLER

ADAPTER PLUG

Fig. 4B-2--Differential Case Removal Fig. 4B-4--Differential Bearing Installation

case. 3. For 8-1/2" and 8-3/4" ring gear:

5. Insure that gear is seated firmly against the case, then a. Install strap J-22779-6 on left bearing by tightening
torque all bolts to 50 lb. ft. bearing bolts alternately and evely to snug fit.
Reassembly With the ring gear tight against the pinion gear (.000"
1. Install thrust washers and side gears into case. If to .001" backlash), insert gauging Tool J-22779 between the
original parts are being reused, replace in origianl positions. left bearing cup and carrier housing. See Figure 4B-6.
2. Position pinions and thrust washers through loading While oscillating tool, turn adjusting nut clockwise
hole in case 180° apart so that they engage side gears. until a noticeable drag is produced.
3. Rotate gears until the differential pinion bores and Tighten lock bolt on side of tool.
the case shaft holes are aligned. b. For 7-1/2" ring gear:
4. Install pinion shaft and lock screw. It is not Position the ring gear tightly against the drive pinion
necessary to torque lock screw until axle shafts are installed. (zero backlash). Being sure that the bearings are properly
5. Differential may be installed in carrier now, or after seated, install a Service Spacer A (.160 inch), Service Shim
service is performed on the drive pinion. B and Feeler Gauge C, as shown in the ring gear side of
Installation and Adjustment Figure 4B-7. The thickness of the Feeler Gauge must be
1. Check condition of bearing, bearing cups, cup seat sufficient to produce a slight "drag" when moved between
in carrier and carrier caps to make sure that they are free the carrier and the Service Shim.
from nicks, burrs and foreign material. 4. Between the right bearing and carrier, install Service
2. Lubricate bearings with axle lubricant; position cups Spacer A (.170 for the 8-1/2" and 8-3/4" ring gear, .160
on proper bearing, then install differential assembly in
carrier and support the assembly to prevent it from falling.

J 22888

Fig. 4B-3--Differential Side Bearing Removal Fig. 4 B - 5 - R in g Gear to Case Installation

4B-6 REAR AXLE DIFFERENTIAL

later procedures, make sure that prelaod remains

established. If backlash is changed, be sure that total
thickness of two shim packs does not change.
10. Mount a dial indicator on the carrier and check the
backlash between the ring gear and pinion, as shown in
Figure 4B-11. The backlash should be within the range of
0.005"-0.008". Check gear lash at four different equally
spaced positions around the gear. Variation in readings
should not exceed .002".
NOTE: Position the dial indicator so that indicator
button is perpendicular to tooth angle and in line with
gear rotation.
11. If variation in backlash readings exceeds .002",
measure ring gear and case runout as shown in Figure 4B-
12. Gear runout should not exceed .003", should runout
exceed this limit check ring gear and case for deformation
Fig. 4B-6--lnstalling Gauging Tool and/or foreign matter between case and gear.
12. If gear lash is not within limits, correct by
decreasing shim thickness on one side and increasing
for the 7-1/2" ring gear, Service Shim B, and Feeler Gauge thickness of other shim the same amount. Total shim
C. Thickness of Feeler Gauge must be sufficient to produce thickness must be maintained at all times to maintain proper
a slight "drag" when moved between carrier and Service preload.
Shim. Now measure the above dimensions as shown in 13. Backlash changes approximately .002" for each
Figure 4B-8, for 8-1/2" and 8-3/4" ring gear, figure 4B-7 .003" change in shim dimensions. If backlash exceeds .008",
for the 7-1/2" ring gear. increase the shim thickness on ring gear side, while
5. For the 8-1/2" and 8-3/4" ring gear: Using a decreasing shim thickness on opposite side an equal amount.
micrometer as in Figure 4B-9, measure the thickness of J- If backlash is less than .005", decrease the shim thickness
22779 in a minimum of three places and average these on ring gear side, while increasing shim thickness on
readings. Record the result. opposite side an equal amount.
Add together the dimensions of the Service Shim, DRIVE PINION
Service Spacer and Feeler Gauge. Record the result.
For the 7-1/2" ring gear: Add together the dimesnions Removal
of the Service Shim, Service Spacer and Feeler Gauge. 1. Remove differential as previously outlined.
Record the result for each side. 2. Check torque required to rotate drive pinion as
6. Use the sample procedure in Figure 4B-8 for the described under "Drive Pinion - Installation and
8-1/2" and 8-3/4" ring gear, Figure 4B-7 for the 7-1/2" ring Adjustment". If there is no torque reading, check for
gear to determine the proper thickness for each shim pack. looseness of pinion assembly by shaking (push-pull) the
companion flange. Looseness indicates the need for bearing
NOTE: Production preloading of the differential replacement.
bearings is accomplished by the use of cast iron preload 3. Install Holder J-8614-11 on flange by using two bolts
shims. These shims cannot be used when rebuilding the with flat washers, as shown in figure 4B-13. Position J-8614-
carrier as they may break when tapped into place. 11 on flange so that the four notches are toward the flange.
For proper bearing prelaod, the shims must not 4. Remove pinion nut and washer.
be installed loosely, nor should they require undue 5. Thread end of J-8614-3 into small O.D. end of J-
force for installation. 8614-2. Then with J-8614-11 installed as in step 3, insert
7. Install left shim first, then wedge right shim between J-8614-2 into J-8614-11 and turn it 1/8 of a turn to locked
bearing cup and spacer (position shim so that chamfered position. Remove flange by turning J-8614-3 while holding
side is outward or next to spacer). If shim does not have J-8614-11 as shown in figure 4B-14.
sufficient chamfer or lead around O.D. to allow easy 6. To remove the drive pinion, first thread the original
installation without scraping spacer, file or grind chamfer pinion nut half-way on the pinion, for thread protection.
before installing. 7. Place the differential cover temporarily back onto
8. If difficulty is encountered in installing shim, the housing, using two screws. This will prevent the pinion
partially remove case slide case and shim into position. Tap from falling to the floor during removal.
shim into position, using soft faced hammer, while rotating 8. Tap the end of the pinion nut with a large hammer
differential case with free hand. See Figure 4B-10. and a soft drift, as shown in figure 4B-15.
9. Install bearing caps in original position and torque
to 60 ft. lbs. for the 8-1/2" and 8-3/4" ring gear, 55 ft. lbs. NOTE: Care must be taken not to damage pinion
for the 7-1/2" ring gear. bearings while removing pinion from carrier. Inspect
bearings and cups for damage and replace if needed.
NOTE: At this point, the differential side bearings are 9. Remove the pinion oil seal and the front pinion
properly preloaded. If any adjustments are required in bearing. Remove the cover and retrieve the drive pinion
 REAR AXLE DIFFERENTIAL 4B-7

EXAMPLE

RING GEAR SIDE OPPOSITE SIDE

Combined total of: Combined total of:

Service Spacer (A ) Service Spacer (A)
.250" .265"
Service Shim (B ) Service Shim (B)
Feeler Gauge (C ) Feeler Gauge (C)

TO M AINTAIN PROPER BACKLASH (.005” - .008"), ring gear is

- .010" + .010"
moved away from pinion by subtracting .010" shims from ring gear
.240" .275”
side and adding .010" shims to other side

TO OBTAIN PROPER PRELOAD on side bearings, add .004" shims

+ .004" + .004"
to each side.

Shim dimension required Shim dimension required

.244” .279"
for ring gear side for opposite side

Fig. 4B -7--D eterm ining Side Bearing Shim Requirem ents 7 -1 /2 "

from the housing. Discard the pinion oil seal, nut and 2. If rear pinion bearing is to be replaced, drive outer
collapsible spacer. Use a new seal, nut and spacer on race from carrier using a drift in slots provided for this
reassembly. purpose.
3. Remove rear pinion bearing from pinion shaft using
Bearing Removal and Cup Replacement rear pinion bearing remover J-8612 for the 8-1/2" ring gear,
1. If front pinion bearing is to be replaced, drive outer J-9746-02 for the 8-3/4" ring gear, and J-21493-01 for the
race from carrier using drift in slots provided for this 7-1/2" ring gear. See figure 4B-16.
purpose. Tap alternately on opposite sides of bearing cup Tighten nuts on tool until plates are under the bearing
to avoid cocking. inner race. Then, set tool on press. Make sure the plates
4B-8 REAR AXLE DIFFERENTIAL

A -S E R V IC E SPACER
B - SERV ICE SHIM
C - F E E LE R GAUGE

BEARING

CA R RIER

Tool J-22779
RING GEAR

EXAMPLE

RING GEAR SIDE OPPOSITE SIDE

Thickness of Tool J-22779 Combined total of:
required to force ring Service Spacer (A)
.250' .265"
gear into contact with Service Shim (B)
pinion Feeler Gauge (C)

TO MAINTAIN PROPER BACKL,*\SH (.005" - .008"), ring gear is

- .010" + .010"
moved away from pinion by subt racting .010" shims from ring gear
.240" .275"
side and adding .010" shims to othe r side

TO OBTAIN PROPER PRELOAD on side bearings, add .004" shims

+ .004" + .004"
to each side.

Shim dimension required Shim dimension required

.244" .279"
for ring gear side for opposite side

Fig. 4B-8~Side Bearing Shim Requirements 8 -1 /2 " and 8-3 /4 "

 REAR AXLE DIFFERENTIAL 4B-9

Fig. 4B-1 1--Checking Ring Gear Backlash

Fig. 4B-9--Measuring Gauge Thickness

Setting Pinion Depth and Installing Pinion

straddle opening on press. Do not position bolts across Bearings
opening. To do so may bend the bolts when pressure is
applied. Press bearing from pinion. Record thickness of NOTE: If the original ring gear and pinion and the
shim removed from between bearing and pinion head. pinion rear bearing assembly are to be reinstalled, the
4. Inspect carrier pinion bearing bores and shoulders original shim thickness may be used.
for nicks. Remove as necessary. Clean the bores and the Ring and pinion gear sets are matched in a special test
installation tools. machine which permits adjustment of pinion depth in ring
5. Lubricate both outer cups with liberal amounts of gear until a point is reached where best operation and proper
hypoid lubricant. tooth contact under load is obtained. At this point, the
6. Install the rear cup, with the large end against the setting of the pinion with reference to the centerline of the
bore shoulder, using Rear Pinion Bearing Cup Installer J- ring gear is indicated by the machine. This setting may vary
8608 for the 8-1/2" ring gear, J-9745 for the 8-3/4" ring slightly from the design or "nominal" setting due to
gear and J-6197 for the 7-1/2" ring gear, as shown in figure allowable variation in machining the parts. When a pinion
4B-17. is found having a plus or minus reading recorded in
7. Install the front cup, with the large end against the thousandths on the rear face of the pinion, this indicates that
bore shoulder, using Installer J-8611-01 for the 8-1/2" and the pinion during testing was found to have best tooth
8-3/4" ring gear and J-7817 for the 7-1/2" ring gear as contact at a position varying from design or nominal depth.
shown in figure 4B-18. In order to compensate for all of the allowable
8. Check both bores to make sure cups are fully seated. machining variables, a procedure of gauging the carrier and
shimming the pinion has been developed. After gauging a
carrier, the assembler must install the appropriate shim

Fig. 4 B -1 0 -ln s ta llin g Differential Shim Fig. 4B-1 2 -C h e c k in g Ring Gear Runout
4B-10 REAR AXLE DIFFERENTIAL

between the drive pinion shoulder and rear bearing so that required to rotate the bearings as shown in figure 4B-20.
pinion depth can be adjusted to the required position for best 5. Mount the side bearing discs J-21777-45 on the ends
tooth contact in each axle assembly. of arbor J-21777-1 (8-1/2" and 8-3/4" ring gear). Side
Proper pinion depth is determined with Pinion Setting bearing discs J-21777-45 on the ends of arbor J-23597-1 (7-
Gauge J-21777-01 for the 8-1/2" and 8-3/4" ring gear, 1/2" ring gear), using the step of the disc that corresponds
gauge J-23597-01 for the 7-1/2" ring gear. to the base of the carrier.
1. Clean the housing assembly and all gauge parts to 6. Place the arbor and plunger assembly into the
insure accurate measurements. carrier, being sure the side bearing discs are seated properly.
2. Lubricate front and rear pinion bearings which will 7. Install the bearing caps finger tight to prevent the
be used in final assembly and position them in their discs from moving.
respective races in the carrier. 8. Position dial indicator J-8001 on the mounting post
3. Position gauge plate J-21777-29 on preload stud J- of the arbor with the contact button resting on the top
21777-43 (8-1/2" and 8-3/4" ring gear) J-23597-11 on surface of the plunger.
preload stud J-21777-43 (7-1/2" ring gear), insert stud 9. Preload the dial indicator one half revolution and
through rear bearing and pilot J-21777-35 (8-1/2" and 8-3/ tighten in this position.
4" ring gear) J-23597-12 (7-1/2" ring gear) and through 10. Place the plunger onto the guage plate. For 8-1/2"
front bearing and pilot J-21777-42. Insert the hex nut until and 8-3/4" ring gear select the button on the gauge plate
snug and rotate the bearings to make sure they are properly that corresponds to the ring gear size and rotate the plate
seated. See figure 4B-19 for illustration of proper until the plunger rests directly upon that button.
positioning. 11. Rock the plunger rod slowly back and forth across
4. Hold the preload stud stationary with a wrench on the button until the dial indicator reads the greatest
the flats and tighten hex nut until 20 in. lbs. of torque are deflection. At this point, set the dial indicator to zero. Tools

Fig. 4B-14--Drive Pinion Flange Removal Fig. 4B-1 6-R em ov in g Drive Pinion Rear Bearing Typical
 REAR AXLE DIFFERENTIAL 4 B -1 1

Fig. 4B-1 7—Installing Pinion Rear Bearing Cup

will now be positioned as shown in figure 4B-21. 14. Check the rear face of the drive pinion being
installed for a pinion code number. This number indicates
NOTE: Select the gauging button that corresponds to the necessary alteration of the pinion shim thickness as
the ring gear size for the 8-1/2" and 8-3/4" ring gear. determined in step 13.
The 8-7/8" button should be used for the 8-3/4" ring a. If the pinion is stamped with a plus + number, add
gear. that many thousandths to the indicator reading. For
It is important to use a dial indicator correctly example, if indicator reading is .019, and pinion is marked
when determining pinion depth requirements. Be sure + 2, the correct depth shim for installation will be .019 +
to record the number indicated by the indicator needle; .002 = .021 inch.
do not record the amount of travel of the needle. b. If the pinion has no plus + or minus - number, use
After "zeroing" the dial indicator on the highest the indicator reading as the correct shim thickness.
point of deflection on the gauge plate, the indicator c. If the pinion is stamped with a minus (-) number,
probe is swung off the gauge plate, allowing the needle subtract that many thousandths from the indicator reading.
to move. The number which the needle points toward For example, if the indicator reading is .031, and pinion is
is the correct shim thickness required for a nominal marked (-3), the correct depth shim for installation will be
pinion. See figure 4B-22. .031 -.003 = .028 inch.
12. Repeat the rocking action of the plunger several 15. Remove bearing caps and depth gauging tools from
times to verify the setting. carrier.
13. Once the zero reading is obtained, swing the 16. Position the shim selected in step 14 on the pinion
plunger until it is removed from the gauging plate button. shaft against pinion head.
The dial indicator will now read the required pinion 17. Lubricate the rear pinion bearing with liberal
shim thickness for a "nominal" pinion. Record this size. amounts of hypoid lubricant and install rear bearing onto

Fig. 4B-1 8 —Installing Pinion Front Bearing Cup Fig. 4 B - 2 0 - M e a s u r i n g Rotating Torque
4B-12 REAR AXLE DIFFERENTIAL

pinion using J-8609-01 (8-1/2" and 8-3/4" ring gear) J-

21022-02 (7-1/2" ring gear) as shown in figure 4B-23.
Installation and Adjustm ent
1. Lubricate the front bearing with liberal amounts of
hypoid lubricant, and place into outer cup.
2. Place a new pinion oil seal into position in carrier
bore. Tap lightly with a protective plate and a hammer until
seal flange seats against carrier, as shown in figure 4B-24.
3. Coat lips of pinion oil seal and seal surface of pinion
flange with gear lube.
4. Install a new pinion bearing spacer onto the drive
pinion.
5. Remove nut and sleeve from Companion Flange
Installer J-9458. Screw J-9458 onto drive pinion and insert
assembly into housing.
6. Position companion flange onto drive pinion. Install
sleeve and nut onto J-9458.
7. Install Companion Flange Holding Tool J-8614-11.
See Figure 4B-25.
8. Tighten nut on Tool J-9458 which draws drive
pinion through front bearing and companion flange.
Tighten only until end play is removed from drive pinion
then remove Tool J-9458.
NOTE: When no further end play is detectable, and
when Holder J-8614-11 will no longer pivot freely as Fig. 4B-22~Use of Dial Ind icator
pinion is rotated, bearing preload specifications are
being neared. Further tightening should be done only additional tightening of the pinion nut as little as 1/8
after nut and washer installation and preload has been turn can add 5 additional inch pounds drag. Therefore,
checked with a torque wrench.
9. Lubricate cavity between end of pinion splines and the pinion nut should be further tightened only a little
pinion flange with a non-hardening sealer (such as Permatex at a time and torque should be checked after each slight
Type A or equivalent) and install washer. Lubricate new nut amount of tightening. Exceeding torque specifications
threads with a liberal amount of hypoid lubricant, and may compress the collapsible spacer too far and require
install on pinion snugly. its replacement.
10. Check preload by using an inch pound torque 11. While observing the preceding caution, carefully set
wrench such as J-5853 as shown in Figure 4B-26. preload drag at 20-25 in lb. on new bearings or 10-15 in.
lb. on reused bearings.
NOTE: After torque has been checked, final tightening 12. Rotate pinion several times to assure that bearings
should be done very cautionsly. For example, if when have been seated. Check preload again. If drag has been
checking, torque was found to be 5 inch pounds, reduced by rotating pinion, re-set preload to specification.
 REAR AXLE DIFFERENTIAL 4B-13

PROTECTIVE
TUBE O R PIPE

REAR P I N I O N B E A R IN G
INSTALLER

Fig. 4B -23~D rive Pinion Rear Bearing Installatio n Fig. 4 B -2 5 -D rive Pinion Flange In sta lla tio n

CHECKS A N D A D JU STM EN TS short life, or both. With a pattern check, the most desirable
Four adjustments are essential for proper operation of contact between ring gear and drive pinion for low noise
the differential and its related parts. These adjustments are level and long life can be assured.
a)Pinion Bearing Preload, b)Side Bearing Preload c(Pinion Gear Tooth Nomencalture
Depth and d)Ring Gear-to-Pinion Backlash. The side of the ring gear tooth which curves outward,
Pinion Bearing Preload is set to specifications in step or is convex, is referred to as the "drive" side. The concave
11 of "Drive Pinion- Installation and Adjustment". side is the "coast" side. The end of the tooth nearest center
Side Bearing Preload is set to specifications in step 6 of ring gear is referred to as the "toe" end. The end of the
of "Differential Case-Installation and Adjustment". tooth farthest away from center is the "heel" end. Toe end
Following service to the Differential Case or to the of tooth is smaller than heel end. See Figure 4B-27.
Drive Pinion and Ring Gear, a Gear Tooth Contact Pattern
Check must be made to verify the accuracy of the work in Test
1. Wipe oil out of carrier and carefully clean each tooth
setting the pinion depth and ring gear-to-pinion backlash. of ring gear.
Gear Tooth Contact Pattern Check 2. Use gear marking compound and apply this mixture
sparingly to all ring-gear teeth using a medium stiff brush.
Prior to final assembly of the differential, a Gear Tooth When properly used, the area of pinion tooth contact will
Contact Pattern Check is necessary to verify the correct be visible when hand load is applied.
relationship between ring ear and drive pinion. Gear sets 3. Tighten bearing cap bolts to 55 lb. ft. (47 lb. ft. for
which are not positioned properly may be noisy, or have B-type axles).
4. Expand brake shoes until a torque of 20-30 lb. ft. is
required to turn the pinion.

SEAL

LUBRICATE THIS
CARRIER CAVITY

Fig. 4 B-24~lnstalling Pinion Oil Seal Fig. 4 B - 2 6 - M e a s u r i n g Rotating Torque

4B-14 REAR AXLE DIFFERENTIAL

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.

NOTE: 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
Fig. 4B-27--Gear Tooth Nom enclature
thickness will move pinion farther away from centerline of
the ring gear.
NOTE: A test made without loading the gears will not Backlash is adjusted by means of the side bearing
give a satisfactory pattern. Turn companion flange with adjusting shims which moves the entire case and ring gear
wrench so that ring gear rotates one full revolution then assembly closer to, or farther from the drive pinion. (The
reverse rotation so that ring gear rotates one revolution adjusting shims are also used to set side bearing preload).
in opposite direction. Excessive turning of ring gear is To increase backlash, increase right shim and decrease left
not recommended. shim an equal amount. To decrease backlash, decrease right
5. Observe pattern on ring gear teeth and compare with shim and increase left shim an equal amount.
Figure 4B-28.
The important thing to note is that the contact pattern
Adjustm ents Affecting Tooth Contact is centrally located up and down on the face of the ring gear
Two adjustments can be made which will affect tooth teeth.
 REAR AXLE DIFFERENTIAL 4B-15

SER IES 10 TRU CK DIFFERENTIAL

8-7/8" RING GEAR
INDEX

Differential Case......................................................... 4B-15 Side Bearing Preload............................................... 4B-24

Removal and Disassembly....................................... 4B-15 Pinion Depth and Backlash..................................... 4B-24
Inspection.................................................................. 4B-16 Gear Tooth Contact Pattern Check....................... 4B-24
Side Bearing Replacement....................................... 4B-17
Ring Gear Replacement.......................................... 4B-17
Installation and Adjustment.................................... 4B-18 DIFFERENTIAL CASE
Drive Pinion................................................................ 4B-18 Removal and Disassembly
Removal..................................................................... 4B-18
Bearing Replacement............................................... 4B-20 NOTE: Before proceeding with following steps, it is
Setting Pinion Depth.................................................4B-21 advisable to check the existing ring gear to pinion
Installation and Adjustment.................................... 4B-23 backlash as described under "Checks and
Checks and Adjustments........................................... 4B-24 Adjustments". This will indicate gear or bearing wear
Pinion Bearing Preload............................................ 4B-24 or an error in backlash or pinion depth setting which
4B-16 REAR AXLE DIFFERENTIAL

l. Companion Flange 7. Differential Case 13. Cover 19. Thrust Washer

2. Deflector 8. Shim 14. Pinion Shaft 20. Differential Pinion
3. Pinion O il Seal 9. Gasket 15. Ring Gear 21. Shim
4. Pinion Front Bearing 10. Differential Bearing 16. Side Gear 22. Pinion Rear Bearing
5. Pinion Bearing Spacer 11 . "C" Lock 17. Bearing Cap 23. Drive Pinion
6. Differential Carrier 12. Pinion Shaft Lock Screw 18. Axle Shaft

Fig. 1B--Cross Section of Differential with 8 -7 /8 " Ring Gear

will help in determining cause of axle noise. Backlash may damage machined face o f caps.
should be recorded so that if same gears are reused, 5. Using a pry bar as shown in figure 2B, pry
they may be reinstalled at original lash to avoid differential case out of carrier. Exercise caution in prying
changing gear tooth contact. on carrier so that gasket sealing surface is not damaged. If
1. Remove screw that retains differential pinion shaft, the bearings are preloaded, the case will suddenly fall free
and remove pinion shaft. when it is pried past a certain point; therefore, make sure
2. Remove rear axle shafts as outlined in the Service case is properly supported to prevent damage. The bearing
Manual. caps may be loosely installed, as shown in Figure 2B, to
3. Roll out the differential pinions and thrust washers, prevent case from falling.
then remove side gears and thrust washers. Mark pinions 6. Place left and right bearing cups with bearing caps
and side gears so that they can be reassembled in original so that they may be reinstalled in original positions. Place
position. shims with appropriate cups.
4. Mark the bearing caps and housing for reassembly
in same position. Loosen bearing cap bolts. Tap surface of Inspection
bearing caps to loosen. 1. Clean all parts in cleaning solvent; inspect all bearing
cups, races and rollers for scoring, chipping or evidence of
CAUTION: Do not attempt to pry caps o ff as this excessive wear.
 REAR AXLE DIFFERENTIAL 4B-17

J—8092
J-22175

j _ 8 107-4

Fig. 2B~Differential Case Removal Fig. 4B -Differential Bearing Installation

2. Inspect axle shaft and side gear splines for evidence Ring Gear or D ifferential Case Replacement
of excessive wear. 1. Remove the ring gear bolts and, using a soft drift and
3. Inspect hypoid ring gear and pinion teeth for possible a hammer, tap ring gear off the case.
scoring, cracking or chipping.
4. Inspect differential case, pinions, side gears, thrust
washers and pinion shaft for cracks, scoring, spalling or
excessive wear. NOTE: Do not attempt to pry ring gear from case. To
5. Check fit of differential side gears in case. do so may damage machined surfaces.
2. Remove any nicks or imbedded dirt from case flange
D ifferential Bearing Replacement surface which mates with ring gear. Clean all surfaces.
1. Install Tool J-22888 and Adapter Plug J-8107-4, 3. Liberally coat the differential case pilot with hypoid
assuring puller legs are fitted securely in notches in case and lubricant. Pre-align ring gear and differential case bolt
against bearing cone, as shown in figure 3B. holes, and press on adaptor plug J-8107-4 to initially start
2. Tighten puller screw to remove bearing. ring gear on case pilot, as shown in figure 5B.
3. Place new bearing on hub with thick side of inner 4. Start all ring gear bolts during initial assembly to
race toward case and drive into place, using J-22175 and maintain bolt hole adlignment. Draw up all bolts evenly,
Driver Handle J-8092, as shown in figure 4B. using a criss-cross pattern to avoid cocking the gear on the
4. Before bearing installation on opposite hub, support case.
differential case on Adapter Plug J-8107-4. This allows
differential case to rest on adapter instead of bearing cage. 5. Insure that the gear is seated firmly against the case,
See figure 4B. Install remaining bearing as instructed in step then torque the bolts to 60 ft. lbs. for truck models.
3.

Fig. 3B -Differential Bearing Removal Fig. 5B--Ring Gear-to-Case Installation

4B-18 REAR AXLE DIFFERENTIAL

NOTE: Production preloading of the differential

bearings is accomplished by the use of cast iron preload
shim. These shims cannot be used when rebuilding the
carrier as they may break when tapped into place.
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. lbs.
Fig. 6 B--Installing G aging Tool
NOTE: At this point, the differential side bearings are
properly preloaded. If any adjustments are required in
Reassembly later procedures, make sure the preload remains as
1. Install thrust washers and side gears into case. If established in step 9. If backlash is changed in later
original parts are being reused, replace in original positions. steps, be sure the total thickness of the two shim packs
2. Position pinions and thrust washers through loading does not change.
hole in case 180° apart so they engage side gears. 13. Mount a dial indicator on the carrier and check the
3. Rotate gears until the differential pinion bores and backlash between the ring gear and pinion, as shown in
the case shaft holes are aligned. figure 10B. The backlash should be within the range of
4. Install pinion shaft and lock screw. It is not 0.005"-0.008". Check gear lash at four different equally
necessary to torque lock screw until axle shafts are installed. spaced positions around the gear. Variation in readings
5. Differential may be installed in carrier now, or after should not exceed .001".
service is performed on the drive pinion.
NOTE: Position the dial indicator so that indicator
Installation and Adjustm ent button is perpendicular to tooth angle and in line with
1. Check condition of bearing, bearing cups, cup seat gear rotation.
in carrier and carrier caps to make sure that they are free 14. If variation in backlash readings exceeds .002";
from nicks, burrs and foreign material. measure ring gear and case runout as shown in figure 1IB.
2. Lubricate bearings with axle lubricant; position cups Gear runout should not exceed .003"; should runout exceed
on proper bearing, then install differential assembly in this limit, check ring gear and case for deformation and/or
carrier and support the assembly to prevent it from falling. foreign matter between case and gear.
3. Install strap J-22779-6 on left bearing by tightening 15. If gear lash is not within limits, correct by
bearing bolts alternately and evenly to snug fit. decreasing shim thickness on one side and increasing
4. With the ring gear tight against the pinion gear thickness of other shim the same amount. Total shim
(.000" to .001" backlash) insert gaging Tool J-22779 thickness must be maintained at all times to maintain proper
between the left bearing cup and carrier housing as shown preload.
in figure 6B. 16. Backlash changes approximately .002" for each
5. While oscillating tool, turn adjusting nut clockwise .003" change in shim dimensions.
until a noticeable drag is produced. If backlash exceeds .008", increase the shim thickness
6. Tighten lock bolt on side of tool. on the ring gear side, while decreasing the shim thickness
7. Between the right bearing and carrier, install Service on the opposite side an equal amount. If backlash is less
Spacer A (.170"), Service Shim B and Feeler Gage C. than .005", decrease the shim thickness on the ring gear
Thickness of Feeler Gage must be sufficient to produce a side, while increasing the shim thickness on the opposite
slight "drag" when moved between carrier and Service side an equal amount.
Shim.
8. Now measure the above dimensions as shown in DRIVE PINION
figure 7B. Removal
a. Using a micrometer as in figure 8B measure the 1. Remove differential as previously outlined.
thickness of J-22779 in a minimum of three places and 2. Check torque required to rotate drive pinion, as
average these readings. Record the result. described under "Drive Pinion - Installation and
b. Add together the dimensions of the Service Shim, Adjustment". If there is no preload reading, check for
Service Spacer and Feeler Gage. Record the result. looseness of pinion assembly by shaking (push-pull) the
9. Use the sample procedure in figure 7B to determine companion flange. Looseness indicates the need for bearing
the proper thickness for each shim pack. replacement.
 REAR AXLE DIFFERENTIAL 4B-19

EXAMPLE

RING GEAR SIDE OPPOSITE SIDE

Thickness of Tool J-22779 Combined total of:

required to force ring Service Spacer (A)
.250” .265"
gear into contact with Service Shim (B )
pinion Feeler Gauge (C)

TO MAINTAIN PROPER BACKLASH (.005" - .008"), ring gear is

- .010" + .010"
moved away from pinion by subtracting .010" shims from ring gear
.240" .275"
side and adding .010" shims to other side

TO OBTAIN PROPER PRELOAD on side bearings, add .004" shims

+ .004" + .004"
to each side.

.244" Shim dimension required Shim dimension required

.279"
for ring gear side for opposite side

Fig. 7B~De term ining Side Bearing Shim Requirements

4B-20 REAR AXLE DIFFERENTIAL

Fig. 8 B -M e a su rin g Gage Plate Thickness Fig. 10 B -C h eckin g Ring Gear Backlash

3. Install Holder J-8614-11 on flange by using two bolts from the housing. Discard the pinion oil seal, nut, and
with flat washers, as shown in figure 12B. Position J-8614- collapsible spacer. Use a new oil seal, nut and spacer on
11 on flange so that the four notches are toward the flange. reassembly.
4. Remove pinion nut and washer.
5. Thread end of J-8614-3 into small O.D. end of J- Bearing Removal and Cup Replacement
1. If front pinion bearing is to be replaced, drive outer
8614-2. Then with J-8614-11 installed as in step 3, insert race from carrier using a drift in slots provided for this
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 purpose. Tap alternately on opposite sides of the bearing cup
J-8614-11 as shown in figure 13B. to avoid cocking.
6. To remove the drive pinion, first thread the original 2. If rear pinion bearing is to be replaced drive outer
pinion nut half way on the pinion, for thread protection. race from carrier using a drift in slots provided for this
7. Place the differential cover temporarily back onto purpose.
the housing, using two screws. This will prevent the pinion 3. Remove rear pinion bearing from pinion shaft using
from falling to the floor during removal. press plate J-22912 as shown in Figure 15B.
8. Tap the end of the pinion nut with a large hammer Tighten nuts on tool until plates are under the bearing
and a soft drift, as shown in figure 14B. inner race. Then set the tool on a press. Make sure the plates
straddle the opening on the press. Do not position bolts
NOTE: Care must be taken not to damage pinion across the opening. To do so may bend the bolts when
bearings while removing pinion from carrier. Inspect pressure is applied. Press bearing from pinion. Record the
bearings and cups for damage and replace if needed. thickness of shim removed from between bearing and pinion
9. Remove the pinion oil seal and the front pinion head.
bearing. Remove the cover and retrieve the drive pinion 4. Inspect carrier pinion bearing bores and shoulders

Fig. 9 B -ln s ta llin g Differential Shim Fig. 1 1 B -Checking Ring Gear Runout
 REAR AXLE DIFFERENTIAL 4B-21

Fig. 12B~Drive Pinion Nut Removal

for nicks. Remove as necessary. Clean the bores and the ring gear is indicated by the machine. This setting may vary
installation tools. slightly from the design or "nominal" setting due to
5. Lubricate both bearing cups with liberal amounts of allowable variation in machining the parts. When a pinion
hypoid lubricant. is found haivng a plus or minus reading recorded in
6. Install the rear cup, with the large end against the thousandths on the rear face of the pinion, this indicates that
bore shoulder, using Installer J-0270-14 for Truck models the pinion during testing was found to have best tooth
as shown in figure 16B. contact at a position varying from design or nominal depth.
7. Install the front cup, with the large end against the In order to compensate for all of the allowable
bore shoulder, using Installer J-7137 as shown in figure 17B. machining variables, a procedure of gaging the carrier and
8. Check both bores to make sure cups are fully seated. shimming the pinion has been developed. After gaging a
carrier, the assembler must install the appropriate shim
Setting Pinion Depth and Installing Pinion between the drive pinion shoulder and rear bearing so that
Bearings pinion depth can be adjusted to the required position for best
tooth contact in each axle assembly.
NOTE: If the original ring tear and pinion and the Proper pinion depth is determined with Pinion Setting
pinion rear bearing assembly are to be reinstalled, the Gage J-21777-01.
original shim thickness may be used. 1. Clean the housing assembly and all gage parts to
Ring and pinion gear sets are matched in a special test insure accurate measurements.
machine which permits adjustment of pinion depth in ring 2. Lubricate front and rear pinion bearings which will
gear until a point is reached where best operation and proper be used in final assembly and position them in their
tooth contact under load is obtained. At this point, the respective races in the carrier.
setting c f the pinion with reference to the centerline of the 3. Use cloverleaf gage plate J-21777-36 mounted on

Fig. 13B--Drive Pinion Flange Removal Fig. 1 5 B -R em ov in g Drive Pinion Rear Bearing
4B-22 REAR AXLE DIFFERENTIAL

Fig. 1 6 B—Installing Pinion Rear Bearing Cup

preload stud J-21777-43 insert stud through rear bearing to the ring gear size and rotate the plate until the plunger
and pilot J-21777-35, and through front bearing and pilot rests directly upon that button.
J-21777-42. Install the hex nut until snug and rotate the 11. Rock the plunger rod slowly back and forth across
bearings to make sure they are properly seated. See figure the button until the dial indicator reads the greatest
18B for illustration of proper positioning. deflection. At this point, set the dial indicator to zero. Tools
4. Hold the preload stud stationary with a wrench on will now be positioned as shown in figure 20B.
the flats and tighten hex nut. Tighten until 20 in. lbs. of 12. Repeat the rocking action of the plunger several
torque are required to rotate the bearings, as shown in figure times to verify the setting.
19B. 13. Once the zero reading is obtained, swing the
5. Mount the side beairng discs J-21777-45 on the ends plunger until it is removed from the gaging plate button.
of arbor J-21777-1, using the step of the disc that The dial indicator will now read the required pinion
corresponds to the bore of the carrier. shim thickness for a "nominal" pinion. Record this figure.
6. Place the arbor and plunger assembly into the 14. Check the rear face of the drive pinion being
carrier, being sure the side bearing discs are seated properly. installed for a pinion code number. This number indicates
7. Install the bearing caps finger tight to hold the discs the necessary alteration of the pinion shim thickness as
from movement. determined in step 13.
8. Position dial indicator J-8001 on the mounting post a. If the pinion is stamped with a plus ( + ) number,
of the arbor with the contact button resting on the top add that many thousandths to the indicator reading. For
surface of the plunger. example, if indicator reading is .019, and pinion is marked
9. Preload the dial indicator one-half revolution, and ( + 2), the correct depth shim for installation will be .019
tighten in this position. + .002 = .021 inch.
10. Select the button on the gage plate that corresponds b. If the pinion has no plus ( + ) or minus (-), use the

Fig. 1 7 B—Installing Pinion Front Bearing Cup Fig. 19 B - M e a s u r i n g Rotating Torque

 REAR AXLE DIFFERENTIAL 4B-23

Fig. 2 0 B -G a g in g Tools Installed in C arrier - Truck Fig. 2 2 B -ln s ta llin g Pinion Oil Seal - Truck

indicator reading as the correct shim thickness.

c. If the pinion is stamped with a minus (-) number, to press seal into bore until gage plate is flush with the
subtract that many thousandths from the indicator carrier shoulder and seal flange. Turn gage plate 180°)2 seal
reading. For example, if the indicator reading is .031, and must be square in carrier to seal propberly.
pinion is marked (-3), the correct depth shim for installation 3. Coat lips of pinion oil seal and seal surface of pinion
will be .031 - .003 = .028 inch. flange with hypoid lubricant.
15. Remove bearing caps and depth gaging tools from 4. Install a new pinion bearing spacer onto drive pinion.
carrier. 5. Place drive pinion into position, and mount a
16. Position the shim selected in step 14 on the pinion suitable thick washer or sheet metal plate over the pinion
shaft against pinion head. stem. Install the original pinion nut and tighten sufficiently
17. Lubricate the rear pinion bearing with liberal to draw pinion through the front bearing far enough to leave
amounts of hypoid lubricant and install rear bearing. Use threads exposed when the companion flange is placed into
J-5590 for truck models, as shown in figure 21B. position. Remove the washer and install the companion
flange, using J-8614-11.
Installation and Adjustm ent
1. Lubricate the front bearing with liberal amounts of pinion. 6. Tighten nut until all end play is removed from drive
hypoid lubricant, and place into outer cup.
2. Position seal in bore and place gage plate J-22804-2 NOTE: When no further end play is detectable, and
over seal and against flange. Gage plate insures proper when Holder J-8614-11 will no longer pivot freely as
seating of seal in carrier bore. See figure 22B. Use J-23911 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 23B, to measure
the rotating torque.
NOTE: After torque has been checked, final tightening
should be done very cautionsly. 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.
8. Rotate the pinion several times to assure that
bearings have been seated. Check preload again. If drag has
Fig. 2 1 B—Installing Rear Bearing - Truck been reduced, re-set preload to specifications.
4B-24 REAR AXLE DIFFERENTIAL

Fig. 23B --M easuring Rotating Torque Fig. 2 4 B -G e a r Tooth Nom enclature

CHECKS AND AD JU S TM E N TS
required to turn the pinion.
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) NOTE: A test made without loading the gears will not
Pinion Depth and d) Ring Gear-to-Pinion Backlash. give a satisfactory pattern. Turn companion flange with
Pinion Bearing Prelaod is set to specifications in step wrench so that ring gear rotates one full revolution then
7 of "Drive Pinion-Installation and Adjustment". reverse rotation so that ring gear rotates one revolution
in opposite direction Excessive turning of ring gear is
Side Bearing Preload is set to specifications in step 9 not recommended.
of "Differential Case-Installation and Adjustment". 5. Observe pattern on ring gear teeth and comapre with
Following service to the Differential Case or to the Figure 25B.
Drive Pinion and Ring Gear, a Gear Tooth Contact Pattern
Check must be made to verify the accurace of the work Adjustm ents A ffecting Tooth Contact
in setting the pinion depth and the ring gear-to-pinion Two adjustments can be made which will affect tooth
backlash.
contact pattern. These are backlash and position of drive
Gear Tooth Contact Pattern Check pinion in carrier. The effects of bearing preloads are not
readily apparent on hand loaded teeth pattern tests;
Prior to final assembly of the differential, a Gear Tooth however, these adjustments should be within specifications
Contact Pattern Check is necessary to verify the correct before proceeding with backlash and drive pinion
relationship between ring gear and drive pinion. Gear sets adjustments.
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 NOTE: It may be necessary to adjust both pinion depth
level and long life can be assured. and backlash to obtain the correct pattern.
The position of the drive pinion is adjusted by
Gear Tooth Nomenclature increasing or decreasing the shim thickness between the
The side of the ring gear tooth which curves outward, pinion head and inner race of rear bearing. The shim is used
or is convex, is referred to as the "drive" side. The concave in the differential to compensate for manufacturing
side is the "coast" side. The end of the tooth nearest center tolerances. Increasing shim thickness will move the pinion
of ring gear is referred to as the "toe" end. The end of the closer to centerline of the ring gear. Decreasing shim
tooth farthest away from center is the "heel" end. Toe end thickness will move pinion farther away from centerline of
of tooth is smaller than heel end. See figure 24B. the ring gear.
Test Backlash is adjusted by means of the side bearing
1. Wipe oil out of carrier and carefully clean each tooth adjusting shims which moves the entire case and ring gear
of ring gear. assembly closer to, or farther from the drive pinion. (The
adjusting shims are also used to set side bearing preload).
2. Use gear marking compound and apply this mixture To increase backlash, increase right shim and decrease left
sparingly to all ring gear teeth using a medium stiff brush. shim an equal amount. To decrease backlash, decrease right
When properly used, the area of pinion tooth contact will shim and increase left shim an equal amount.
be visible when hand load is applied. The important thing to note is that the contact pattern
3. Tighten bearing cap bolts to 55 lb. ft. is centrally located up and down on the face of the ring gear
4. Expand brake shoes until a torque of 20-30 lb. ft. is teeth.
 REAR AXLE DIFFERENTIAL 4B-25

Fig. 25B--Gear Tooth Contact Pattern Check

CORVETTE DIFFERENTIAL
INDEX

Differential Case...........................................................4B-25 Pinion Depth and Backlash..................................... 4B-33

Removal and Disassembly.........................................4B-25 Gear Tooth Contact Pattern Check....................... 4B-33
Side Bearing Replacement.........................................4B-26
Ring Gear Replacement............................................4B-27
Reassembly................................................................ ..4B-27 DIFFERENTIAL CASE
Drive Yoke Bearing Replacement.......................... ..4B-27 Removal and Disassembly
Installation and Adjustment......................................4B-27 1. Clamp carrier in Holding Fixture J-3289.
Drive Pinion................................................................ ..4B-29 2. Remove snap rings securing side gear yokes and pull
Removal........................................................................4B-29 yokes out of carrier. See figure 1C.
Bearing Replacement............................................... ..4B-30 3. Mark differential bearing caps for reassembly in
Setting Pinion Depth............................................... ..4B-31 same relative location and remove caps.
Installation and Adjustment......................................4B-32 4. Pull differential assembly out of carrier, taking care
Checks and Adjustments.............................................4B-33 not to damage machined mounting surface on carrier. See
Pinion Bearing Preload............................................ ..4B-33 figure 2C. Remove differential bearing shims and mark for
Side Bearing Preload............................................... ..4B-33 future reference.
4B-26 REAR AXLE DIFFERENTIAL

i
1. Cover B olt 11. D iffere ntia l Pinion 19. Side Bearing Cap 26. Side Gear Yoke
2 C arrier Cover Pin Retainer B olt Bearing Seal
3. F iller Plug 12. H ypoid Ring Gear 20. Side Bearing Cap 27. Side Gear Yoke
4. Cover Gasket 13. H ypoid Drive Pinion 21. D iffere ntia l Side 28. Pinion Front Bearing
5 D iffere ntia l Pinion 14. Pinion Bearing Shim Bearing Cup
6. Ring Gear B olt 15. Pinion Rear Bearing 22. Side Bearing Cup 29. Pinion Front Bearing
7. D iffere ntia l Case 16. Pinion Rear Bearing 23. Side Bearing Shim 30. Pinion Oil Seal
8. Pinion Shaft Cup and Spacer 31. Com panion Flange
9. D iffere ntia l Side Gear 17. Pinion Bearing 24. D iffere ntia l Carrier 32 Pinion W asher
10. Side Gear Thrust Spacer 25. Side Gear Yoke 33. Pinion Nut
W asher 18. Side Gear Yoke Snap Bearing
Ring

Fig. 1C -C arrier Assem bly - Exploded V iew

5. To disassemble, and reassemble, follow procedures

outlined in "Limited Slip Differential Unit" section.
Inspection
1. Clean all gears and bearings in cleaning solvent and
blow dry.
2. Inspect gears for scoring, pitting or cracks.
3. Inspect bearings for spalling, pitting or scoring.
Discard all parts that show excessive wear or failure.
4. Inspect side gear driveshaft yokes closely for spline
wear or yoke cracking. If equipment is available, use
magnetic penetrant method to check for minute fractures
in yokes or gears.
D ifferential Bearing Replacement
1. Place Puller J-22888 over differential bearing using
Adapter Plug 1-8107 in side gear bore. Tighten puller screw
to remove bearing as in figure 3C.
1. Install new bearing on hub using Installer J-22175.
See figure 4C.
3. Before bearing installation on opposite hub, support Fig. 2C~Removing D iffere ntia l Case
 REAR AXLE DIFFERENTIAL 4B-27

J 22888

Fig. 3C~Removing D iffere ntia l Bearing Fig. 5C--Ring Gear Guide Pins Installed

differential case on Adapter Plug J-8107-4. This allows Side Gear Yoke Bearing and/or Seal
differential case to rest on plug instead of bearing cage. See Replacement
figure 4C. Install remaining bearing. 1. Place new yoke bearings on Installer J-9773 and
Ring Gear or Differential Case Replacement install bearing into carrier bore using Handle J-7079-2. See
1. Remove ring gear bolts and tap ring gear off figure 6C Drive bearing until it is fully seated.
differential case. 2. Place a new seal on Installer J-9774 and install into
2. Install guide pins fabricated from 3/8-24 x 1 1/2" seal bore outboard of bearing as in figure 1C.
bolts with heads removed and ends slotted as shown in
figure 5C. Installation and Adjustm ent
1. Check condition of bearing cups, cup seat in carrier
3. Clean ring gear mounting surface and mounting and carrier caps to make sure they are free from nicks, burrs
flange on case. Place ring gear on pilot case diameter. and foreign material.
4. Install every other ring gear bolt and draw ring gear 2. Lubricate bearings with axle lubricant. Position cups
up evenly until gear is seated against flange. on proper bearings then install differential assembly in
5. Remove guide pins and install remaining ring gear carrier as shown in figure 8C. Install right bearing cap,
bolts. Torque bolts to specifications. tightening the bolts to a snug fit.
3. Service spacers are available in one thickness only

J-7079-2

j-97 7 3

Fig. 4 C -D iffe re n tia l Bearing Installation Fig. 6C--lnstalling Side Gear Yoke Bearings
4B-28 REAR AXLE DIFFERENTIAL

Shim Identification
Shim Notches
Thickness
I.D. O.D.
.040 0 0
.042 4 1
.044 4 2
.046 4 3
.048 4 4
J- 9 7 7 4
.050 5 0
.052 5 1
.054 5 2
.056 5 3
.058 5 4
.060 6 0
.062 6 1
.064 0 2
.066 0 3
.068 0 4
Fig. 7 C—Installing Side Gear Yoke Seal
.070 1 0
.072 1 1
.074 1 2
- .170" plus or minus .001". Steel service shims are used with .076 1 3
the service spacer. See following Shim Chart for shim .078 1 4
availability and identification. .080 2 0
.082 2 1
NOTE: Production preloading of the differential .084 2 2
bearings is accomplished by the use of cast iron shims. .086 2 3
These shims cannot be used when rebuilding the carrier .088 2 4
.090 3 0
as they may break when tapped into place. .092 3 1
4. Install strap J-22779-6 on left bearing by tightening .094 3 2
bearing bolts alternately and evenly to a snug fit. .096 3 3
5. With the ring gear tight against the pinion gear .098 3 4
(.000" to .001" backlash), insert gaging Tool J-22779 .100 4 0
between the left bearing cup and carrier housing. See figure Fig. 9C--Shim C hart
10C. Turn adjusting nut clockwise while oscillating the tool
until a noticeable drag is produced.
6. Tighten lock bolt on side of the tool, then remove 9. The required thickness of the service shim is
tool. determined by subtracting the thickness of the service
7. Using a micrometer, measure the thickness of the spacer from the higher of the two averaged readings
gaging plates in a minimum of three places as shown in obtained in Steps 7 and 8.
figure 11C. Average these readings and record the result. Example:
8. Turn the ring gear 90 degrees and repeat Steps 5, 6
and 7. Gage thickness (higher reading) .254"

Fig. 8C~lnstalling Differential Assembly Fig. 10 C - M e a s u r i n g Differential Shim Requirement

 REAR AXLE DIFFERENTIAL 4B-29

Fig. 1 1C--Measuring Gage Plate Thickness Fig. 1 2C—I nsta 11i ng D iffere ntia l Shim

Service spacer minus .170" 18. If variation in backlash exceeds .003", measure ring
Service shim size (left side) .084" gear and case runout as shown in figure 14C. Gear runout
10. Install the selected shim between the service spacer should not exceed .003"; should runout exceed this limit,
and bearing. Remove strap J-22779-6 and install left bearing check ring gear and case for deformation and/or foreign
cap. Torque bearing cap bolts to specifications. matter between case and gear.
11. Remove right-hand bearing cap and install Tool 19. If gear lash is not within limits, correct by
J-22779 between right bearing cup and carrier housing. decreasing shim thickness on one side and increasing
12. Turn adjusting nut clockwise while oscillating tool thickness of the other shim the same amount. Total shim
until a noticeable drag is produced (bearing outer race thickness must be maintained to maintain proper preload.
rotates with tool). Remove tool and measure the thickness EXAMPLE: By decreasing shim on the right side .003"
of the gaging plate in a minimum of three places. Average and increasing shim thickness on the left side by .003",
these readings and record the results. backlash will decrease by .002".
13. Turn the ring gear 90 degrees and repeat Steps 11 DRIVE PINION
and 12.
14. The required thickness of the service shim is Removal
determined as in Step 9; however, an additional .008" must 1. Remove differential case as previously outlined.
be added to obtain proper side bearing preload. 2. Check pinion bearing preload as described under
EXAMPLE: "Drive Pinion - Installation and Adjustment". If there is no
Gage thickness (higher reading) .226" preload reading, check for looseness of pinion assembly by
Service spacer used minus .170" shaking the companion flange. Looseness indicates the need
Difference .056" for bearing replacement.
For preload add .008" 3. Turn holding fixture over and install Holder J-8614-
Service shim size .064"
NOTE: Service shims are available in increments of
.002 in.- if the shim measurement falls between the
available shims, select a shim thinner by .001 inch.
15. Install the selected shim between the service spacer
and bearing, using a soft face hammer. See figure 12C.
16. Install the right bearing cap and torque both
bearing caps to specifications.
17. Mount a dial indicator on the carrier and check
backlash between the ring gear and pinion, as shown in
figure 13C. Backlash should be within the range of .003"
to .010" with a reading of .005" to .008" preferred. Check
reading at four equally spaced positions around the ring
gear. Variation in reading should not exceed .003".
NOTE: Position the dial indicator so that indicator
button is perpendicular to tooth angle and in line with
gear rotation. Fig. 1 3 C -C h e c k in g Backlash
4B-30 REAR AXLE DIFFERENTIAL

J— 8 6 1 4 - 3

\
J— 8 6 1 4 - 1 1

Fig. 14C~Checking Ring Gear Runout Fig. 16C -R em oving C om panion Flange

11 on flange by using two bolts with flat washers, as shown Inspection

in figure 15C. Position J-8614-11 on flange so that the four 1. Clean all gears and bearings in cleaning solvent and
notches are toward the flange. blow dry.
4. Remove pinion nut and washer. Discard pinion nut
and use a new one upon reassembly. NOTE: Do not spin bearings during drying process.
The extremely fast spinning and lack of lubrication
5. Thread end of J-8614-3 into small O.D. end of J- may quickly result in the failure of an otherwise
8614-2. Then with J-8614-11 installed as in Step 3, insert reusable bearing.
J-8614-2 into J-8614-11 and turn it 1/8 of a turn to locked 2. Inspect gears for scoring, pitting or cracks.
position. Remove flange by turning J-8614-3 while holding 3. Inspect bearings for spalling, pitting or scoring.
J-8614-11 as shown in figure 16C. Discard all parts that show excessive wear or failure.
6. With companion flange removed, drive pinion and Pinion and/or Bearing Replacement
rear bearing assembly can be removed from carrier. 1. If necessary to replace pinion bearings, tap old cups
7. Pry companion flange seal out of carrier using out of carrier using a brass drift. See figure 17C. Tap
screwdriver and discard seal. Remove pinion front bearing alternately on opposite sides of cup to prevent cups from
assembly. cocking in carrier. Inspect cup seats and bore for any nicks
or burrs and remove as necessary before installing new
8. Pry differential side gear yoke seals out of carrier and bearing cups.
discard seals. Using a piece of 1 3/4" O.D. pipe of suitable 2. Select front and rear pinion bearings and drive cups
length, tap yoke bearings out of bore. into carrier using Drive Handle J-8092 and Cup Installers
J-8608 for the rear cup and J-7137 for front cup. See figures
18C and 19C. Seat cups securely and squarely against
shoulders in carrier.

J-8614-11

Fig. 1 5C--Removing Companion Flange Nut Fig. 1 7 C -R em ov in g Pinion Bearing Cup

 REAR AXLE DIFFERENTIAL 4B-31

Fig. 20 C -R e m oving Pinion Rear Bearing

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
3. Remove pinion rear bearing using Press Plates J- is found having a plus or minus reading recroded in
9771 in Holder J-0358-1 as shown in figure 20C. Remove thousandths on the rear face of the pinion, this indicates that
and discard shim between bearing and gear head. the pinion during testing was found to have best tooth
Setting Pinion Depth
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
NOTE: If the original ring gear and pinion and the shimming the pinion has been developed. After gaging a
pinion rear bearing assembly are to be reinstalled, the carrier, the assembler must install the appropriate shim
original shim thickness may be used. between the drive pinion shoulder and the rear bearing so
Ring and pinion gear sets are matched in a special test that pinion depth can be adjusted to the required position
machine which permits adjustment of pinion depth in ring 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 accuracy of measurements.
2. Lubricate the front and rear pinion bearings which
will be used in final assembly and position them in their
repsective races in the carrier.
3. With cloverleaf gage plate J-21777-36 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 make sure they are properly seated. See figure
21C for illustration of proper positioning.
4. Hold the preload stud stationary with a wrench on
the flats and tighten hex nut until 20 in. lbs. of torque are
required to rotate the bearings, as shown in figure 22C.
5. Mount the side bearing discs 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
Fig. 1 9 C--Installing Pinion Rear Bearing Cup of the arbor with the contact button resting on the top
4B-32 REAR AXLE DIFFERENTIAL

surface of the plunger. ( + 2), the correct depth shim for installation will be .019
9. Preload the dial indicator one half revolution, and + .002 = .021 inch.
tighten in this position. b. If the pinion has no plus ( + ) or minus N) number,
10. Select the button on the gage plate that corresponds use the indicator reading as the correct shim thickness.
to the ring gear size and rotate the plate until the plunger c. If the pinion is stamped with a minus (-) number,
rests directly upon that button. subtract that many thousandths from the indicator
11. Rock the plunger rod slowly back and forth across reading. For example, if the indicator reading is .031, and
the button until the dial indicator reads the greatest pinion is makred (-3), the correct depth shim for installation
deflection. At this point, set the dial indicator to zero. Tools will be .031 - .003 = .028 inch.
will now be positioned as shown in figure 23C. 15. Remove bearing caps and depth gaging tools from
12. Repeat the rocking action of the plunger several carrier.
times to verify the setting. 16. Position the shim selected in step 14 on the pinion
13. Once the zero reading is obtained, swing the shaft against the pinion head.
plunger until it is removed from the gaging plate button. 17. Install the rear bearing on drive pinion, using J-
The dial indicator will now read the required pinion 8609 as shown in figure 24C.
shim thickness for a "nominal" pinion. Installation and Adjustm ent
14. Check the rear face of the pinion being installed for 1. Lubricate pinion bearings and outer races and place
a pinion code number. This number indicates the necessary drive pinion in carrier.
alteration of the pinion shim thickness as determined in step 2. Place a new pinion bearing spacer over pinion so it
13. seats on inner race of rear bearing.
a. If the pinion is stamped with a plus ( + ) number, 3. Slide pinion front bearing cone and roller assembly
add that many thousandths to the indicator reading. For
example, if indicator reading is .019, and pinion is marked

Fig. 2 2 C ~ M e a s u rin g Rotating Torque Fig. 24C--lnstalling Pinion Rear Bearing

 REAR AXLE DIFFERENTIAL 4B-33

Fig. 25C --lnstalling C om panion Flange

Fig. 27C~Gear Tooth N om enclature

over pinion shaft so it seats against spacer.

4. Pack the cavity between the seal lips of the pinion CHECKS AND A D JU S TM E N TS
Four adjustments are essential for proper operation of
flange oil seal with a lithium-base extreme pressure the differential and its related parts. These adjustments are
lubricant. a) Pinion Bearing Preload, b) Side Bearing Preload, c)
5. Place oil seal in carrier bore and tap into position Pinion Depth and d) Ring gear-to-Pinion Backlash.
with a hammer and drift, until oil seal flange seats against Pinion Bearing Preload is set to specifications in step
the carrier. 8 of "Drive Pinion - Installation and Adjustment".
Side Bearing Preload is set to specifications in step 14
6. Install Companion Flange Using Holder J-8614-11 of "Differential Case - Installation and Adjustment."
and Installer J-5780. See figure 25C. Following service to the Differential Case or to the
7. Pack the cavity between end of pinion splines and Drive Pinion and Ring Gear, a Gear Tooth Contact Pattern
pinion flange with a nonhardening sealer (such as Permatex Check must be made to verify the accuracy of the work
Type A or equivalent) prior to installing washer and nut on in setting the pinion depth and Ring Gear-to-Pinion
pinion. backlash.
8. Install a new nut on pinion shaft. Tighten nut to Gear Tooth Contact Pattern Check
remove end play - continue alternately tightening in small Prior to final assembly of the differential, a Gear Tooth
increments, and checking preload with torque wrench J- Contact Pattern Check is necessary to verify the correct
5853 and adapter J-5810 until torque required to rotate relationship between ring gear and drive pinion. Gear sets
pinion is 20-30 in. lbs. for new bearings and seal, or 5-15 which are not positioned properly may be noisy, or have
in. lbs. when used parts are reinstalled. See figure 26C. 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
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 27C.
Test
1. Wipe oil out of carrier and carefully clean each tooth
of ring gear.
2. Use gear marking compound and apply this mixutre
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 lb. ft.
4. Expand brake shoes until a torque of 20-30 lb. ft. is
Fig. 2 6 C - M e a s u r i n g Rotating Torque required to turn the pinion.
4B-34 REAR AXLE DIFFERENTIAL

Fig. 28 C -G ea r Tooth C ontact Pattern

NOTE: A test made without loaidng the gears will not The position of the drive pinion is adjusted by
give a satisfactory pattern. Turn companion flange with increasing or decreasing the shim thickness between the
wrench so that ring gear rotates one full revolution then pinion head and inner race of rear bearing. The shim is used
reverse rotation so that ring gear rotates one revolution in the differential to compensate for manufacturing
in opposite direction. Excessive turning of ring gear is tolerances. Increasing shim thickness will move the pinion
not recommended. closer to centerline of the ring gear. Decreasing shim
5. Observe pattern on ring gear teeth and compare with thickness will move pinion farther away from centerline of
figure 28C. the ring gear.
Adjustm ents Affecting Tooth Contact Backlash is adjusted by means of the side bearing
Two adjustments can be made which will affect tooth adjusting shims which moves the entire case and ring gear
contact pattern. These are backlash and position of drive assembly closer to, or farther from the drive pinion. (The
pinion in carrier. The effects of bearing preloads are not adjusting shims are also used to set side bearing preload).
readily apparent on hand loaded teeth pattern tests: To increase backlash, increase right shim and decrease left
however, these adjustments should be within specifications shim an equal amount. To decrease backlash, decrease right
before proceeding with backlash and drive pinion shim and increase left shim an equal amount.
adjustments.
The important thing to note is that the contact pattern
NOTE: It may be necessary to adjust both pinion depth is centrally located up and do wn on the face of the ring gear
and backlash to obtain the correct pattern. teeth.
 REAR AXLE DIFFERENTIAL 4B-S5

CH EVRO LET SERIES 20-30 TRU CK DIFFERENTIAL

10-1/2" RING GEAR
INDEX

Differential Case..........................................................4B-35 4. Inspect bearings and hub for nicks, burrs or evidence
Removal.......................................................................4B-35 of abnormal wear.
Side Bearing Replacement........................................4B-35 5. To install bearings, place bearing onto hub, and use
Rear Gear Replacement..............................................4B-35 driver handle J-8092 and bearing installer J-24430 to drive
Disassembly and Reassembly...................................4B-35 bearing onto hub until it seats against the shoulder.
Installation and Adjustment.....................................4B-35 6. When installing the second bearing, support case on
Drive Pinion................................................................ ..4B-37 pilot plug as shown in figure 5E to prevent damage to first
Removal.......................................................................4B-37 bearing installed.
Disassembly.................................................................4B-37
Inspection.................................................................. ..4B-38 Ring Gear Replacement
Reassembly................................................................ ..4B-38 1. Remove the ring gear bolts and lock washers, and
Installation and Adjustment......................................4B-39 use a soft faced hammer to tap the ring gear from the case.
Checks and Adjustments........................................... ..4B-39 2. Place new ring gear into position on case and install
Pinion Bearing Preload............................................ ..4B-40 lock washers and bolts.
Side Bearing Preload............................................... ..4B-40 3. Torque bolts alternately to specifications.
Pinion Depth and Backlash.......................................4B-40 Disassembly of Case
Gear Tooth Contact Pattern Check.........................4B-40 1. Mark the case and cover halves with a scribe line
for reassembly in the same position.
DIFFERENTIAL CASE 2. With ring gear removed, separate case and cover.
Removal 3. Remove the internal parts and keep separated so they
1. Mount axle assembly in a bench vise or holding may be installed in the same relative positions.
fixture. Inspection
2. Remove cover bolts and cover, as seen in figure 2E, 1. Inspect the differential gears, pinions, thrust
and allow lubricant to drain into pan. washers, spider and all mating surfaces for evidence of
3. Remove axle shafts as outlined in Truck Service abnormal wear.
Manual. 2. Clean all parts thoroughly in suitable solvent.
3. Replace parts as necessary.
NOTE: Before proceeding with following steps, it is
advisable to check the existing ring gear to pinion Reassembly of D ifferential
backlash as described in Step 9 of "Differential Case 1. Lubricate internal parts with hypoid gear lubricant.
- Installation." This will indicate gear or bearing wear 2. Place differential pinions and thrust washers onto
or an error in backlash or pinion depth setting which spider.
will help in determining cause of axle noise. Backlash 3. Assemble differential gears and washers to case and
should be recorded so that if same gears are reused, cover.
then may be reinstalled at original lash to avoid 4. Assemble differential case and cover making sure
changing gear tooth contact. scribe marks align.
4. Remove adjusting nut lock retainers from bearing 5. Install ring gear and attaching bolts and lockwashers
caps. and torque alternately to specifications.
5. Mark bearing caps for reinstallation in the same 6. The differential may be installed into the carrier at
position, and remove caps. this point, or may be installed after servicing the drive
6. Loosen side bearing adjusting nuts, using J-24429 as pinion.
shown in figure 3E.
7. Remove differential from carrier. Installation and Adjustm ent
1. Place bearing cups over side bearings and lift the
Side Bearing Replacement differential assembly into the carrier. Install bearing caps,
1. Install bearing puller J-8107 onto one side bearing, making sure marked caps are installed in original positions.
with puller screw centered on pilot plug as shown in figure Secure the cap bolts snugly.
4E. Be sure to install puller fingers into notches of case, in 2. Loosen the right side adjusting nut and tighten the
order to pull on inner race only. left side nut, using J-24429 as shown in figure 3E, until the
2. Tighten puller screw, while rotating bearing to insure ring gear contacts the drive pinion. Do not force the gears
that bearing cage is not being distorted. into contact so as to bind them. At this point, zero lash is
3. Remove the other bearing in the same manner. obtained.
4B-36 REAR AXLE DIFFERENTIAL

1. Companion Flange 10. Straddle Bearing 19. Retainer Screw

2. Oil Deflector 11. RingGear 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. IE -C ro s s Section of C hevrolet Truck D iffere ntia l w ith 10 1 /2 " Ring Gear

3. Back off the left adjusting nut approximately two properly preloaded. If any additional adjustments are
slots. Install locking fingers into holes and fasten fingers to required in the following procedures make sure that the
bearing cap. preload remains as established. If one adjusting nut is
4. Tighten right adjusting nut firmly to force the case loosened the other nut must be tightened an equal
into solid contact with the left adjusting nut. am ount to maintain this preload.
5. Loosen right adjusting nut until it is free from its 9. Mount a dial indicator on the housing and measure
bearing, then retighten until it contacts the bearing. the backlash between the ring gear and pinion. Backlash
6. Tighten right adjusting nut approximately two slots should be from .003" to .012" with .005" to .008" preferred.
if used bearings are being installed, or three slots if new Refer to figure 6E.
bearings are being installed.
7. Install locking retainer into holes and attach fingers NOTE: If backlash is more than .012" loosen the right
to bearing cap. adjusting nut one slot and tighten left adjusting nut one
8. Torque bearing cap bolts to specifications. slot. If backlash is less than .003" loosen the left
adjusting nut one slot and tighten the right adjusting
NOTE: At this point the differential bearings are nut one slot.
 REAR AXLE DIFFERENTIAL 4B-37

Fig. 2E--Cover Removed from Carrier Fig. 4 E -D iffe re n tia l Bearing Removal

DRIVE P INIO N ASSEMBLY and washer. Discard the pinion nut and use a new one upon
Removal
reassembly.
1. Remove differential as previously outlined. 4. Thread end of J-8614-3 into small O.D. end of J-
2. Check pinion bearing preload as described under 8614-2. Then with J-8614-11 installed as a step 2, insert
"Drive Pinion - Reassembly". Record the result. If there is J-8614-2 into J-8614-11 and turn it 1/8 of a turn to locked
no preload reading, check for looseness of pinion assembly position. Remove flange by turning J-8614-3 while holding
by shaking the companion flange. Looseness indicates the J-8614-11 as shown in figure 9E.
need for bearing replacement. 5. Support the bearing retainer as shown in figure 10E
3. Remove the pinion bearing retainer bolts from the and press out the drive pinion. Do not allow drive pinion
housing as shown in figure 7E. to fall onto the floor.
4. Remove the pinion and bearing retainer assembly. 6. Separate the pinion flange, the oil seal, the front
It may be necessary to rap on the pilot end of the pinion bearing and the bearing retainer. The oil seal may have to
to assist the assembly from the carrier. be driven from the bearing reatiner if it is being replaced.
5. Record the thickness of the shims removed from 7. Drive the pinion front and rear bearing cups from
between the bearing retainer flange and the carrier housing. the bearing retainer, using a drift.
Disassembly 8. To remove the rear bearing, use J-22912 as shown
1. Clamp the pinion assembly in vise. in figure 11E.
2. Install Holder J-8614-11 on flange by using two bolts 9. Drive the pinion straddle bearing from the carrier
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

Fig. 3E-Loosening Adjusting Nuts Fig. 5E--Differential Bearing Installation

4B-38 REAR AXLE DIFFERENTIAL

Fig. 6E~M easuring Backlash Fig. 8E-R em oving Pinion Nut

housing, using a drift as shown in figure 12E. 5. Place bearing retainer, with cups in position, onto
the drive pinion. Install a new collapsible spacer into
Inspection
position.
1. Clean all parts in a suitable solvent and dry with air.
2. Inspect the drive pinion for chipped, cracked or 6. Press front bearing onto drive pinion.
excessively worn teeth and inspect the splines for wear. 7. Lubricate the oil seal lips with a lithium-base
3. Inspect the bearings for worn or pitted rollers or extreme pressure lubricant, and install the seal in the
races. Inspect the pinion flange splines for wear. retainer bore. Use J-24434 with driver handle J-8092. Press
4. Inspect the bearing retainer for cracks, the seal into the bore until it seats against internal shoulder.
imperfections, corrosion, pits and grooves. 8. Install pinion flange and oil deflector onto the
5. Replace parts as required. splines, then install lock washer and new pinion nut.
Reassembly 9. Clamp the pinion flange into a vise. Install J-8614-11
1. Lubricate all parts with hypoid lubricant. as in figure 8E. Tighten the nut to achieve proper bearing
2. Press pinion rear bearing onto drive pinion as shown preload.
in figure 13E, using J-24433. a. Proper preload is attained when rotational torque
3. Install the front end rear pinion bearing cups into required to rotate the pinion is 25-35 in. lbs. for new
the bearing retainer, using driver handle J-8092 on J-8608 bearings, or 5-15 in. lbs. for used bearings.
for the front cup, and on J-24432 for the rear cup.
4. Install the pinion straddle bearing into the carrier b. Tighten pinion nut to approximately 350 ft. lbs., then
housing, using driver handle J-8092 and installer J-23322, take a torque reading as shown in figure 15E, using J-5853.
as shown in figure 14E. c. Continue tightening pinion nut in small increments

J—8614-3

J—861 4-2
J -8 6 1 4 -1 1

Fig. 7E~Removing Retainer Bolts Fig. 9 E -R e m o v in g Flange

 REAR AXLE DIFFERENTIAL 4B-39

Fig. 10E~Pressing Drive Pinion from Bearing Retainer Fig. 1 2E--Removing Straddle Bearing

until proper preload is attained. the carrier housing, making sure the bolt holes align with
those of carrier, and that the mating surfaces are clean and
CAUTION: Over-tightening of pinion nut may free from foreign material.
collapse spacer too much, requiring its 5. Place the pinion retainer assembly into position, and
replacement. align bolt holes to carrier. Install retaining bolts and tighten
in a crosswise manner. Torque to specifications.
Installation and Adjustm ent
1. Examine the head of the drive pinion for a pinion 6. Following dirve pinion service, a Contact Pattern
depth code number. Check must be made.
2. Compare the depth code number with the number CHECK AND A D JU S TM E N TS
on the original pinion. Use the following chart to select the Four adjustments are essential for proper operation of
proper shim for preliminary setting of pinion depth. the differential and its related parts. These adjustments are
3. Refer to the thickness of the shim recorded earlier a) Pinion Bearing Preload, b) Side Bearing Preload, c)
in Pinion Removal procedures. Increase or decrease the Pinion Depth and d) Ring Gear-to-Pinion Backlash.
shim dimension as indicated by the chart in figure 16E. Pinion Bearing Preload is set to specifications in step
a. For example, if original shim measured .014 inch, 9 of "Drive Pinion Reassembly".
original code was -1 and new code is +2, the correct shim Side Bearing Preload is set to specifications in step 6
would be .014 inch plus .003 = .017 inch. of "Differential Case-Installation and Adjustment".
b. If original shim was .012 inch, original code +2, and Following service to the Differential assembly or to the
new code is -2, the correct shim would be .012 minus .004 Drive Pinion, the Pinion Depth and Ring-Gear-to-Pinion
= .008 inch. Backlash must be checked, using a Gear Tooth Contact
4. Place the pinion shim as determined in step 3 onto Pattern Check as outlined below.

Fig. 1 1E--Removing Pinion Rear Bearing Fig. 1 3 E--Installing Pinion Rear Bearing
4B-40 REAR AXLE DIFFERENTIAL

CODE NUMBER ON O RIGINAL PINION

+2 +1 0 -1 -2

+2 - ADD .001 ADD .002 ADD .003 ADD .004

CODE + 1 SUBT. -
ADD ADD ADD
NUMBER .001 .001 .002 .003
ON
SERVICE 0 SUBT. SUBT.
-
ADD ADD
PINION .002 .001 .001 .002

SUBT. SUBT. SUBT. ADD

-1 -
.003 .002 .001 .001

SUBT. SUBT. SUBT. SUBT.

-2 -
.004 .003 .002 .001

Fig. 1 4 E—Insta 11i n g S traddle Bearing Fig. 16E--Pinion Depth Codes

Gear Tooth Contact Pattern Check 3. Tighten bearing cap bolts to specifications.
Prior to final assembly of the differential, a Gear Tooth 4. Apply load to gears by expanding brake shoes or by
Contact Pattern Check is necessary to verify the correct wrapping a heavy rag around the companion flange to resist
realtionship between ring gear and drive pinion. Gear sets rotation.
which are not positioned properly may be noisy, or have
short life, or both. With a pattern check, the most desireable NOTE: A test made without loading the gears will not
contact between ring gear and drive pinion for low noise give a satisfactory pattern. Turn companion flange with
level and long life can be assured. wrench so that ring gear rotates one full revolution then
reverse rotation so that ring gear rotates one revolution
Gear Tooth Nomenclature
The side of the ring gear tooth which curves outward, in opposite direction. Excessive turning of ring gear is
or is convex, is referred to as the "drive" side. The concave not recommended.
side is the "coast" side. The end of the tooth nearest center 5. Observe pattern on ring gear teeth and compare with
of ring gear is referred to as the "toe-in" end. The end of figure 18E. Make adjustments as outlined below.
the tooth farthest away from center is the "heel" end. Toe 6. The important thing to achieve in the pattern check
end of tooth is smaller than heel end. See Figure 17E. and subsequent adjustments is to locate the contact pattern
centrally on the face of the ring gear teeth.
Pattern Check
1. Wipe oil out of carrier and carefully clean each tooth Pinion Depth Adjustm ent
of ring gear. 1. The pinion depth shim may be replaced as necessary
2. Use gear marking compound and apply this mixture to place the drive pinion at the correct depth. See figure 18E.
to ring gear teeth. When properly applied, the area of tooth 2. Depth shims are availabel from .006 inch to .024
contact will be clearly visible after load is applied. inch, in increments of .001 inch.

Fig. 1 5E--Measuring Rotating Torque Fig. 1 7 E - G e a r Tooth Nomenclature

 REAR AXLE DIFFERENTIAL 4B-41

Fig. 18E~Gear Teeth C ontact Pattern Check

Backlash Adjustm ent
1. Remove locking retainers from side bearing a. To increase backlash, loosen the left adjusting nut
adjusting nuts. and tighten the right adjusting nut an equal am ount .
2. Move adjusting nuts an equal amount in or out b. To decrease backlash, loosen the right adjusting nut
to achieve proper backlash. and tighten the left adjusting nut an equal amount.

DANA DIFFERENTIALS
10-1 / 2 . " RING GEAR
INDEX
Differential Case - Removal and Disassembly .....................................4B-42
Drive Pinion - Removal and Disassembly ...........................................4B-43
Differential Case - Reassembly ............................................................4B-44
Shim Requirements - Gauging Procedures .........................................4B-44
Drive Pinion - Assembly and Installation ............................................4B-45
Differential Case - Installation and Adjustment..................................4B-46
Checks and Adjustments ................................................................. ..4B-47
G ENERAL DESCRIPTION 2. The drive pinion assembly incorporates an inner and
This Dana Spicer axle is similar in design to other outer bearing shim pack. The inner shim is used to maintain
Salisbury type axles with the following exceptions: proper pinion depth. The outer shim is used to maintain
1. In order to remove the differential case, the carrier must proper preload on the pinion bearings,
be spread.
4B-42 REAR AXLE DIFFERENTIAL

1. Pinion N u t 11. P inio n Rear Bearing 21. D iffe re n tia l Spider

2. Washer 12. D rive P inion 22. D iffe re n tia l Side Gear
3. C om panion Flange 13. R ing Gear 23. Washer
4. O il Seal 14. D iffe re n tia l Case 24. P inio n Gear
5. O il Slinger 15. R ing Gear B o lt 25 Washer
6. P inion F ro n t Bearing 16. D iffe re n tia l Side Bearing 26. Gasket
7. F ro n t Bearing Cup 17. Side Bearing Cup 27. Cover
8. Preload Shim Pack 18. Side Bearing A d ju s tin g Shim s 28. C over Screw
9. P inion D ep th Shim Pack 19. Bearing Cap 29. D rain Plug
10. Rear Bearing Cup 20. Bearing Cap B o lt

Fig. 1 F-Dana D iffere ntia l w ith 1 0 -1 /2 " Ring Gear - Exploded V ie w

DIFFERENTIAL CASE shown in figure 2F, spread carrier a maximum of .015 inch.
Removal CAUTION: Do not exceed this dimension, as
1. Place vehicle on hoist with rear axle hanging free. carrier may be permanently damaged.
2. Remove wheel and tire assemblies. 8. Remove the dial indicator and use a prybar to
remove the differential case from the carrier. Record the
3. The axle shafts are full-floating type with flanged dimensions and location of the side bearing shims. Remove
outer end of shaft attached to wheel hub by studs and nuts. the spreader tool.
Wheel is supported by tapered roller bearings at outer end
of axle housing. Disassembly
a. Remove axle shaft to hub attaching nuts. 1. Remove differential side bearings by placing J-22912
under bearings and supporting plates on a press bed. Apply
b. Rap on axle shaft to loosen shaft from hub and force to pilot plug J-8107-3 to drive the case from the
remove shafts. bearing.
4. Remove plug in carrier and drain lubricant.
NOTE: Use care not to damage case hubs with tool
5. Remove cap screws and lock washers attaching cover J-22912.
to carrier. Remove cover and gasket. 2. Remove the ring gear bolts and the ring gear. Tap
6. Mark one side of carrier and matching cap for the ring gear with a soft-faced hammer to free it from the
reassembly in the same position. Remove bearing caps. case.
7. Using spreader tool J-24385, and a dial indicator as 3. Scribe both case halves for reassembly in same
 REAR AXLE DIFFERENTIAL 4B-43

Fig. 2F~Spreading the C arrier

position. shaking the companion flange. Looseness indicates the need

4. Remove bolts holding case halves together, as shown for bearing replacement.
in figure 3F. 3. Install Holder J-8614-11 on flange by using two bolts
5. Tap lightly on top half of case to free it from the with flat washers, as shown in figure 5F. Position J-8614-11
bottom half. Remove top half of case. on flange so that the four notches are toward the flange.
6. Lift out all internal parts. 4. Remove pinion nut and washer. Discard pinion nut
and use a new one upon reassembly.
Inspection
1. Clean all gears and bearings in solvent. Inspect cups, 5. Thread end of J-8614-3 into small O.D. end of J-
races and rollers for scoring, chipping or evidence of 8614-2. Then with J-8614-11 installed as in step 3, insert
excessive wear. 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
2. Inspect ring gear teeth and machined surfaces. J-8614-22 as shown in figure 6F.
Examine fit of internal gears. 6. Remove drive pinion from carrier. It may be
3. Inspect pinion cross-shaft. necessary to tap on the pinion with a soft faced hammer.
4. Replace parts as required. 7. With a long drift, tap on inner race of outer pinion,
DRIVE P INIO N bearing to remove pinion oil seal, slinger, gasket, outer
pinion cone and roller and shim pack. Tag shim pack for
Removal and Disassembly reassembly.
1. Remove differential as previously outlined. 8. Should inspection indicate necessity, pinion bearing
2. Check pinion bearing preload as described under cups can be removed from carrier using a long drift and
"Drive Pinion - Installation and Adjustment." If there is no hammer. Remove shims and oil slinger which are located
preload reading, check for looseness of pinion assembly by behind the inner bearing cup. Tag shims for reassembly.

Fig. 3 F - S e p a ra t in g Case Halves Fig. 5 F-R e m o v ing Pinion Nut

4B-44 REAR AXLE DIFFERENTIAL

J— 2 4 3 8 3

Fig. 6F -R em oving Com panion Flange Fig. 7 F—Installin g Side Bearing

9. Remove rear pinion bearing using J-22912, and an SHIM REQUIREM ENTS - GAGING
arbor press. PROCEDURES
Inspection Side Bearing Shims
1. Clean all gears and bearings in cleaning solvent and 1. With the pinion removed from the carrier, place the
inspect all bearing cups, races and rollers for scoring, bearing cups over the side bearings, and install the
chipping or evidence of excessive wear. On pinion bearing differential case into the carrier.
rollers, inspect large end of rollers for wear. This is where 2. Place the shim which was originally installed on the
wear is most evident on tapered roller bearings. ring gear side into its original position.
2. Inspect pinion splines and flange splines for evidence 3. Install the bearing caps lightly in their marked
of excessive wear. positions. Tighten the caps just enough to keep the bearings
3. Inspect ring gear and pinion teeth for possible in place.
scoring, cracking or chipping. 4. Mount a dial indicator on the carrier with the tip
4. Inspect differential case for cracks or scores or side of the indicator on the back face of the ring gear.
gears, thrust washers, and pinion thrust faces. 5. Position two screwdrivers between the bearing shim
5. Check fit of differential side gears in case. and carrier on the ring gear side of the case. Pull on the
6. Check fit of side gears and axle shaft splines. screwdrivers and force the differential case as far as possible
7. Inspect differential pinion shaft and spacer for away from the dial indicator.
scoring or evidence of excessive wear. 6. With force still applied, set the indicator dial to
"zero", being sure the probe is still in contact with the ring
DIFFERENTIAL CASE
gear.
Reassembly 7. Reposition the screwdrivers to the opposite side of
1. Assemble new washers to side gears. Apply a small the differential case as shown in figure 8F.
amount of hypoid lubricant on the side gear hubs. 8. Pull on the screwdrivers and force the differential
2. Assemble pinion gears and new washers onto cross case back toward the dial indicator. Repeat several times
shaft. until the same indicator reading is obtained.
3. Place side gears, pinion gears, cross shaft and 9. To the dial indicator reading, add the thickness of
washers into flanged half of case. the shim. Record the result, as this figure will be used during
4. Assemble top half of case to bottom half, making determination of side bearing shim requirements.
sure scribe marks are aligned. Pinion Shims
5. Assemble body bolts finger tight. Then tighten bolts Ring gears and pinions are supplied in matched sets
alternately to specifications. only. Matching numbers on both pinion and ring gear are
6. Install ring gear to differential case. etched for verficiation. If a new gear set is being used, verify
7. Install ring gear-to-case bolts finger tight, then the numbers of each pinion and ring gear before proceeding
tighten alternately to specifications. with assembly.
8. Place side bearing into position and install, using On the rear face of each pinion there is etched a plus
tools J-8092 and bearing installer J-24383 as shown in figure ( + ) number, a minus (-) number, or a zero (0) number,
7F. which indicates the best running position for each particular
9. Install bearing on opposite side in the same manner. gear set. This dimension is controlled by the shimming
Be sure to support differential case on pilot plug J-8107-3. behind the inner bearing cup. Whenever baffles or oil
slingers are used, they become a part of the adjusting shim
 REAR AXLE DIFFERENTIAL 4B-45

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
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.
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.
Fig. 8F--Screw drivers A ga in st Case
4. To the outer shim pack (for setting preload) add or
remove an equal amount as was added or removed from the
pack. inner shim pack.
For example: if a pinion is etched +3, this pinion 5. Install outer cup in carrier bore, using installer J-
would require .003" less shims than a pinion etched "0". 7818 with Drive Handle J-8092.
This means by removing shims, the mounting distance of 6. Press rear pinion bearing onto pinion shaft, using
the pinion is increased by .003" which is just what a +3 installer J-24433.
etching indicates. Or if a pinion is etched -3 we would want 7. Install drive pinion and bearing into the differential
to add .003" more shims than would be required if the carrier.
pinions were etched "0". By adding .003" shims, the 8. Install preload shims and front pinion bearing. Do
mounting distance of the pinion was decreased .003" which not install oil seal at this time.
is just what a -3 etching indicated. Refer to figure 10F. 9. Install flange and holding bar J-8614-11 as shown
If the old ring and pinion set is to be reused, measure in "Drive Pinion - Removal".
the old shim pack and build a new shim pack to this same 10. Install washer and nut onto pinion shaft. Torque
dimension. If baffle is in the axle assembly, it is considered nut to 250 lbs. ft.
as part of the shim pack. 11. Remove holding bar and with an inch pound torque
To change the pinion adjustment, shims are available wrench measure rotating torque. Rotating torque should be
in thicknesses of .003", .005" and .010". 10 to 20 in. lbs. with original bearings or 20 to 40 in. lb.
with new bearings.
NOTE: If baffle or slinger is bent or mutilated, it NOTE: Torque reading to start shaft turning must be
should be replaced. disregarded.

Old Pinion
New Pinion Marking
Marking
-4 -3 -2 -1 0 +1 +2 +3 +4
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002
+1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003
0 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004
-1 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005
-2 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006
-3 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006 - 0.007
-4 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006 - 0.007 - 0.008
Fig. 9F~Dana Pinion Code Chart
4B-46 REAR AXLE DIFFERENTIAL

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 operation 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
Fig. 10F~Pinion Code Location 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
12. If torque requirements (preload) are not to carrier on the ring gear side of the case.
specifications, adjust shim pack as necessary. 10. To determine the correct dimension for the
a. To increase preload, decrease the thickness of remaining shim, first refer to the dimension obtained in step
preload shims. 8 of "Gaging Procedures-Side Bearing Shims". From that
b. To decrease preload, increase the thickness of figure, subtract the size of the shim installed in step 9 above;
preload shims. then add .006 inch for preload and backlash.
13. When bearing preload meets specifications, remove For example, if the reading in step 18 was .329 inch,
nut, washer and flange from pinion shaft. and the shim just installed on the ring gear side of the case
14. Install new pinion oil seal into housing as shown was .172 inch, the correct shim dimension would be
in figure 11F, using J-24384. .329-. 172 = .157 + .006 = .163 inch.
15. Install flange, washer and nut. Using holder bar 11. Spread the differential carrier as shown in figure
J-8614-11, torque nut to 250 lbs. ft. 2F.
DIFFERENTIAL CASE 12. Assemble the shim determined in step 10 into place
between the bearing cup and the carrier.
Installation and Adjustm ent
1. Place the differential case, with side bearings and 13. Remove the spreader and the dial indicator.
cups installed, into position in the carrier. 14. Install the bearing caps in marked positions and
2. Select the smallest of the original shims as a "gaging" torque cap screws to specifications.
shim and place it between the bearing cup and the carrier 15. Install dial indicator and check ring gear backlash
on the ring gear side of the case. at four equally spaced points around the ring gear. Backlash
3. Install bearing caps and bearing screws finger tight. 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 am ount .
b. High backlash is corrected by increasing the shim
on the ring gear side and decreasing the opposite side shim
an equal am ount .
17. Check gear tooth contact, as described in "Gear
Tooth Contact Pattern Check".
18. Using 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.
Fig. 1 1 F--Installing Pinion Oil Seal 22. Fill differential with lubricant.
 REAR AXLE DIFFERENTIAL 4B-47

Test
1. Wipe oil out of carrier and carefully clean each tooth
of ring gear.
2. Use gear marking compound and apply this mixutre
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.
NOTE: 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
Fig. 1 2F -G ear Tooth N om enclature in opposite direction. Excessive turning of ring gear is
not recommended.
5. Observe pattern on ring gear teeth and compare with
23. Install wheel and tire assembly. figure 13F. Make adjustments as necessary.
CHECKS A N D A D JU STM EN TS 6. The important thing to achieve in the pattern check
Four adjustments are essential for proper operation of and subsequent adjustments is to locate the contact pattern
the differential and its related parts. These adjustments are centrally on the face of the ring gear teeth.
a) Pinion Bearing Preload, b) Side Bearing Preload, c)
Pinion Depth and d) Ring Gear-to-Pinion Backlash. Adjustments A ffecting Tooth Contact
Two adjustments can be made which will affect tooth
Pinion Bearing Preload is set to specifications in step contact pattern. These adjustments are backlash and
12 of "Drive Pinion - Assembly and Installation". Side position of drive pinion in carrier. The effects of bearing
Bearing Preload is set to specifications in step 10 of preloads are not readily apparent on hand loaded teeth
"Differential Case - Installation and Adjustment". pattern tests; however, these adjustments should be within
Following service to the Differential Case or to the Drive specifications before proceeding with backlash and drive
Pinion and Ring Gear, a Gear Tooth Contact Pattern Check pinion adjustments.
must be made, to verify the accuracy of the work in setting
the pinion depth and the ring gear-to-pinion backlash.
NOTE: It may be necessary to adjust both pinion depth
GEAR TOOTH CONTACT PATTERN CHECK and backlash to obtain the correct pattern.
Prior to final assembly of the differential, a Gear Tooth The position of the drive pinion is adjusted by
Contact Pattern Check is necessary to verify the correct increasing or decreasing the shim thickness of the inner
relationship between ring gear and drive pinion. Gear sets shim, located between the rear bearing cup and the carrier
which are not positioned properly may be noisy, or have housing. Increasing the shim thickness will move the pinion
short life or both. With pattern check, the most desireable closer to centerline of the ring gear. Decreasing shim
contact between ring gear and drive pinion for low noise thickness will move pinion farther away from centerline of
level and long life can be assured. the ring gear.
Gear Tooth Nomenclature Backlash is adjusted by means of the side bearing
The side of the ring gear tooth which curves outward, adjusting shims which moves the entire case and ring gear
or is convex, is referred to as the "drive" side. The concave assembly closer to, or farther from the drive pinion. (The
side is the "coast" side. The end of the tooth nearest center adjusting shims are also used to set side bearing preload).
of ring gear is referred to as the "toe" end. The end of the To increase backlash, increase right shim and decrease left
tooth farthest away from center is the "heel" end. Toe end shim an equal amount. To decrease backlash, decrease
of tooth is smaller than heel end. See figure 12F. right shim and increase left shim an equal amount.
4B-50 REAR AXLE DIFFERENTIAL

J 22888

Fig. 16F--Removing D iffere ntia l Side Bearings

wear is most evident on tapered roller bearings.

Fig. 15 F -T oo l J -2 4 3 8 5 M ounted on C arrier

NOTE: The pinion bearings are of the tapered type,
and the natural wear pattern is a frosted condition with
cone and rollers for assembly. occasional slight scratches on races or rollers. This does
not indicate a defective bearing.
NOTE: If ring gear and pinion are to be reassembled, 2. Inspect pinion splines and flange splines for evidence
note position of shims and replace accordingly. of excessive wear.
4. Remove spacer, pinion shaft, pinions, side gears and 3. Inspect ring gear and pinion teeth for possible
thrust washers from differential case. scoring, cracking or chipping.
5. Remove screws attaching ring gear to differential
case. Remove gear. 4. Inspect differential case for carcks or scores. Inspect
DRIVE PINION
side gears, thrust washers, and pinion thrust faces.
Removal 5. Check fit of differential side gears in case.
1. Separate rear universal joint, tape trunnion bearings 6. Check fit of side gears and axle shaft splines.
to joint, position propeller shaft to one side and tie propeller
shaft to frame side rail. 7. Inspect differential pinion shaft and spacer for
2. Using Holding Bar J-8614-11, attached to pinion scoring or evidence of excessive wear.
shaft flange, remove self- 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 J-8614-1

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
behind the inner bearing cup. Tag shims for reassembly.
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 Fig. 1 7 F-R e m o v ing Pinion Flange
 REAR AXLE DIFFERENTIAL 4B-51

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). 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 "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
Fig. 18F-R em oving Inner Pinion Bearing Cone and Roller of shims needed (less preload) for setting backlash later
during assembly.
11. Remove differential from carrier.
DIFFERENTIAL CASE
DRIVE PINION
Reassembly Installation and A djustm ent of Depth and
1. Position differential side gears and new thrust Preload
washers in differential case. Ring gears and pinions are supplied in matched sets
2. Position differential pinions and new thrust washers only. Matching numbers on both pinion and ring gear are
in differential case. Align pinions with holes in differential etched for verification. If a new gear set is being used, verify
case. the numbers of each pinion and ring gear before proceeding
3. Install pinion shaft in differential case. Align hole with assembly.
in shaft with hole in case, then install lock pin. Peen hole On the button end of each pinion there is etched a plus
to prevent pin dropping out of case. ( + ) number, a minus (-) number, or a zero (0) number,
4. Position ring gear to case, then install cap screws. which indicates the best running position for each particular
Tighten cap screws evenly and alternately to specifications. gear set. This dimension is controlled by the shimming
5. With an arbor press, press differential side bearings behind the inner bearing cup. Whenever baffles or oil
onto case using Tool J-21051. Do not install shims at this slingers are used, they become a part of the adjusting shim
time. pack.
6. Place differential case in carrier and install bearing For example: If a pinion is etched +3, this pinion
caps. Care should be taken to install caps in original would require .003" less shims than a pinion etched "0".
position. Use mark placed on caps and carrier at removal. This means by removing shims, the mounting distance of
Tighten caps just enough to keep bearing caps in place. the pinion is increased by .003" which is just what a +3
7. Install dial indicator on carrier with indicator button etching indicates. Or if a pinion is etched -3 we would want
contacting back of ring gear, as in figure 19F. Rotate to add .003" more shims than would be required if the
pinions were etched "0". 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".
NOTE: 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
thickness of the old shim pack to compensate for the
difference of these two figures.
Fig. 19F~ Checking Runout For example: If the old pinion reads ( + 2) and the new
4B-52 REAR AXLE DIFFERENTIAL

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. lbs.
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. lb.
with new bearings.
NOTE: 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.
Fig. 20F--M arking From Nom inal on Pinion 13. Install flange, washer and nut. Torque nut to
specifications.
pinion is (-2), add .004" shims to the original shim pack. DIFFERENTIAL CASE
1. Determine proper inner shim pack (for setting pinion Preload and Adjustm ent
depth) by using chart in figure 2IF. 1. Place differential assembly (with pinion assembled)
2. Install inner shim pack and oil slinger in inner cup into housing. Install bearing caps in their proper position
bore and drive inner cup into position using Tool J-21059 and tighten screws just enough to hold the bearing cups in
used with J-8092. place.
3. To the outer shim pack (for setting preload) add or 2. Install dial indicator on carrier with indicator button
remove an equal amount as was added or removed from the contacting back of ring gear, as in figure 19F.
inner shim pack. 3. Place two screwdrivers between bearing cup and
4. Install outer cup in carrier bore, using installer J- housing on ring gear side of case, and pry ring gear into
7818 with Drive Handle J-8092 as shown in figure 22F. 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
5. Press inner pinion bearing cone and roller onto applied, set indicator to "0".
pinion shaft using Installer J-9772 on arbor press as shown 4. Reposition screw drivers on opposite side of ring gear
in figure 23F. and pry ring gear as far as it will go. Now take an indicator
6. Install drive pinion and inner bearing cone and roller reading. Repeat until the same reading is obtained every
assembly in differential carrier. time. This reading will be the necessary amount of shims
7. Install shims and outer pinion cone and roller on between the differential case and differential bearing on the
pinion shaft using Tool J-5590 and companion flange to ring side gear. Remove differential bearing from the ring
Old Pinion New Pinion Marking
Marking
-4 -3 -2 -1 0 +1 +2 +3 +4
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002
+1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003
0 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004
-1 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005
-2 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006
-3 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006 - 0.007
-4 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006 - 0.007 - 0.008

Fig. 21F--Dana Pinion Code Chart

 REAR AXLE DIFFERENTIAL 4B-53

J-5590

Fig. 22 F —Installing O uter Pinion Bearing Cup Fig. 24F —Installin g Pinion Flange

side and assemble proper amount of shims. Reassemble Installation

bearing. 1. Spread differential carrier, using spreader as shown
5. Remove the differential bearing from the opposite in figure 15F.
side of ring gear. To determine the amount of shims needed 2. Install differential bearing outer races in their correct
here, use the following method. location, then install differential case into carrier.
a. Subtract the size of shim pack just installed on ring
gear side of case from the reading obtained and recoreded 3. Install differential bearing caps in the correct
in step 10 of Differential Case-Reassembly. location as indicated by marks made at disassembly. Install
b. To this figure, add an additional .015" shims to cap screws finger tight. Rotate differential assembly and rap
compensate for preload and backlash. on case with a soft faced hammer to ensoure proper seating
Example: If reading in step 10 of Differential Case- of case in carrier.
Reassembly was .085", and the shims installed on ring gear 4. Remove spreader and torque cap bolts to
side of case was .055", the correct amount of shim will be specifications.
.085" - .055" + .015" = .045". 5. Install dial indicator and check ring gear backlash
6. Install shims as indicated in step 5, (which will give at four equally spaced points around the ring gear. Backlash
the proper bearing preload and backlash) and install side must be held to .004" to .009" and must not vary more than
bearing. .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 earlier in
"Dana 10-1/2" Ring Gear" section, under "Gear Tooth
Contact Pattern Check". Refer to figure 25F.
8. Using a new gasket, install housing cover and torque
bolts to specifications.
9. Reinstall the rear universal joint, and torque "U"
bolt nuts to specifications.
10. Install axles into carrier and axle flange over hub
studs. Torque hub stud nuts to specifications.
11. Fill differential with lubricant.
12. Install wheel and tire assembly.
CAUTION: See Caution on page 1 o f this section
regarding the fasteners referred to in the above
Fig. 23F--lnstalling Inner Pinion Cone and Roller steps.
4B-54 REAR AXLE DIFFERENTIAL

Fig. 25F--Gear Teeth C ontact Pattern Check

CH EVRO LET TRU CK DIFFERENTIAL

12-1/4" RING GEAR
INDEX

Case and Drive Pinion............................................. .4B-55 Differential Bearing Replacement...................... 4B-57

Removal................................................................. .4B-55 Differential Reassembly....................................... 4B-57
Disassembly............................................................4B-55 Reassembly............................................................ 4B-58
Repairs.........................................................................4B-56
Pinion Disassembly.............................................. .4B-56 Ring Gear and Pinion Adjustmnet........................ 4B-58
Pinion Inspection................................................. .4B-56 Backlash and Preload Adjustment..................... 4B-58
Pinion Reassembly............................................... .4B-56 Ring Gear Thrust Pad Adjustment................... 4B-58
Differential Disassembly.......................................4B-57
Differential Inspection..........................................4B-57 Installation............................................................. 4B-59
Ring Gear Replacement.......................................4B-57
 REAR AXLE DIFFERENTIAL 4B-55

1. Universal Joint Yoke 8 Ring Gear Thrust Pad 14 . Axle Shaft

15 .
10
2. Pinion Bearing Oil 9. Ring Gear Differential Bearing

11.
Seal and Retainer Differential Spider 16 Differential Bearing
3. Oil Seal Differential Pinion Adjusting Nut
4. Oil Seal Gasket (Spider) Gear 17 . Adjusting Nut Lock
5. Front Pinion Bearing 12 . Differential Side Gear 18 Differential
6. Drive Pinion 13 . Differential C ase-Left C ase-Right Half
7. Rear Pinion Bearing Half

Fig. 1G~Cross Section of T ruck D iffere ntia l w ith 12 1 /4 " Ring Gear

CASE A N D DRIVE PINION Disassembly

Removal 1. Mount carrier assembly in a bench vise or holding
1. Drain lubricant from differential, remove axle shaft fixture.
as outlined in Truck Service Manual. See "Axle Shaft 2. Loosen ring gear thrust pad locknut and remove
Removal". thrust pad.
2. Remove two trunnion bearing "U" bolts from the 3. Remove differential adjusting nut locks and bearing
rear yoke and split the rear universal joint. cap bolts and lock washers.
4. Mark bearing caps and carrier for reassembly in
NOTE: The bearings can be left on the trunnion and same position. Remove bearing caps and adjusting nuts by
held in place with tape. tapping on bosses of caps with a soft faced hammer until
3. Swing propeller shaft to one side and tie to the frame caps are free from dowels.
side rail. CAUTION: Do not attempt to pry cap o ff as this
4. Remove bolts and lock washers which retain the may damage machined face o f cap.
carrier assembly to the axle housing. Support the differential 5. Remove differential and ring gear assembly from the
housing with a floor jack and roll it from under truck. carrier.
4B-56 REAR AXLE DIFFERENTIAL

REAR
PINION BEARING

PRESS
PLATE

Fig. 2G -P inion Rear Bearing Removal Fig. 3 G -D rive Pinion Front Bearing Removal

Pinion Reassembly
1. Pack the cavity between the pinion oil seal lips with
CAUTION: Exercise care that differential bearing a lithium-base EP lubricant to provide initial lubrication
outer races are not dropped while removing and to aid in inserting pinion flange.
assembly from carrier. 2. Press the oil seal into the reatiner. Position seal lips
6. Remove the bolts which attach the pinion bearing toward the pinion bearing, using Tool J-22281 as shown in
retainer to the carrier. figure 4G.
7. Remove the pinion and bearing assembly from the 3. Install the pinion rear bearing assembly on pinion
carrier. shaft making sure that chamfered side of inner race seats
against shoulder on pinion shaft. Then install pinion bearing
NOTE: It may be necessary to drive this unit from lock ring using Tool J-1364 as shown in figure 5G.
carrier. Use brass drift against pilot end of pinion. 4. To install pinion front bearing, position the one-piece
double row ball bearing on pinion shaft, so that extended
Repairs portion of inner race is toward pinion head. Then, using a
suitable length of 2 inch pipe, press bearing onto shaft until
Pinion Disassembly it seats against the pinion head.
1. Clamp pinion drive flange in bench vise.
2. Remove cotter pin, nut and washer from end of CAUTION: When pressing bearing on pinion,
pinion. exercise care to prevent damage to ground surface
3. Remove drive flange and bearing retainer assembly o f pilot.
from pinion. 5. Slide oil seal retainer on pinion shaft, then tap drive
4. Drive oil seal from retainer. Discard seal as new flange onto pinion splines.
parts should be used at assembly.
5. Remove pinion rear bearing snap ring and press
bearing from pinion, using Too! 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.
Fig. 4G--Pinion Oil Seal Installation
 REAR AXLE DIFFERENTIAL 4B-57

Fig. 7G --D ifferential Bearing Removal

6. Clamp drive flange in a bench vise and install flange pinions for chipping or excessive wear.
washer and nut. Torque to specifications and install cotter 6. Check thrust washers for wear and replace if even
pin without backing off on nut. slight wear is indicated.
Differential Disassembly 7. Check differential side bearings and cups for broken
1. Check differential case to make sure that the two races, discoloration or roughness.
halves are marked so they may be reassembled in same 8. Inspect differential case for cracks or distortion.
relation. See figure 6G. Ring Gear Replacement
2. Remove bolts holding case and cover together. 1. Remove ring gear from case by tapping the back of
the gear with a soft faced hammer.
NOTE: Ring gear is mounted on the case. 2. Inspect ring gear pilot case flange and back of ring
3. Separate cover from case and remove differential side gear for dirt or burrs.
gears and thrust washers, pinion gears with thrust washers 3. Install two guide pins (made from cap screws with
and differential spider. heads cut off and ends slotted) to new gear diametrically
D ifferential Inspection opposite each other.
1. Wash all parts thoroughly in cleaning solvent. 4. Start guide pins through case flange and tap ring gear
2. Inspect ring gear for chipped, scored or worn teeth. on case.
3. Check radial clearance between differential side Differential Bearing Replacement
gears and differential case, also fit of differential pinions on 1. Install Tool J-8107 making sure puller legs are fitted
spider. securely in notches in case and tighten retaining yoke as
4. Inspect spider arms for wear and distortion. shown in figure 7G.
5. Inspect splines and teeth of differential side gears and 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.
NOTE: 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 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.
Fig. 6G--Differential Case Line-Up Marks 6. Remove two guide pins and install remaining two
4B-58 REAR AXLE DIFFERENTIAL

Fig. 8G ~D ifferential Bearing Installatio n Fig. 9G--Backlash and Preload A djustm en t

bolts. Torque all bolts alternately and evenly to 10G. Backlash should be from .003" to .012" (.005" to .008"
specifications. preferred).
Reassembly
NOTE: If backlash is more than .012 inch, loosen the
1. Place new pinion bearing retainer gasket on the right hand adjusting nut one notch and tighten left
retainer and install pinion assembly in carrier. hand adjusting nut one notch. If backlash is less than
NOTE: The pinion assembly should be pressed into the
.003 inch, loosen the left hand adjusting nut one notch
carrier to prevent the possibility of damaging the shims. and tighten right hand nut one notch.
2. Install pinion bearing retainer bolts and lock washers 7. Tighten bearing cap bolts to specifications.
and torque bolts to specifications. 8. Install side bearing adjusting nut locks and torque
3. Lubricate differential bearing rollers with engine oil to specifications.
and place outer races over them. Ring Gear Thrust Pad Adjustm ent
4. Install differenital assembly in carrier and install 1. Inspect bronze tip of thrust pad and if worn install
adjusting nuts. a new one.
2. Install thrust pad and tighten screw until bronze tip
CAUTION: Carefully slide adjusting nuts engages back face of ring gear while rotating gear.
alongside the bearings so that threads on nuts fit 3. Back off screw one-twelfth (1/12) turn and tighten
into threads in carrier. locknut to specifications. See figure 11G.
5. Install differential bearing caps making sure the
marks on the caps line up with the marks on the carrier. NOTE: Make sure screw does not turn during locking
6. Install bearing cap bolts and lock washers and process. This adjustment provides .005 in. to .007 in.
tighten until lock washers just flatten out. clearance between thrust pad and ring gear face.
Backlash and Preload Adjustm ent
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 adjusting 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.
NOTE: 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 Fig. 10G--Checking Backlash
 REAR AXLE DIFFERENTIAL 4B-59

2. Assemble differential carrier to axle housing, install

lockwashers and bolts and tighten securely.
3. Replace axle housing inspection cover, if removed,
using new gasket.
4. Assemble rear universal joint.

CAUTION: This propeller shaft to pinion flange

fastener is an important attaching part in that it
could affect the performance o f vital components
and systems, and/or could result in major repair
expense. It must be replaced with one o f the same
part number or with an equivalent part if
replacement becomes necessary. Do not use a
replacement part o f lesser quality or substitute
design. Torque values must be used as specified
Fig. 1 1G--Ring Gear T hrust Pad A djustm en t during reassembly to assure proper retention o f
this part.
5. Install axle shafts as outlined in applicable axle
installation procedure in Service Manual.
Installation 6. Fill axle with lubricant to a level even with bottom
1. Clean out axle housing and cover and place new of filler hole. See Section 0 in the Truck Service Manual for
gasket over axle housing. proper lubricant.

LIMITED SLIP DIFFERENTIAL UNITS

INDEX

Eaton Limited Slip-

Disassembly...................................................................................4B-60
Inspection..................................................................................... .4B-60
Reassembly....................................................................................4B-61
Chevrolet Limited Slip.................................................................... .4B-65
Disassembly...................................................................................4B-65
Inspection..................................................................................... .4B-65
Reassembly................................................................................... .4B-65
Borg Warner (Cone Type)...............................................................4B-65
Description....................................................................................4B-65
Disassembly...................................................................................4B-65
Inspection..................................................................................... .4B-66
Assembly....................................................................................... .4B-66
Power-Lok Differential................................................................... .4B-68
Disassembly...................................................................................4B-68
Inspection..................................................................................... .4B-68
Assembly....................................................................................... .4B-68
Testing Procedure.........................................................................4B-69
Eaton Positive Locking Differentials
1/2 Ton and 3/4 Ton Units........................................................4B-69
Description....................................................................................4B-69
Disassembly...................................................................................4B-70
Inspection..................................................................................... .4B-71
Cam/Clutch Service.................................................................... .4B-71
Reassembly................................................................................... .4B-73
4B-60 REAR AXLE DIFFERENTIAL

1. Ring Gear-to-Case 5. Ring Gear 11. Spring Retainer

Bolt 6 Shim 12. Pinion Thrust washer
2. Differential Case 7. Clutch Pack Guide 13. Pinion Gear
3. Side Bearing 8. Clutch Disc 14. Pinion Shaft
4. Pinion Lock Screw 9 Clutch Plates 15. Preload Spring
and Washer 10 . Side Gear

Fig. 1 D -Eaton Lim ited Slip Exploded V iew

EATON LIMITED SLIP - FIGURE 1D

Disassembly figure 4D.

1. Remove ring gear and side bearings following the 4. After installing the retaining bolts continue to drive
procedures established for the conventional differential unit. spring retainer from the case until enough of the retainer
2. For all models except Corvette, remove the is exposed to permit installation of bar stock and "C" clamp
preload spring retainer and springs by tapping on the spring as shown in figure 5D. Center the bar stock over the axle
retainer through the observation hole in the case. See figure shaft hole in the spring retainer, then compress "C" clamp
2D. Drive the spring retainer from the case sufficienly to sufficiently to permit withdrawal of spring pack.
allow insertion of a 1/4 inch bolt in each of the two front 5. Position spring pack in vise and remove 1/4 inch
springs. Secure each bolt with a nut as in figure 3D. bolts. Alternately relieve "C" clamp pressure and vise
3. On Corvette it will be necessary to raise the spring pressure until spring compression is relieved. See figure 6D.
retainers slightly to clear the shoulder on the side gears. 6. For Truck Models , roll out the differential
Install Tool J-22311 to clutch pack so that slotted ends are pinions and thrust washers.
equally engaged at front and rear of spring retainer. See For Passenger models , pinion gears can be
 REAR AXLE DIFFERENTIAL 4B-61

removed by rotating them in one direction only. Using Fig. 4D -R em oving Preload Spring Pack (Corvette)
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 of properly preloading the clutch pack, replace springs that
be necessary to assist pinion gear upon its seat by prying on are weak or questionable.
gear through observation holes on case. Mark pinions and 4. Examine spring retainer for alignment between the
side gears for reassembly in original position. retainer halves and for excessive wear at spring seats.
7. Remove side gear, clutch pack, shims and guides
from case. Tap the assembly from the case, using a brass Reassembly
drift as shown in figure 8D. Repeat removal on opposite 1. Lubricate clutch plates and discs with special limited
gear. slip lubricant.
8. Separate clutch pack assembly from side gear. Retain 2. Alternately position clutch plate and clutch disc on
clutch pack assembly with original side gear. side gear, beginning and ending with clutch plate, until
Inspection assembly of clutch pack is complete. See figure 9D.
1. Check clutch plates and discs for excessive wear and 3. Install clutch pack guides on the clutch plate lugs.
signs of overheating. Make sure that the clutch disc lugs engage with side gear
teeth.
NOTE: Clutch plates and discs are not serviced 4. Select shims of equal thickness as those removed
separately. If replacement is required, clutch pack must from the case, or if old shims are suitable, reinstall them
be replaced as an assembly. over the side gear hub.
2. Inspect preload springs for distortion and other 5. Lubricate and assemble opposite side gear as above.
defects. 6. Install one side gear, clutch pack assembly and
3. Compress springs and determine if they are capable shim(s) in the differential case.

Fig. 3D--lnstalling Bolts to Retain Springs Fig. 5 D -C -C la m p and Bar Stock Installed for Spring Removal
4B-62 REAR AXLE DIFFERENTIAL

Fig. 6D--Removing Preload Springs from Pack

Fig. 8D -R em oving Side Gear

7. Position pinion gears and thrust washers on side

gears. Install pinion shaft through case and gears. 16. Position spring pack between side gears and remove
8. Install dial indicator in case so that contact button bar stock and "C" clamp.
rests against pinion gear as shown in figure 10D. 17. On Corvette , install Tool J-22311 to compress
9. Compress clutch pack, using a screwdriver as shown clutch pack, secure pack with 1/4" bolts as shown in figure
in figure 11D. Move the pinion gear to obtain tooth 12D. Partially install pack then remove bolts and complete
clearance. pack installation. Remove tool.
10. Tooth clearance should be .001" to .008". If 18. Drive spring pack into side gears sufficiently to
required, change shims to obtain proper tooth clearance. retain front springs, then remove 1/4 inch bolts from
springs. Drive spring pack into position. See figure 13D.
11. Remove side gear assembly and repeat tooth 19. Install the pinion shaft and lock screw to retain side
clearance procedure for other side gear on opposite side of gears until axle shafts are installed.
case. 20. Check alignment of spring retainer with side gears.
12. Remove pinion shaft, gears and thrust washers. Slight movement of the spring pack can be made if
13. Install remaining side gear, clutch pack assembly necessary.
and shims in case. 21. Install side bearings and ring gear to case using
14. Install pinion gears and thrust washers. Installation procedure outlined for the conventional differential.
of pinion gears can be performed by reversing the pinion 22. Place differential in carrier and adjust bearings and
gear removal procedure. backlash as outlined for the conventional differential.
15. For all except Corvette assemble springs in 23. Check operation of unit as follows:
spring retainer and clamp assembly in vise. Install "C" a. Raise rear of vehicle until rear wheels are off the
clamp and bar stock on spring retainer then install a 1/4 ground, and remove one wheel and tire assembly.
inch bolt and nut in each front spring. See figure 11D. 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

Fig. 7D~Removing Differential Pinion Gears Fig. 9D--Assembling Clutch Pack

 REAR AXLE DIFFERENTIAL 4B-63

firmly to prevent turning, measure torque required to rotate

opposite axle shaft with a 0-150 lb. torque wrench attached
to J-5748. Torque required to rotate axle shaft should be no
less than 40 ft. lbs.

Fig. 12D—Installin g Spring Pack Com pression Tool (Corvette)

Fig. 10D--M easuring Pinion Gear Tooth Clearance

Fig. 13 D—Installin g S pring Pack

Fig. 1 1 D -S p rin g Pack Compressed for Installation Fig. 1 4 D - M e a s u r i n g Positraction Rotating Torque
4B-64 REAR AXLE DIFFERENTIAL

CHEVRO LET LIMITED SLIP - FIGURE 15D

Disassembly NOTE: The force required to compress the preload

1. Remove ring gear and side bearings following the spring to 1-5/16 inches should be 300 -j- 30 lbs.
procedures established for the conventional differential unit. Reassembly
Remove pinion shaft. 1. Lubricate the clutch discs and plates with limited slip
2. Using a wide, blunt instrument such as a drift or lubricant.
block of wood, drive the preload spring from the case. 2. Alternately position clutch plates and discs on a side
3. Support an axle shaft in a vise, and slide the case into gear, beginning and ending with a clutch plate.
the shaft; then turn the case to remove both pinions and 3. Position the side gear, clutch pack and original shim
thrust washers. into the case.
4. Remove the case from the axle shaft and remove 4. Install both pinion gears and thrust washers into the
both side gears, clutch packs and shims. Mark the gears, case, and install pinion shaft.
clutch packs and shims for reinstallation in same positions. 5. Place the case onto an axle shaft supported in a vise.
Inspection 6. Insert a screwdriver between the pinion shaft and the
Check the clutch plates and discs for wear and signs face of the side gear. Force the screwdriver in until the
of overheating. Check the condition of the preload spring. clutch pack is compressed.
Check the gear teeth for signs of wear. Replace parts as 7. Check the backlash between side gear and pinion
needed. Clean all parts to be used for assembly. gears. If backlash does not fall into the range of .005" to

SHIM

BOLT
(PINION SHAFT)
SPLINED
PINION DISC (3)
SHAFT FIXED
DISC (4)
THRUST
WASHER
BOLT
(RING GEAR) PINION
GEAR
SIDE •-PRELOAD
BEARING SPRING

Fig. 1 5D--Chevrolet Limited Slip - Exploded

 REAR AXLE DIFFERENTIAL 4B-65

.008", adjust the shim dimension as required. Increasing gears into case.
shim thickness will decrease backlash; to increase backlash, 12. Mount the case onto the axle shaft locked in a vise.
decrease the thickness of the shim. Place both pinions and thrust washers into position-180°-
apart-and carefully "roll in" by turning the case on the shaft.
NOTE: Service shims are availabel from .070" to .122"
in increments of .004".
8. Remove the pinion shaft, pinion gears, side gear, NOTE: A large "C" clamp may be used to apply slight
clutch pack and shim from the caSe. compression against pinion gears to aid the "rolling in"
9. Install the opposite gear, clutch pack and original procedure.
shim into the opposite side of the case. Place both pinion 13. Tap the preload spring into place with a hammer.
gears, and thrust washers into position, and install the
pinion shaft. 14. Install the pinion shaft and lock screw.
10. Follow the procedure in steps 5, 6 and 7 to 15. Install the side bearings and ring gear using the
determine the proper shim dimension. procedure outlined for conventional units.
11. When the proper shims have been determined to
achieve .005" to .008" backlash between both pinion gears 16. Place the differential unit in the carrier and adjust
and both side gears, install shims, clutch packs and side ring gear and pinion backlash, and gear tooth pattern.

BORG W ARNER (CONE TYPE)

DESCRIPTION
Differential Case
The limited slip differential can be identified by a tag Disassemble
attached to the lower right section of axle cover. It is 1. Before disassembling differential case, inspect
designed to direct the major driving force to the wheel with differential side bearings for visible damage of rollers and
greater traction, thereby reducing the posibility of the car outer races.
becoming stuck while driving under adverse conditions. 2. Place one outer race onto its matched inner race and
All rear axle parts of cars equipped with the limited roller assembly and turn slowly, applying hand load.
slip differential are interchangeable with those equipped 3. If bearing outer race turns smoothly and no visible
with the conventional differential, except for the case damage is found, bearing can be reused.
assembly. It is similar in all respects to the conventional case 4. Repeat above operation with other race and matched
assembly, with the addition of cone clutches splined to each bearing and check for smoothness.
side gear.
LUBRICATION NOTE: Both side bearings and their outer races are
The differential should be checked for leaks and level matched parts. If either bearing is to be replaced, its
every oil change. Maintain level to within 3/8" of the filler matching outer race must also be replaced.
plug opening. 5. Inspect fit of inner races on case hubs by prying
against shoulders at puller recesses. Bearing inner races
If necessary to add lubricant, use only lubricant No. must be tight on case hubs.
1052271 or equivalent.
NOTE: If either bearing is loose on case, entire case
SERVICE PROCEDURES
must be replaced.
Rear axle service procedures are the same for the 6. If bearing inspection indicates that bearings should
limited slip as for the conventional differential, except for be replaced, remove side bearings by using tools as shown
servicing the case assembly. in the 1978 Service Manual.
If the case, clutch cone/side gears, or pinion gears are 7. If removing ring gear, clamp case in vise so jaws are
damaged, it is necessary to replace case assembly. 90° to pinion shaft holes and remove ten ring gear retaining
bolts.
8. Partially install two bolts on opposite sides of ring
gear.
W A R N IN G : Never raise one wheel and 9. Remove ring gear from case by alternately tapping
run the engine w ith the transmission in on bolts.
gear. The driving force to the wheel on
the floor w ill cause the car to move. Do
not use "on the car" type wheel balancers NOTE: Do not pry between case and ring gear.
on the rear wheels, unless both wheels 10. Remove differential case half attaching bolts.
are o ff the floor. 11. Lift cap half of case from flange half. Remove
clutch cone/side gears, spring blocks, preload springs,
4B-66 REAR AXLE DIFFERENTIAL

CLUTCH CONE/
SIDE GEAR

SPRING
BLOCK
PINION
THRUST
WASHER

PINION
GEAR It

SPRING*^

CLUTCH CONE/
SIDE GEAR
Assembly
1. Install proper cone/gear assembly, seating it into
position in cap half of case. (Fig. 4B-17D).
CASE
NOTE: Be certain 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
130 FT. LBS^| 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
Fig. 4B -16D--Limited Slip (Cone Type) differential case. This prevents pinion shaft from sliding out
and causing damage to carrier. (Fig. 4B-18D).
pinion gears and shaft. NOTE: Be certain that pinion gears are installed in
their original locations.
NOTE: Be certain that each clutch cone/side gear and 3. Insert five springs into spring block that is already
pinion gear are marked so they can be installed in their installed into case, then place second spring block over
original location. springs. (Fig. 4B-19D).
4. Install second cone/gear assembly face down on
Cleaning and Inspection spring block so that gear will mesh with pinion gears.
1. Make certain all parts are absolutely clean and dry. 5. Install flange half of differential case over cone,
insert case bolts finger tight. (Fig. 4B-20D).
2. Inspect pinion shaft, pinion and side gears, brake 6. Tighten bolts one turn at a time in sequence shown
cone surfaces and corresponding cone seats in case. The in Fig. 4B-21D. Then torque case bolts to 30 ft. lbs.
cone seats in case should be smooth and free of any excessive 7. If side bearings were removed, lubricate outer
scoring. Slight grooves or scratches, indicating passage of bearing surfaces and press on bearings as shown in the 1978
foreign material, are permissable and normal. The land Service Manual.
surface on the heavy spirals of male cones will duplicate case 8. After making sure that matching surfaces are clean
surface condition. If case or clutch cone/side gear are and free of burrs, position ring gear on case so holes are in
damaged, it is necessary to replace case assembly. All other line.
parts are serviceable. 9. Lubricate NEW attaching bolts with clean engine oil
and install.
 REAR AXLE DIFFERENTIAL 4B-67

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.

NOTE: Do not use hammer to force ring gear on case.

11. Install unit into axle carrier following instructions

given for Standard Differential.

Fig. 4 B - 19D--Spring and Spring Block Fig. 4 B - 2 1 D - B o l t Torque Seq uence

4B-68 REAR AXLE DIFFERENTIAL

POWER-LOK DIFFERENTIAL

The Power-Lok differential shown in figure 22D is a friction plates on each side of differential side gears
unit which is installed as optional equipment in place of the transmits drive from differential case to axle shafts.
standard differential. The locking differential permits the Carefully observe the order in which the plates are
major driving force to be transmitted to the wheel with used, since they must be replaced in the same order.
better traction. This means that the vehicle can be operated Refer to figure 22D.
on ice, snow, sand or under other adverse conditions with 8. Remove side gear ring and side gear.
a minimum amount of slippage through one wheel. 9. Remove two cross shafts and pinion gears.
Disassembly 10. Remove side gear, side gear ring, and five plates and
1. Remove differential bearing cups and tag for discs from the opposite side. Observe the order in which the
reassembly reference. plates are used.
2. Remove differential bearing cones, using Puller Tool Inspection
J-22888. 1. Inspect cross shafts and pinions for scoring, wear,
3. Tag each bearing cone and shim for reassembly pitting, etc. If the center lands of either cross shaft show
reference, as they should be replaced in their original signs of wear, examine ends of axle shafts to determine if
locations. the axle shaft is rubbing against cross shaft. This rubbing
4. Scribe mark on both halves of differential so they can condition may cause a whine or howl that is similar to a
be reassembled in their original locations. pinion bearing noise, at 40 to 50 MPH. This condition can
5. Remove eight bolts attaching two halves of case be corrected by grinding 1/32" off the end of the axle shaft.
together. 2. Inspect clutch discs and plates for wear, cracked, or
6. Separate plain half of differential case from flanged distorted condition.
half. 3. Inspect side gear rings, side gears, and differential
7. Remove five plates and discs from side gear ring. cases for worn, cracked, or distorted condition that would
render these parts unfit for further services.
NOTE: A series of clutch plates and dished (Belleville)

il&Q0
10 I

10

1. Differential Case Bolt Friction Plate-Tabbed 6. Friction Plate-Tabbed 8. Side Gear Ring
2. Differential (Belleville) (Flat) 9. Side Gear
Case-Plain Half 5. Friction Disc-Toothed 7. Friction Disc-Toothed 10. Pinion Gears
3. Differential (Belleville) (Flat) 11. Cross Shafts
Case-Flanged Half

Fig. 22D--Po wer-Lok Differential

 REAR AXLE DIFFERENTIAL 4B-69

Assembly
During assembly operations, all parts should be kept its ramp or if there is clearance it should be only a few
clean and free of dirt or other foreign material. As each part thousandths, and it should be equal at all four cross shaft
is assembled in its proper position, it is necessary that it be ends.
lightly coated with the correct lubricant.
1. Place tabbed Belleville friction plate (4) in flanged Testing Procedure
differential case, being extremely careful that convex
(bulged) side is toward the side gear. See figure 22D. The Power-Lok can be effectively tested for correct
2. Assemble remaining plates and discs to splines of operation by placing one rear wheel on good dry pavement
side gear ring, being sure they are assembled in the same and the other on ice, snow, mud, gravel, grease, etc.
order of removal. The convex (bulged) side of the Belleveille
friction disc (5) should be toward the side gear and it should It can easily be determined whether or not the non­
nest into the Belleville friction plate (4). slipping wheel is providing pulling power. The procedure
3. Place assembled side gear ring with plates and discs should then be repeated with the opposite wheels on the dry
in flanged half of differential case. and slippery surfaces.
4. Install side gear and cross shafts with pinions.
5. In the order listed install the following: (1) side gear, The above testing procedure is a rough test that can
(2) side gear ring, (3) flat plate with tabs, (4) flat disc with be made by the owner of the vehicle. However, if it is
teeth, (5) flat plate with tabs, (6) Belleville disc with convex suspected that the unit is not operating properly, it can be
(bulged) side up, or toward side gear, (7) Belleville plate, checked by the following procedure.
with convex (bulged) side up, or side toward gear. Be sure the transmission is in neutral. Raise one wheel
6. Position plain half of differential case over previously off the floor and place a block in the front and rear of the
assembled parts with scribe markings on both halves of case opposite wheel. Remove the hub cap and install a special
in alignment. tool across two wheel studs. Apply a torque wrench to
7. Install differential case bolts, but do not tighten at special tool. Disregard breakaway torque and observe only
this time. the torque required to continuously turn the wheel
8. Before tightening bolts, use axle shafts and align smoothly.
splines of the side gear and side gear ring, on each side.
Tighten bolts evenly and alternately. Remove axle shafts. If the torque reading is less than 40 foot-pounds or
9. Observe if Power-Lok components have been more than 200 ft. lbs., the unit should be disassembled and
assembled properly. Each pinion cross shaft can be tight on the necessary repairs made.

EATON POSITIVE LOCKING DIFFERENTIAL

DESCRIPTION Service Test Procedure

Chevrolet Trucks equipped with locking differentials 1. Place the Truck on a frame-contact hoist, allowing
use one of the Eaton locking units in Figure 4B-1H, 2H. free rotation of the rear wheels.
These differentials provide true differential action and also 2. Raise hoist until wheels clear floor. Holding one
incorporates a speed sensitive device which automatically wheel stationary, slowly rotate other wheel approximately
and positively locks both rear wheels together if either wheel 1/2 revolution per second, in both the forward and reverse
should spin excessively during slow vehicle operation. directions. Wheel should rotate freely. If both wheels
attempt to turn together, the differential is locking and is
Locking is accomplished through the use of a flyweight defective.
governor mechanism, cam system, and multi-disc clutch.
The flywheights on the governor mechanism move outward NOTE: Rapid wheel rotation will cause a properly
to engage a latching bracket whenever the wheel-to-wheel operating differential to lock and both wheels will
speed varies by approximately 100 rpm or more. This action rotate in the same direction.
retards a cam which, in turn, compresses a multi-disc clutch 3. Raise hoist to maximum height with one person in
locking one side gear to the case. At wheel-to-wheel vehicle.
differentials of less than approximatley 100 rpm, the unit 4. Start engine making sure that carburetor is set to
operates as a standard or open differential. 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
NOTE: At vehicle speeds above approximately 20 transmission in first gear.
mph, the latching bracket overcomes a spring preload 6. Lock one rear wheel by pulling one parking brake
and swings away from the flyweights. At this vehicle cable from under the vehicle.
speed or greater, the differential will not lock as the 7. With engine at low idle, slowly release brakes. With
added traction is not necessary. manual transmission, slowly engage clutch.
8. Locked rear wheel will remain stationary and free
4B-70 REAR AXLE DIFFERENTIAL

B U SH IN G

LO CK W ASHER
B U SH IN G

LO CK SC REW
STOP PIN
P IN IO N THRUST W ASH ER (2)

PIN IO N SHAFT

SHIM

SIDE GEAR

CAM FORM SIDE GEAR

CAM PLATE
THRUST BLO CK
PIN IO N G EA R (2)
W AVE SPRIN G

SHIM

THRUST RIN G

G U ID E CLIP
G O V ER N O R ASS'Y LA TC H IN G BRK'T A SS 'Y

D ISC PACK S/A

Fig. 4B-1 H -1 /2 Ton Unit

wheel will begin turning. It is important that brakes or replaced.

clutch be released slowly enough to start the free wheel Internal clearances are such that shims,
turning and allow the free wheel to gradually increase in reaction block, and thrust rings should not be
speed. As speed of the free wheel is increased, the replaced unnecessarily even if slight wear
differential will lock causing the rotating wheel to stop or indications are present. I f shims, reaction block,
both wheels to turn at the same speed. The engine may stall or thrust ring must be replaced due to damage,
if equipped with a manual transmission. It may be necessary correct measurement and replacement procedures
to accelerate engine until approximately 10 mph is indicated must be followed. Failure to do so may disturb
on vehicle speedometer to cause differential lock. If critical clearances and could result in differential
indicated speed can be increased beyond 20 mph without complaints.
causing differential lock, the unit is not functioning Internal components can be inspected
properly. through the windows o f the differential housing.
I f the go vernor assembly and latching bracket
NOTE: Rapid release of brakes or clutch, or rapid are the only items to be replaced, proceed only
acceleration of engine will invalidate test. through step No. 2 o f the disassembly procedure.
9. Lock opposite rear wheel and repeat procedure. The To install new governor and latching bracket,
following chart provides guidelines for diagnosis and repair begin at step No. 6 o f the reassembly procedure.
of differential complaints. Disassembly
OVERHAUL PROCEDURES 8 -7 /8 RING GEAR 1. Note position of governor and latching bracket
AXLE 1 /2 TON TRUCKS assembly, Figure 4B-4H. Remove ring gear and side
bearings following procedures established for the standard
CAUTION: Due to critical internal clearance differential.
dimensions, differential side gears and case cannot 2. Using bushing puller tool No. J-26252, remove
be serviced separately. I f any side gear or case governor assembly and latching bracket by pulling the
damage is found, the entire differential must be retaining bushings as shown in Figure 4B-5H. Pull the
 REAR AXLE DIFFERENTIAL 4B-71

SCREW (3)

S H IM

DISC PACK S/A

THRUST WASHER (3)

GUIDE CLIP (6)

PINION GEAR (3)

GOVERNOR ASS'Y
SIDE GEAR

SHIM EARED DISC (3)

PINION YOKE
SPIINED DISC (2) THRUST BLOCK (2)

LATCHING BRK'T ASS'Y

Fig. 4 B -2 H -3 /4 Ton Unit

latching bracket spring out of the way while pulling the • Flange end shim (4 sizes).
governor assembly bushing to prevent damage. Remove the
stop pin by driving through the case with a drive pin punch. CAUTION: Attempts to service other components
3. Remove lock screw and pinion shaft, and roll out may disturb critical clearances and could result in
differential pinion gears. differential complaints.
4. Remove thrust block and pinion thrust washers. I f reaction block or flange end shim must be
5. Remove cam gear, disc pack assembly and disc pack replaced, the original pieces must be carefully
guide clips. measured for thickness and replaced with a piece
6. Remove plain side gear and shims. o f the same size.
Inspection C A M /C L U T C H SERVICE
1. Clean all parts with solvent. Inspect all bearing for Disassembly
chipping or evidence of excessive wear. Replace parts as If cam plate or clutch discs must be replaced, the cam
needed. gear sub-assembly must be serviced as follows:
2. Inspect all differential components for excessive 1. Measure and record overall length of gear assembly
wear and breakage. Replace parts as needed. The following (front face of gear to back side of thrust ring, include shim).
are serviceable components for this differential: This dimension will be needed to reassembly unit if thrust
• Governor assembly and latching bracket with spring ring is replaced. DO NOT REPLACE THRUST RING
and stop pin. UNLESS NECESSARY. If ring is excessively worn or
• Cam plate. scored, check bore in case for scoring. If bore is scored,
• Clutch disc pack with guides and guide clip. replace entire differential.
• Pinion cross-shaft. 2. With gear hub end up, compress disc pack and install
• Pinion gears. jaws of split ring bearing remover (J-22912) between the
thrust ring and the top eared disc. Bevel side of bearing
• Pinion thrust washers. remover should face up toward thrust ring.
• Reaction block (4 sizes). 3. Place cam gear assembly with bearing remover
• Thrust ring. attached in an arbor press supporting the bearing remover
4B-72 REAR AXLE DIFFERENTIAL

DIFFERENTIAL DIAGNOSIS

Complaint Possible Cause Correction

Does not lock: A. Little or no spring A. Replace governor assembly

preload on the latching and latching bracket.
bracket.

B. Flyweights on governor B. Replace governor assembly and

assembly stuck closed. latching bracket.

C. Broken Drive teeth on C. Replace cam plate, governor

governor and/or cam assembly and latching bracket.
gear assembly.

D. Broken clutch plates D. Replace clutch plates and

in cam gear assembly. wave spring.

Locks in turns: A. Governor assembly A. Free up governor assembly.

tight in case.

B. Broken or weak B. Replace governor assembly

governor flyweight and latching bracket.
spring.

C. Flyweight in governor C. Replace governor assembly

assembly stuck open. and latching bracket.

D. Broken cam plate and/or D. Replace cam plate, governor

governor drive teeth. assembly and latching bracket.

Noisy:

NOTE: In 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. Replace clutch plates and

wave spring.

B. Broken reaction block. B. Replace reaction block.* Check

closely for other damage.
Replace entire unit if
housing, side gear, or pinion
gears are damaged.

C. Broken differential C. Replace entire unit.

gears.

Reaction blocks must be replaced with blocks of identical thickness.

Fig. 4 B -3H -D ia g n o sis Chart

 REAR AXLE DIFFERENTIAL 4B-73

Fig. 4B -6H-B earing Remover J-229 1 2

Fig. 4B-4H-Governor and Latching Bracket

4. Assemble on to gear hub (3) splined discs and (3)
eared discs alternately as shown. Begin with a splined disc
on both sides. and end with an eared disc.
4. Install a 1-1/2" to 1-3/4" diameter plug similar to 5. Locate cam gear assembly in arbor press with hub
(J-8107-4) on gear hub. Press against plug with ram of press end up. Place thrust ring on gear hub and press to shoulder
to remove thrust ring. Keep all components in the proper making sure that ring is square with hub.
order, Figure 4B-6H.
Reassembly NOTE: Compress disc pack by pushing down on the
Replace cam plate and wave spring or clutch discs as discs to keep the splined discs from becoming wedged
necessary and reassemble as follows: See Fig. 4B-1H. between the thrust ring and gear shoulder while
1. Place gear on bench with hub end up. pressing the sub-assembly together. Completed sub-
2. Assemble cam plate with cam form down to mate assembly should be checked for proper disc sequence.
with cam form on gear. Also, make sure the first splined disc (large spline) is
properly located on the cam plate.
3. Assemble onto cam plate: (2) eared discs, (1) splined
disc, and (1) wave spring alternaely as shown. Reassembly
1. Install (4) clutch pack guide clips on the ears 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.
NOTE: INCORRECT SHIMMING WILL
DISTURB CRITICAL CLEARANCE
DIMENSIONS AND MAY RESULT IN
DIFFERENTIAL FAILURE.
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.
Fig. 4B-5H--Bearing Puller J -2 6 2 5 2 NOTE: ORIGINAL SHIM MUST BE USED TO
4B-74 REAR AXLE DIFFERENTIAL

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 washers are in their proper
location.
NOTE: 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 Fig. 4 B -7 H -3 /4 Ton Unit
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 Disassembly
end play. Press bushing for latching bracket into case to 1. Remove ring gear and side bearings following
remove end play. A 3/8 diameter plug or socket will aid in procedures established for the standard differential.
pressing the bushings into the housing. Press stop pin flush 2. Remove (3) screws on front face of ring gear flange.
with top of case. 3. Set unit on right side case half and gently pry apart
NOTE: For the latching bracket use bushing with the
at yoke hole locations Fig. 4B-7H.
tapered hole. The bushing for the governor assembly 4. Remove left side case half. To prevent side gear from
has a straight hole. falling out, hold thumb against inside of gear hub while
7. Install ring gear and side bearings using the separating case halves.
procedure outlined for conventional differentials. 5. Inspect components for damage. If the governor
8. Place differential unit in carrier and adjust ring gear assembly and latching bracket are the only items to be
and pinion backlash and gear tooth pattern as outlined in replaced, remove and proceed to Step 7 of reassembly
the conventional differential section. procedure. Pry under pinion yoke and remove and proceed
9. Check operation as outlined in the Service Test with detailed inspection if further damage is observed.
Procedure.
NOTE: USE STANDARD DIFFERENTIAL
LUBRICANT. DO NOT USE LUBRICANT
DESIGNED FOR "LIMITED SLIP"
DIFFERENTIALS.
1 0-1/2 " RING GEAR AXLE 3 /4 TON AND 1-
TON TRUCKS

CAUTION: Due to critical internal clearance

dimensions, differential side gears and case cannot
be serviced separately. I f any side gear or case
damage is found, the entire differential must be
replaced.
Internal clearances are such that shims,
reaction blocks, and thrust ring should not be
replaced unnecessarily even if slight wear
indications are present. I f 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. 4 B - 8 H - 3 / 4 Ton Assembly
 REAR AXLE DIFFERENTIAL 4B-75

C A M /C LU TC H 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 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 (J-8107-4)
on gear hub. Press against plug with ram of press to remove
thrust ring. Keep all components in the proper order.
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.
Fig. 4B-9H--Cam Plate and Clutch Discs 4. Assemble onto gear hub: (4) eared discs and (3)
splined discs alternately as shown. Begin and end with an
eared disc.
Inspection 5. Locate cam gear assembly in arbor press with hub
1. Clean all parts with solvent. Inspect all bearings for end up. Place thrust ring on gear hub and press to shoulder
chipping or evidence of excessive wear. Replace parts as making sure that ring is square with hub.
needed.
2. Inspect all differential components for excessive NOTE: Compress disc pack by pushing down on the
wear and breakage. Replace parts as needed. THE discs to keep the splined discs from becoming wedged
FOLLOWING ARE SERVICEABLE COMPONENTS between the thrust ring and gear shoulder while
FOR THIS DIFFERENTIAL. pressing the sub-assembly together. Completed sub-
• Governor assembly and latching bracket with spring. assembly should be checked for proper disc sequence.
Also, make sure the first splined disc (large spline) is
• Cam Plate. properly located on the cam plate.
• Clutch disc pack with wave spring and guide clips. Reassembly
• Pinion yoke. 1. Install (6) clutch pack guide clips on the ears of the
• Pinion gears. cam gear clutch pack using grease for retention.
• Pinion thrust washers. 2. Install cam gear assembly and original shim in right
• Reaction blocks (4 sizes). side case half. If a new thrust ring has been pressed on the
cam gear, reshimming may be necessary. Measure the
• Thrust ring. overall length of the new cam gear assembly, including the
• Right side shim (4 sizes). shim and compare to the dimension obtained in Step A of
• Left side guide clips. cam gear service section. If the length of the new assembly
varies by more than .003 " larger or smaller than the original
Attempts to service other components will disturb dimension, reshimming will be necessary. Select a shim
critical clearances and may result in differential failure. If which will result in a reading closest to the original.
reaction blocks or right side shim must be replaced, the
original pieces must be carefully measured for thickness and INCORRECT SHIMMING WILL
replaced with a piece of the same size. NOTE:
DISTURB CRITICAL CLEARANCE
DIMENSIONS AND MAY RESULT IN
4B-76 REAR AXLE DIFFERENTIAL

DIFFERENTIAL FAILURE. 8. Install (6) clutch pack guide clips on the left side disc
3. Install right side reaction block on gear face with pack assembly using grease for retention.
button side of block facing up. Use original block unless 9. Install original shim in left side case half.
severely scored or worn. If new block is used, determine
face-to-face thickness of original block with calipers and NOTE: ORIGINAL SHIM MUST BE USED.
replace with a service block of the same thickness. ATTEMPTS TO INSTALL OTHER THAN
NOTE: INCORRECT BLOCK THICKNESS WILL
ORIGINAL SHIM WILL DISTURB CRITICAL
DISTURB CRITICAL CLEARANCES AND MAY CLEARENCES AND MAY RESULT IN
RESULT IN DIFFERENTIAL FAILURE. DIFFERENTIAL FAILURE. Slight polishing or
scuffing on discs and shims is normal.
4. Preassemble pinions and pinion thrust wahsers on 10. Remove disc pack from side gear and carefully
pinion yoke. Index yoke to proper position and install in lower disc pack assembly into left side case half. Make sure
housing with center over button end of reaction block. A car guide clips are in their proper position.
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 11. Install side gear in left side case half. Rotate gear
side up. Use original block unless severely scored or worn. to engage spline with splines on discs.
If new block is used, determine face-to-face thickness of 12. Being careful not to dislodge side gear assembly
original block with calipers and replace with a service block (hold thumb on inside of side gear spline), lower the left
of the same thickness. hand case assembly onto the right hand case. Index left hand
case so holes in housing will line up for the governor
NOTE: Right and left side reaction blocks may not be assembly and latching bracket shafts.
the same thickness. If blocks are broken or cannot be 13. Turn entire unit over and install three (3) screws.
accurately measured for thickness, the entire 14. Lock an axle shaft in a vise in a vertical position.
differential must be replaced. Incorrect block thickness Install differential assembly on axle shaft engaging the
will disturb critical clearances and may result in spline of the axle with a side gear. Rotate unit slowly. A
differential failure. short shaft held in pinion yoke hole will aid in rotating. The
6. Install governor assembly and latching barcket in unit should turn smoothly without binding or locking up.
their respective locations. Place straight end of latching
bracket spring over and to the outside of the governor shaft NOTE: Differential will lock if turned rapidly-50 rpm
to preload the latching bracket against the governor or greater.
assembly. 15. Install ring gear and side bearings using the
7. Install the original (3) eared and (2) splined clutch procedure outlined for conventional differentials.
plates on the left side gear alternately, starting and ending
with an eared disc. 16. Place differential unit in carrier and adjust ring gear
to pinion backlash and gear tooth pattern as outlined in the
NOTE: ORIGINAL DISCS MUST BE USED. conventional differential section.
ATTEMPTS TO INSTALL OTHER THAN
ORIGINAL DISCS WILL DISTURB CRITICAL NOTE: Use standards differential lubricant. DO NOT
CLEARANCES AND MAY RESULT IN use lubricants specifically designed for "limited slip
DIFFERENTIAL FAILURE. differentials".
 REAR AXLE DIFFERENTIAL 4B-77

S P E C IA L TOOLS

i-J «_l

OW' —- •<*
%
M ___

8 10 12 13

e
14 15 16 17 18

21
1. J 6 2 66 Pinion Setting Gauge 9. J-22888 Differential Bearing Remover
J-6266-28 Barrel Adapter 10. J-7079-2 Driver Handle (Insert Type)
J-6266-25 Plug 11. J-8092 Driver Handle (Threaded Type)
J 6 2 66-5 2 Gauge Plate 12. J-8609 01 Pinion Rear Bearing Installer - Passenger Car
J-6266-53 Gauge Plate J-5590 (7 -1 /2 " )
J-6266-31 Adapter Rings 13. J-8612 Rear Pinion Bearing Remover
2. J 23 597 1 Pinion Setting Gauge (7 -1 /2 " ) J-253200 (7 -1 /2 " )
J 21 777 1 Arbor 14. J 8608 Pinion Rear Bearing Cup Installer
J 21 777-45 Side Discs J 7817 (7 -1 /2 " )
J 21 7 7 7 29 Gauge Plate 15. J-1313 0 150 Ft. Lbs. Torque Wrench
J 21 777-42 Front Bearing Plug 16. J-5853 In. Lbs. Torque Wrench
J-21777-43 Stud 17. J 7137 Pinion Front Bearing Cup Installer
3. J 22779 Side Bearing Shim Gauge (Used with J-8092)
J 22 779 Strap J 7817 (7 -1 /2 " )
4. J 22 175 Side Bearing Installer (8 -3 /4 " )-(8 -7 /8 " ) 18. J-8107-4 Differential Bearing Remover - Installer
J 22761 (8 -1 /2 " ) (Used with J 9 5 37 and J 22779)
J 25 299 (7 -1 /2 " ) 19. J 8614 Companion Flange Holder
5. J 9 4 58 Companion Flange Installer - Passenger Car 20. J -2 2 8 6 4 -1 ,2 Pinion Seal Gauge Plate (7 1 /2 " ,8 1 /2 " ,8 7 /8 '
6. J 55 90 Pinion Rear Bearing Cup Installer - Truck Axle 21. J 23911 Pinion Oil Seal Installer (7 1 /2 " ,8 -1 /2 " ,8 -7 /8 " )
7. J 8001 Dial Indicator Set 22. J-0270-14 Pinion Rear Bearing Cup Installer
8. J 5 7 48 Positraction Torque Measuring Adapter Truck Axle (Used with J-8092)

Fig. 1T~Special Tools - 7 - 1 / 2 " , 8 - 1 / 2 " , 8 - 3 / 4 " , 8 - 7 / 8 " Ring Gear Differentials
 M i

4B-78 REAR AXLE DIFFERENTIAL

> >

1. J-6266 Pinion Setting Gauge 10. J-22175 Differential Bearing Installer

J-6266-28 Barrel Gauge 11. J-22888 Differential Bearing Remover (Used with
J-6266-31 Sleeves J-8107-4)
J-6266-53 Gauge Plate 12. J-9774 Differential Yoke Bearing Seal Installer
J-0358-1 Press Plate Holder 13. J-5780 Companion Flange Installer
J-9771 Drive Pinion Bearing Cone and Roller Assembly 14. J-8092 Driver Handle (Threaded Type)
Remover (Used with J-0358-1) 15. J-7079-2 Driver Handle (Insert Type)
J-5748 Positraction Torque Measuring Adapter 16. J-8001 Dial Indicator Set
J-21777-01 Pinion Setting Gauge 17. J-22779 Side Bearing Shim Gauge
J-21777-45 Side Discs J-22779-6 Strap
J-21777-29 Gauge Plate 18. J-4880 Snap Ring Pliers
J-21777-42 Front Bearing Pinion 19. J-5810 Torque Wrench Adapter (3/4" Male to 3 /8 ”
J-21777-43 Stud Female)
J-21777-1 Arbor 20. J-3289 Differential Carrier Holding Fixture
6. J-9773 Differential Yoke Bearing Installer 21. J-22311 Positraction Clutch Pack Remover and Installer
(Used with J-7079-2) 22. J-1313 Ft.-Lb. Torque Wrench
7. J-8609 Positraction Torque Measuring Adapter 23. J-5853 In.-Lb. Torque Wrench
8 . J-7137 Drive Pinion Front Bearing Cup Installer 24. J-8614 Companion Flange Holder and Remover
(Used with J-8092)
9. J-8608 Drive Pinion Rear Bearing Cup Installer
(Used with J 8092)

Fig. 2 T - S p e c ia l Tools - Corvette Differential

 REAR AXLE DIFFERENTIAL 4B-79

15

1
16 19 21 23

v’ r 24
20 22
17
18
1. J-22912 Press Plate 13. J-8001 Dial Indicator Set
2. J-1453 Pinion Bearing Press Plate 14. J-0972 Differential Nut Wrench
3. J-8107 Differential Bearing Puller Set 15. J-24381 Pinion Rear Bearing Cup Installer
4. J-8107-3 Adapter Plug 16. J-24383 Side Bearing Installer
5. J-22888 Differential Side Bearing Remover 17. J-24384 Pinion Oil Seal Installer
6. J-1364 Pinion Bearing Ring Drive 18. J-24385 Case Spreader Tool
7. J-1488 Differential Side Bearing Replacer 19. J-24430 Side Bearing Installer
8. J-8608 Drive Pinion Rear Bearing Cup Installer 20. J-24432 Pinion Rear Cup Installer
(Used with J-8092) 21. J-23322 Pinion Straddle Bearing Installer
9. J-5853 In.-Lbs. Torque Wrench 22. J-24429 Adjusting Nut Wrench
10. J-8092 Drive Handle 23. J-24434 Pinion Oil Seal Installer
11. J-8614 Companion Flange Holder and Remover 24. J-24433 Pinion Rear Bearing Installer
12. J-22281 Pinion Flange Oil Seal Installer

Fig. 3 T - S p e c i a l Tools 1 0 - 1 / 2 " and 1 2 - 1 / 4 " Ring Gear Differentials

4B-80 REAR AXLE DIFFERENTIAL
 FRONT WHEEL DRIVE 4C-1

SECTION 4C

FRONT AXLE DIFFERENTIAL

(4-WHEEL DRIVE)
CONTENTS
Front Axle Differential........................ .......................... 4C-1 Drive Pinion.................................................................... 4C-5
General Information.......................... ....................... 4C-1 Installation and Adjustment......................... .............. 4C-5
Differential Case................................. .......................... 4C-1 Differential Case.............................................. .............. 4C-6
Removal............................................. .......................... 4C-1 Preload and Adjustment............................... .............. 4C-6
Oil Seal Replacement....................... .......................... 4C-1 ' Installation....................................................... .............. 4C-6
Disassembly........................................ 4C-4 Gear Tooth Contact Pattern Check............................ 4C-7
Drive Pinion......................................... 4C-4 Gear Tooth Nomenclature............................ .............. 4C-7
Removal.............................................. .......................... 4C-4 ............. 4C-7
Inspection........................................... . 4C-4 Adjustments.................................................... ............. 4C-7
Differential Case................................. 4C-4 Special Tools..................................................... ............. 4C-9
Reassembly......................................... 4C-4

GENERAL INFORMATION
K 10-20 Models use a Chevrolet or a Dana (44 Series) FRONT AXLE DIFFERENTIAL
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" Differential Case (Dana-Models)
ring gear. 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.
The following procedures pertain to Dana model axles 2. Remove cover attaching bolts and lock washers and
only. Procedures for the Chevrolet 8-1/2" model are the the metal tag secured by one of the attaching bolts. Remove
same as covered previously in Section 4B of this manual. cover and gasket.
NOTE: 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".
CAUTION: Do not attemtp to remove differential
without using the spreader tool. Do not expand
carrier 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
Fig. 4C-1~Spreading Case W ith J - 2 4 3 8 5 carrier, using tool J-25111.
4C-2 FRONT WHEEL DRIVE

1. Nut 11. Differential Bearing Cone 20. Differential Case 29. Thrust Washer
2. Washer 12. Differential Bearing Cup 21. Differential Bearing Adjusting 30. Ring Gear Bolt
3. Pinion Flange 13. Bearing Cap Shims 31. Oil Slinger
4. Outer Bearing Shims 14. Differential Bearing Adjusting 22. Differential Bearing Cap 32. Differential Carrier
5. Drive Pinion Shims 23. Differential Bearing Cone 33. I nner Bearing Cone
6. I nner Bearing Shims 15. Differential Pinion 24. Differential Bearing Cup 34. I nner Bearing Cup
7. Lock Pin 16. Thrust Washer 25. Cover Bolt 35. Outer Bearing Cup
8. Differential Side Gear 17. Cover 26. Gasket 36. Outer Bearing Cone
9. Thrust Washer 18. Pinion Cross Shaft 27. Axle Shaft 37. Oil Slinger
10. Axle Shaft 19. Ring Gear 28. Oil Seal 38. Oil Seal

Fig. 4C-2~Front Axle Differential Assembly

Fig. 4C-3--Differential - Exploded
View

FRONT
1. Nut 11. Shims (Inner Pinion 17. Cover and Plug 24. B olt (D ifferential
2. Washer Bearing) 18. Lock Pin (Pinion Bearing Cap)
3. Companion Flange 12. Cup (Inner Pinion Shaft) 25. B olt (Ring Gear)

WHEEL DRIVE
4. Pinion Oil Seal Bearing) 19. D ifferential Case 26. Pinion Shaft
5. Gasket 13. Cone and Roller 20. Shims (D ifferential 27. Thrust Washer
6. O uter Pinion Oil Slinger (Inner Pinion) Adjusting) (Pinion)
7 and 8. Cone and Roller 14. Ring and Pinion 21. Cone and Roller 28. Pinion
(Outer Pinion Bearing) 15. Gasket (Housing (D ifferential Bearing) 29. Side Gear
9. Shims (Outer Pinion Cover) 22. Cup (D ifferential 30. Thrust Washer (Side
Bearing) 16. Screw and Washer Bearing) Gear)
10. Inner Pinion Oil Slinger (Cover) 23. Cap (D ifferential

4C-3
Bearing)
4C-4 FRONT WHEEL DRIVE

J 22888
J-8614-1

Fig. 4C-5--Removing Pinion Flange

Fig. 4C -4-R em oving Side Bearing

not indicate a defective bearing.

Disassembly 2. Inspect pinion splines and flange splines for evidence
1. Remove bearing cups from differential case and of excessive wear.
identify for reassembly. 3. Inspect ring gear and pinion teeth for possible
2. Remove bearing cones from case, using puller J- scoring, cracking or chipping.
22888 and correct plug (fig. 4C-4) and remove shims from 4. Inspect differential case for carcks or scores or side
case. Identify all parts so they may be reassembled in their gears, thrust washers, and pinion thrust faces.
original location. 5. Check fit of differential side gears in case.
3. Drive the pinion shaft lock pin out of case. 6. Check fit of side gears and axle shaft splines.
4. Remove ring gear bolts from case and separate ring 7. Inspect differential pinion shaft and spacer for
gear from case. scoring or evidence of excessive wear.
5. Remove pinion shaft, pinions, side gears and thrust
washers from case. DIFFERENTIAL CASE
Reassembly
DRIVE PINION
1. Position differential side gears and new thrust
Removal washers in differential case.
1. Using Holding Bar J-8614-1, attached to pinion shaft 2. Position differential pinions and new thrust washers
flange, remove self-locking nut and washer from pinion in differential case. Align pinions with holes in differential
shaft. case.
2. Install Tool J-8614-2, and 3 into holding bar as 3. Install pinion shaft in differential case. Align hole
shown in Figure 4C-5 and remove flange from drive pinion. in shaft with hole in case, then install lock pin. Peen hole
Remove drive pinion from carrier. to prevent pin dropping out of case.
3. With a long drift, tap on inner race of outer pinion 4. Position ring gear to case, then install cap screws.
bearing to remove pinion oil seal, slinger, gasket, outer Tighten cap screws evenly and alternately to specifications.
pinion cone and roller and shim pack. Tag shim pack for
reassembly.
4. 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.
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.
NOTE: 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 Fig. 4C-6--Removing Inner Pinion Bearing Cone and Roller
 FRONT WHEEL DRIVE 4C-5

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 "0".
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 "0". 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
in thicknesses of .003", .005" and .010".
NOTE: If baffle or slinger is bent or mutilated, it
should be replaced.
Fig. 4C-7--Checking Runout

Measure each shim separately with a micrometer and

5. With an arbor press, press differential side bearings add together to get total shim pack thickness from original
onto case using Tool J-22175. Do not install shims at this build up.
time. If a new gear set is being used, notice the plus or minus
6. Place differential case in carrier and install bearing etching on both the old and new pinion, and adjust the
caps. Care should be taken to install caps in original thickness of the old shim pack to compensate for the
position. Use mark placed on caps and carrier at removal. difference of these two figures.
Tighten caps just enough to keep bearing caps in place. For example: If the old pinion reads +2 and the new
7. Install dial indicator on carrier with indicator button pinion is -2, add .004" shims to the original shim pack.
contacting back of ring gear (Fig. 4C-7). Rotate differential 1. Determine proper inner shim pack (for setting pinion
case and check for runout. If runout is greater than .002", depth) by using chart (fig. 4C-8).
the assembly should be removed and the ring gear removed 2. Install inner shim pack and oil slinger in inner cup
from case. Again install differential case and check runout bore and drive inner cup into position using Tool J-21059
at differential case flange. used with J-8092.
8. Should runout of case flange be greater than .002", 3. To the outer shim pack (for setting preload) add or
the defect is probably due to bearings or differential case, remove an equal amount as was added or removed from the
and should be corrected before proceeding further. inner shim pack.
9. Position two screwdrivers between bearing cup and 4. Install outer cup in carrier bore, using installer J-
carrier on opposite side of ring gear (away from dial 7818 with Drive Handle J-8092.
indicator side). Pull on screwdrivers and force differential 5. Press inner pinion bearing cone and roller onto
case as far as possible toward the dial indicator. Rock the pinion shaft using Installer J-9772 on arbor press as shown
ring gear to set the bearings. With force still applied, set in Figure 4C-9.
indicator at "0". 6. Install drive pinion and inner bearing cone and roller
10. Reposition screwdrivers between bearing cup and assembly in differential carrier.
carrier on ring gear side. Pull on screwdrivers and force 7. Install shims and outer pinion cone and roller on
differential case as far as possible toward center of carrier. pinion shaft using Tool J-5590 and companion flange to
Repeat several times until the same reading is obtained. press bearing onto pinion (Fig. 4C-10).
Record the indicator reading. This will be the total amount 8. Install flange holding bar and install washer and nut
of shims needed (less preload) for setting backlash later on pinion shaft. Torque nut to 255 ft. lbs.
during assembly. 9. Remove holding bar and with an inch pound torque
11. Remove differential from carrier. wrench measure rotating torque. Rotating torque should be
10 to 20 in. lbs. with original bearings or 20 to 40 in. lb.
DRIVE PINIO N
with new bearings.
Installation and Adjustm ent of Depth and NOTE: Torque reading to start shaft turning must be
Preload disregarded.
Ring gears and pinions are supplied in matched sets 10. If torque requirements (preload) are not to
only. Matching numbers on both pinion and ring gear are specifications, adjust shim pack as necessary. Increase the
etched for verification. If a new gear set is being used, verify outer shim pack to reduce rotation torque. Decrease shim
the numbers of each pinion and ring before proceeding with pack to increase rotating torque.
assembly. 11. Remove nut, washer and flange from pinion shaft.
On the button end of each pinion there is etched a plus 12. Install oil slinger, gasket and using Tool J-22804
+ number, a minus - number, or a zero(0) number, which install oil seal.
indicates the best running position for each particular gear 13. Install flange, washer and nut. Torque nut to
set. This dimension is contolled by the shimming behind the specifications.
4C-6 FRONT WHEEL DRIVE

New Pinion Marking

Old Pinion
Marking
- 4 - 3 - 2 - 1 0 +1 +2 +3 +4

+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0

+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001

+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002

+ 1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003

0 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004

\

- 1 + 0.003 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005

- 2 + 0.002 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006

- 3 + 0.001 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006 - 0.007

- 4 0 - 0.001 - 0.002 - 0.003 - 0.004 - 0.005 - 0.006 - 0.007 - 0.008

Fig. 4C -8-D rive Pinion Shim Chart

DIFFERENTIAL CASE a. Subtract the size of shim pack just installed on ring
gear side of case from the reading obtained and recorded
Preload and Adjustm ent in step 10 of Differential Case Reassembly.
1. Place differential assembly (with pinion assembled) b. To this figure, add an additional .015" shims to
into housing Install bearing caps in their proper position and compensate for preload and backlash.
tighten screws just enough to hold the bearing cups in place. Example: If reading in step 10 of Differential Case--
2. Install dial indicator on carrier with indicator button Reassembly was .085" and the shims installed on ring gear
contacting back of ring gear (Fig. 4C-7). side of case was .055", the correct amount of shim will be
3. Place two screwdrivers between bearing cup and .085" - .055" + .015" =.045".
housing on ring gear side of case, and pry ring gear into 6. Install shims as indicated in step 5, (which will give
mesh with pinion gear as far as it will go. Rock ring gear the proper bearing preload and backlash) and install side
to allow bearings to seat and gears to mesh. With force still bearing.
applied, set indicator to "0".
4. Reposition screw drivers on opposite side of ring gear Installation
1. Spread differential carrier, using spreader as shown
and pry ring gear as far as it will go. Now take and indicator in Figure 4C-1.
reading. Repeat until the same reading is obtained every 2. Install differential bearing cups in their correct
time. This reading will be the necessary amount of shims locations then install differential case into carrier.
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
J-5590

side of ring gear. To determine the amount of shims needed

here, use the following method.

Fig. 4C-9--lnstalling Inner Pinion Core and Roller Fig. 4C-10--lnstalling Pinion Flange
 FRONT WHEEL DRIVE 4C-7

Gear Tooth Nomenclature

The side of the ring gear tooth which curves outward,
or is convex, is referred to as the "drive" side. The concave
side is the "coast" side. The end of the tooth nearest center
of ring gear is referred to as the "toe" end. The end of the
tooth farthest away from center is the "heel" end. Toe end
of tooth is smaller than heel end. 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 lb. ft.
4. Apply a load until a torque of 40-50 lb. ft. is required
to turn the pinion.
NOTE: A test made without loading the gears will not
Fig. 4C-1 1~Gear Tooth N om enclature
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
3. Install differential bearing caps in the correct in opposite direction. Excessive turning of ring gear is
location as indicated by marks made at disassembly. Install not recommended.
cap screws finger tight. Rotate differential assembly and rap 5. Observe pattern on ring gear teeth and compare with
on case with a soft-faced hammer to ensure proper seating Figure 4C-12.
of case in carrier.
4. Remove spreader and torque cap bolts to Adjustm ents A ffecting Tooth Contact
specifications. Two adjustments can be made which will affect tooth
5. Install dial indicator and check ring gear backlash contact pattern. These are backlash and position of drive
at four equally spaced points around the ring gear. Backlash pinion in carrier. The effects of bearing preloads are not
must be held to .004" to .009" and must not vary more than readily apparent on hand loaded teeth pattern tests:
.002" between positions checked. however, these adjustments should be within specifications
before proceeding with backlash and drive pinion
6. Whenever backlash is not within limits, differential adjustments.
bearing shim pack should be corrected to bring backlash NOTE: It may be necessary to adjust both pinion depth
within limits. and backlash to obtain the correct pattern.
7. Check gear tooth contact as described in "Gear The position of the drive pinion is adjusted by
Tooth Contact Pattern Check". increasing or decreasing the shim thickness between the
8. After a successful pattern check, install housing pinion head and inner race of rear bearing. The shim is used
cover using a new gasket. in the differential to compensate for manufacturing
tolerences. Increasing shim thickness will move the pinion
9. Install axle shafts and install axle assembly into closer to centerline of the ring gear. Decreasing shim
vehicle (See Service Manual). thickness will move pinion farther away from centerline of
10. Fill with recommended lubricant, lower vehicle to the ring gear.
floor and road test vehicle. Backlash is adjusted by means of the side bearing
adjusting shims which moves the entire case and ring gear
GEAR TOOTH CONTACT PATTERN CHECK assembly closer to, or farther from the drive pinion. (The
Prior to final assembly of the differential, a Gear Tooth adjusting shims are also used to set side bearing preload).
Contact Pattern Check is necessary to verify the correct To increase backlash, increase right shim and decrease left
relationship between ring gear and drive pinion. Gear sets shim an equal amount. To decrease backlash, decrease right
which are not positioned properly may be noisy, or have shim and increase left shim an equal amount.
short life, or both. With a pattern check, the most desirable The important thing to note is that the contact pattern
contact between ring gear and drive pinion for low noise is centrally located up and down on the face of the ring gear
level and long life can be assured. teeth.
4C-8 FRONT WHEEL DRIVE

Fig. 4C-1 2-G ea r Tooth Pattern C ontact Pattern

 FRONT WHEEL DRIVE 4C-9

1. J-24385 Spreader - Axle Carrier 8. J-8614-01 Holder and Remover -

2. J-22888 Puller - Side Bearing Companion Flange
3. J 22175 Installer - Side Bearing 9. J-23476 Installer - Companion Flange
4. J-5590 Installer - Pinion inner and 10. J-5341 Gauge - Pinion Depth Consists
outer bearing cone of Parts:
5. J-6368 Installer - Pinion outer (1) SE 1065-1, (2)-5, (2)-6,
bearing cup (use with J;8092) (2)-9SS, (1)-10,
6. L-8092 Driver Handle (use with J-6368) (1)-58 with 1” micrometer
7. J-9276-2 Installer - Pinion inner bearing 11. J-8001 Dial Indicator Set
12. J-22912 Press Plate Pinion bearing
13. J-23494 Installer - Pinion oil seal
use with J-23476

Fig. 4C-1 3~Special Tools Chart 4C-A

 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 A N IM PORTANT
ATTACH ING P ART IN THAT IT COULD AFFECT THE
PERFORMANCE OF VITAL COMPONENTS AN D SYSTEMS
AN D /O R COULD RESULT IN MAJOR REPAIR EXPENSE. IT
M UST BE REPLACED WITH ONE OF THE SAM E PART
NUMBER OR WITH A N EQUIVALENT P ART IF
REPLACEM ENT BECOMES NECESSARY. DO N O T USE A
REPLACEM ENT P AR T OF LESSER QU ALITY OR SUBSTITUTE
DESIGN. TORQUE VALUES M UST BE USED A S SPECIFIED
DURING REASSEMBL Y TO ASSURE PROPER RETENTION OF
THIS PART.
CONTENTS
Delco Tandem Power Brake Unit................................................ ...... 5-1
Bendix Tandem Power Brake Unit..................................................... 5-6
Delco Single Diaphragm Power Brake Unit..................................... 5-11
Bendix Single Diaphragm Power Brake U nit................................... 5-18
Bendix Hydro-Boost Power Unit........................................................ 5-22
DELCO TANDEM POWER BRAKE UNIT
UNIT REPAIR
D isassem bly Power Piston Group (Fig. 5-3A)
NOTE: Scribe a line across front and rear housing to 1. Remove reaction retainer and piston rod from the
facilitate reassembly. power piston.
1. Remove and discard the vacuum check valve and 2. Remove the power head silencer from the neck of
grommet from the front housing. the power piston tube.
2. Attach base of Holding Fixture J-22805 to front 3. Turn power piston group upside down so that end
housing with nuts and washers and draw down tight to of push rod is against a hard surface. Grasp entire power
eliminate damage to studs. Clamp base in a bench vise with piston group with both hands and use slight force or impact
the power section up (fig. 5-2A). on push rod to remove diaphragm retainer.
3. Place Spanner Wrench J-9504 over studs on rear 4. Remove diaphragms, support plates and divider
housing and attach with nuts and washers. Draw nuts down from the power piston.
tight to eliminate bending or damaging of studs. 5. Separate both the primary and secondary
Press down on Spanner Wrench J-9504 and rotate the diaphragms from the support plate.
rear housing counterclockwise to separate the two housings. 6. Using a screwdriver, remove reaction body retainer.
CAUTION: Care must be exercised not to damage 7. Remove reaction body.
or loosen studs in housing. Also, take care that no 8. Remove reaction disc and reaction piston from the
pressure is brought to bear on plastic power center of reaction body by pushing down on the end of the
piston. reaction piston with a small cylindrical object, such as a
4. Remove Tools J-9504 and J-22805 from front and pencil or dowel.
rear housings. 9. Remove air valve spring.
5. Remove the power piston return spring. 10. Remove the rubber reaction bumper on the end of
6. Remove front housing seal. the air valve.
Rear Housing Group 11. Using Truarc No. 2 pliers (J-4880 or equivalent)
1. Remove the boot and boot retainer from the rear remove the retaining ring from the air valve.
housing and push rod. Remove the felt silencer from inside 12. Remove the air filter from the tubular section of
the boot. the power piston.
2. Remove the power piston group from the rear 13. Remove the air valve push rod assembly from the
housing and remove the power piston bearing from the push rod end of the power piston. The following removal
center opening of the rear housing. methods are recommended.
5-2 BRAKES

FRONT HOUSING SEAL

Fig. 5-1A--Delco Tandem Power Brake U n it-E xplo de

a. Place the power piston in an arbor press and press straight out. A considerable force will be required.
the air valve push rod assembly out of the bottom of the 14. Removal of the air valve push rod assembly will
power piston tube with a rod not exceeding 1/2" in disassembly the control valve retainer.
diameter. 15. Remove the "O" ring from the air valve.
b. An alternate method would be the use of a heavy, 16. Models using air valve push rod rod assemblies with
round shanked screwdriver. Insert screwdriver on both sides a formed eye on the end of the push rod will be serviced
of the push rod, and pull the air valve push rod assembly using a complete assembly, since the floating control valve
cannot be removed over the eye end of the push rod.
Cleaning
J-9504
After disassembly, immerse all metal parts in metal
cleaner. Plastic parts, as well as the rubber power
diaphragms, should be cleaned in denatured alcohol or clean
brake fluid. Care should be taken to avoid chipping or
damaging plastic parts in handling. After parts have been
thoroughly cleaned, those parts which come in contact with
hydraulic brake fluid (that is, all master cylinder parts and
the power section push rod) should be thoroughly washed
in denatured alcohol or clean brake fluid before assembly.
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
J-22805

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,
Fig. 5 -2 A - U n lo c k in g Front and Rear Housings REPLACE them!
 BRAKES 5-3

Fig. 5-3A~Power Piston Group--Explode

Inspecting M etal Parts Power Piston Group (Fig. 5-3A)

BADLY DAMAGED ITEMS, OR THOSE WHICH 1. Lubricate the "O" ring seal with silicone lubricant
WOULD TAKE EXTENSIVE WORK OR TIME TO and place on the air valve.
REPAIR, SHOULD BE REPLACED. In case of doubt, 2. Wipe a thin film of silicone lubricant on the large
install new parts. and small O.D. of the floaing control valve.
3. If the floating control valve needs replacement,
Assembly replace the complete air valve push rod assembly.
1. Be careful during the rebuild procedure that no 4. Place the air valve end of the air valve push rod
grease or mineral oil comes in contact with the rubber parts assembly into the tube of the power piston. Manually press
of the power brake unit. the air valve push rod assembly so that the floating control
2. Lubricate power unit parts, as outlined below, with valve bottoms on the tube section of the power piston.
power brake silicone lubricant. This lubricant is provided 5. Place lip of retainer on the O.D. of Tool J-23175 (fig.
in the service repair kit. 5-4A). Manually press the retainer until seated in the power
piston tube (fig. 5-5A).
Front Housing Group Assembly 6. Install filter element over the push rod eye and press
1. Insert the NEW grommet in the front housing. into the power piston tube.
7. Using snap ring pliers, place the snap ring into the
2. Install the NEW vacuum check valve into the groove in the air valve.
grommet. 8. Install the rubber reaction bumper on the end of the
3. Install NEW front housing seal. air valve.
5-4 BRAKES

Fig. 5 -6 A ~ lnstallin g Secondary Diaphragm and S upport Plate

Assem bly

9. Install air valve spring on end of air valve. piston (fig. 5-6A).
10. Install reaction body with large I.D. hole up. 16. Assemble secondary diaphragm to secondary
11. Replace reaction body retainer. support plate. Press the raised flange on the I.D. of the
12. Install reaction piston into reaction body large diaphragm through the center hole of the support plate. Be
diameter up. sure that the edge of the support plate center hole fits into
13. Apply a light film of silicone lubricant to the O.D. the groove in the raised flange of the diaphragm. Apply a
of the rubber reaction disc. thin coat of silicone lubricant to the I.D. of the secondary
14. Place the rubber reaction disc in the cavity of the diaphragm.
reaction body. 17. With assembly Tool J-28458 mounted on the power
15. Place the power piston on bench with the push rod piston, place the secondary diaphragm and support plate
up. Install assembly cone J-28458 over push rod end of assembly over the power piston (see Figure 5-6A) and push

J-23175
 BRAKES 5-5

the secondary diaphragm (fig. 5-7A).

21. Assemble the 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. 5-8A).
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. 5-9A).
26. Wipe a thin film of silicone lubricant on the O.D.
of the piston rod retainer. Insert the master cylinder piston
Fig. 5 -8 A ~ ln sta llin g Primary S up po rt Plate and Diaphragm rod retiner into the cavity in the power piston so that the
A ssem bly flat end bottoms against the rubber reaction disc in the
bottom of the cavity.
down until it bottoms on power piston.
18. Hold the housing divider so that the formed over Rear Housing Group
1. Place the power piston bearing in rear housing center
flange (that holds the primary diaphragm) of the divider hole so that the formed flange of the housing center hole
faces down. Place the power piston bearing in the I.D. of fits into the groove of the power piston bearing. The thin
the divider so that the extended lip of the bearing faces up. lip of the bearing will protrude to the outside of the housing.
19. Lubricate the I.D. of the power piston bearing with 2. Coat the I.D. of the power piston bearing with
silicone lubricant. silicone lubricant.
20. With Tool J-28458 still positioned on the power
piston, hold the housing divider so that formed over flange Final Assembly
of the divider faces up. Press the divider down over the tool 1. Mount Holding Fixture J-22805 in a vise and
and onto the power piston tube where it will rest against position the front housing on the tool so that the housing
studs fit in the holes provided in the tool. Install washers
and nuts and draw them down tight to eliminate damage
to studs.
2. Position the power piston return spring over the inset
in the front housing.
3. Assemble the power piston group to the rear housing
by pressing the tube of the 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.
4. Place the piston rod retainer plate on the end of the
power piston return spring in the front housing.
5. Hold the rear housing assembly (with mounting
studs up) over the front housing. (Make sure that the piston
rod retainer does not dislodge from the power piston during
this operation.) Position the rear housing so that when the
tangs on the edge of the front housing are locked in the slots
on the edge of the rear housing, the scribe marks on the top
of the housings will be in line.
6. Lower the rear housing assembly onto the front
housing. The power piston spring must seat in the
depression of the power piston retainer. Check that the bead
on the O.D. of the secondary diaphragm is positioned
between the edges of the housing.
7. Place Spanner Wrench J-9504 over studs on the rear
housing, and attach with nuts and washers- draw nuts
5-6 BRAKES

rear housing.
10. Remove the power head assembly from Holding
Fixture J-22805 and remove Fixture J-22805 from the vise.
Gaging
1. Place the power head assembly in a padded vise
(front housing up). Do not clamp tight.
2. Insert the master cylinder piston rod, flat end first,
into the piston rod retainer.
3. Press down on the master cylinder piston rod (with
approximately a 40-50 pound load) to be sure it is properly
seated.
4. Remove the front housing seal to assure that no
vacuum is in the power head while gaging.
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
Fig. 5-10A~G aging Piston Rod without contacting the studs (fig. 5-10A).
6. The center section of the gage has two levels. The
down tight to eliminate bending or damageing of studs. piston rod should alw ays contact the longer section (lower
Press down on spanner wrench and twist rear housing level) of the gage. The piston rod should never contact the
clockwise in relation to front housing until fully locked. shorter section (higher level) of the gage. Move gage from
NOTE: If unit is not easily locked, hold housings
side to side to check piston rod height.
together and apply vacuum to check valve in front 7. Any variation beyond these two limits must be
housing. Do not put pressure on power piston compensated for by obtaining the service adjustable piston
extension. rod and adjusting the self-locking screw to meet gaging
8. Remove Tool J-9404 from the rear housing. specifications.
9. Place the silencer in the closed end of the power head 8. Wipe a thin film of silicone lubricant on the I.D. of
boot. Push the boot retainer over the boot. Stretch the boot the front housing seal and position seal in the depression in
over the push rod and over the flange in the center of the the housing.

BENDIX TANDEM POWER BRAKE UNIT

UNIT REPAIR
Disassembly lances will clear the cutouts in the front housing. If the metal
1. Scribe a line across the front and rear housings to tabs that form the deep lances break during straightening,
facilitate reassembly. the housing must be replaced (fig. 5-3B).
2. Carefully remove hydraulic push rod and 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
 BRAKES 5-7

J-9504

J-22805 1V i" OPEN END

WRENCH

Fig. 5-2B--Air Valve Rod Assem bly

Fig. 5-4B--Holding and S eparating Housings Using J -2 2 8 0 5
and J-9 5 0 4 in A rb o r Press

10. Remove the hydraulic push rod and vacuum seal

from the front housing. rear housing down far enough to relieve tension of
11. Attach base of Holding Fixture J-22805 to front diaphragm rubber lip and spring.
housing with nuts and washers and draw down tight to 14. Rotate spanner bar counterclockwise until the
eliminate bending or damage to studs. lances in the edge of the rear housing are aligned with the
12. Place power unit with Holding Fixture J-22805 in cut-outs in the front housing. Considerable effort may be
an arbor press with rear housing up and secure to plate of required to rotate the front housing.
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 W A R N IN G : The diaphragm return spring
and allowing unit to turn against back of arbor press, press is compressed in the power section and
will hold unit from turning. expands as the pressure on the housings
13. Place Spanner Wrench J-9504 over studs on rear is removed. If the housings do not
shell (fig. 5-4B). Use three washers and nuts to attach separate w hen the screw has been turned
wrench to housing. Use a suitable piece of pipe of slightly to reduce the pressure, tap the
approximately two inches I.D. and approximately three housings w ith a rubber hammer to break
inches in length. Place over plastic diaphragm plate hub. the bond.
Place a piece of flat stock steel over end of pipe and press
15. Slowly release press to permit the two housings to
separate.
16. Continue to release press until diaphragm spring
tension has been removed.
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.
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
Fig. 5-3B--Lances in Rear Housing the plates from Tool J-22839 and place on a bench with the
5-8 BRAKES

SQUARE SECTIO NED O -RING

V A L V E RETURN SPRING

V A L V E PLUNGER

REAR D IA PH R A G M PLATE,

REAR D IA P H R A G M ,

REAR D IA PH R A G M R E TA IN ER

REAR SHELL

V A L V E POPPET

POPPET R E T A IN E R

V A L V E ROD SPRING

SILENCER

SILENCER R E T A IN E R

FRO NT SHELL

SPRING

REA C TIO N DISC

FR O N T D IA PH R A G M PLATE

FR O N T D IA PH R A G M

CENTER PLATE

Fig. 5-5 B -D ia ph rag m and Plates

front plate down. Unscrew the rear plate completely and Cleaning
carefully lift it off the front plate hub, grasping the air valve
plunger and valve return spring as the parts are separated All parts to be reused should be washed in denatured
(fig. 5-5B). alcohol or brake fluid. Dry the parts with compressed air
25. Remove the square ring seal from the shoulder of and place them on clean paper or lint free cloth.
the front diaphragm plate hub.
26. Remove the reaction disc from inside the front Small rust spots inside the shells may be removed with
diaphragm plate hub. Carefully slide the center plate off the crocus cloth or fine emery cloth. Be sure to clean thoroughly
hub of the front plate. after using any abrasive.
27. Remove the diaphragms from the plates.
28. Use a blunt punch or 1-1/4" socket to drive seal Inspect all parts and replace any that are damaged or
from rear housing (figs. 5-6B and 5-7B). show excessive wear.
 BRAKES 5-9

Fig. 5-6B~Removing Rear Seal

Assembly 8. Set rear plate over hub of front plate, and using
1. Press the new bearing and seal into the cavity in the hands only, screw plate on hub, making sure that valve and
rear housing using Tool J-22677 (fig. 5-8B). The flat rubber spring are properly aligned. Hand torque plates to 150 in.
surface of the seal should be 5/16" below the flat, inside lbs. Check travel of valve plunger with index finger.
surface of the rear housing. 9. Assemble rear diaphragm to rear plate and place lip
2. Install reaction disc in hub of front plate with small of diaphragm in groove in rear plate. Install diaphragm
tip toward hole. Use rounded rod to seat disc. retainer over rear diaphragm and lip of center plate. Using
3. Mount Tool J-22839 in vise. fingers, press retainer until it seats on shoulder of center
4. Install front diaphragm on front plate. Long fold of plate (fig. 5-1 IB).
diaphragm must be facing down. 10. Apply talcum powder to inside wall of rear housing
5. Install Tool J-22733 over threads on front plate hub and silicone lubricant to the scalloped cutouts of front
(fig- 5-9B). housing and to seal in rear housing. Assemble diaphragm
6. Apply a light film of silicone lubricant to front plate and plate assembly into rear housing by carefully guiding
hub and to seal in center plate, then guide center plate, seal rear plate hub through seal in rear housing. Bosses on center
first, onto the front plate hub, being careful not to damage plate must be aligned between lances in rear housing for
center plate seal. Remove Seal Protector J-22733. reassembly. Work outer rim of front diaphragm into rear
7. Apply a light coat of silicone lubricant to bearing housing with screwdriver blade so that it is under lances in
surfaces of air valve plunger, being careful not to apply housing.
lubricant to rubber grommet inside plunger. Install square 11. Attach base of Holding Fixture J-22805 to front
ring seal on shoulder of front plate hub and install valve housing with nuts and washers and draw down tight to
plunger return spring and plunger in base of front plate hub eliminate bending or damage to studs.
(fig. 5-10B). 12. Secure front housing and Holding Fixture J-22805

REAR BEARING
AND VACUUM
SEAL

REAR
SHELL

Fig. 5-7B--Rear Bearing and Rear Shell Fig. 5-9B~Seal Protector J - 2 2 7 3 3 Installed
5-10 BRAKES

A IR V A L V E
PLU N G ER

SPRING

Fig. 5-12B G aging Piston Rod

18. Remove Holding Fixture J-22805 from front

housing by removing two nuts and washers.
19. Wet poppet valve with denatured alcohol and
Fig. 5-10B —Installin g A ir Valve Plunger 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
on arbor press plate by a suitable means (fig. 5-4B). ridge on rod and return spring over ball end of operating
13. Place Spanner Wrench J-9504 over studs on rear valve rod. Wet grommet in valve plunger with denatured
housing. Use three washers and nuts to attach wrench to alcohol and guide air valve rod into valve plunger. Tap end
housing. Place a suitable piece of pipe (approximately two of operating valve rod with plastic hammer to lock ball in
inch I.D. and approximately three inches in length) over grommet. Press filters and silencers into hub and install
plastic diaphragm plate hub. Place a piece of flat stock steel retainer on hub.
over end of pipe. 20. Assemble silencer in dust boot, wet dust boot
14. Install diaphragm return spring so that small end opening with denatured alcohol and assemble over
of spring is against front housing. operating valve rod and over flange of rear housing.
15. Place rear housing over front housing, and align 21. Install new check valve and grommet.
scribe marks. 22. Apply silicone lubricant to piston end of hydraulic
16. Rotate spanner wrench clockwise until housings are push rod and insert in cavity in front plate. Twist rod to
locked together. Bend tabs of the four deep lances back to eliminate air bubbles at reaction disc. Assemble seal over
their original position. push rod and press into recess in front housing.
17. Remove three nuts and lock washers securing rear Piston Rod Gauging
housing to spanner wrench. 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.
REAR PLATE
IREAR DIAPHRAGM 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. 5-12B).
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
FRONT DIAPHRAGM
shorter section (higher level) of the gage. Move gage from
CENTER PLATE 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
Fig. 5-1 1 B—Installing Rear Diaphragm Retainer specifications.
 BRAKES 5-11

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.

DELCO SINGLE DIAPHRAGM POWER BRAKE UNIT

UNIT REPAIR
Disassembly 4. Lift rear housing and power piston assembly from
unit. Then remove return spring.
1. Scribe a mark on bottom center of front and rear 5. Remove retaining ring on push rod that holds
housings to facilitate reassembly. silencer in place on push rod; remove silencer.
2. Attach base of Tool J-22805 to front housing with 6. Remove seal and vacuum check valve and grommet
nuts and washers and draw down tight to eliminate bending from front housing.
or damage to studs. Clamp base in bench vise with power Power Piston Assembly Group (Fig. 5-5C)
section up (fig. 5-2C). CAUTION: Care must be used in handling the
3. Separate front and rear housings as follows: diaphragm o f power piston assembly. Guard
a. Straight Mounting Bracket (Fig. 5-3C) - Place diaphragm against grease, oil, foreign matter and
Spanner Wrench J-9504 over studs on rear housing and nicks or cuts.
attach with nuts and washers. Draw nuts down tight to 1. Remove power piston assembly from rear housing.
eliminate bending or damaging of studs. 2. Remove silencer from neck of power piston tube.
b. T ilt Mounting Bracket (Fig. 5-4C)- Place tool 3. Remove lock ring from power piston by prying one
J-22893 inside tilted mounting bracket. Place Spanner Wrench end out from under large divided locking lug and then
J-9504 on top of J-22893 and tighten nuts and washers proceed to pull ring from under other two locking lugs on
securing spanner wrench. power piston (fig. 5-6C).
c. Press down on Spanner Wrench J-9504 and rotate 4. Remove reaction retainer, piston, reaction plate,
the rear housing counterclockwise to unlocked position. three (3) reaction levers and air valve spring. Also remove
Loosen housing carefully as it is spring loaded. reaction bumper and air valve spring retainer from air valve
d. Remove Tools J-9504 and J-22893 from rear housing (fig. 5-7C).
(tilted mounting bracket type): Tool J-9504 on regular type. 5. Place power piston Wrench J-21524 with square

Fig. 5-1C-- Typical Power Brake Unit - Exploded V ie w

5-12 BRAKES

Fig. 5-2C ~H olding Power C ylind er Using Tool J-2 2 8 0 5 Fig. 5-4C--Separating T ilt B racket Type Housings

shank in vise. Hold support plate and power piston with disassembles the following parts from power piston: floating
tube of power piston up (fig. 5-8C). control valve assembly, floating valve retainer, push rod
6. Pull diaphragm edges away from support plate so limiter washer and air filter.
hands can grip steel support plate. Position assembly on 13. Remove floating control valve assembly from push
power piston Wrench J-21524 so three lugs on tool fit into rod as it must be replaced by a new floating control valve
three notches in power piston (fig. 5-9C). assembly at rebuild.
7. Press down on support plate and rotate 14. The master cylinder push rod can now be pushed
counterclockwise until support plate separates from power from center of reaction retainer. Remove "O" ring from
piston (fig. 5-IOC). groove in master cylinder piston rod.
8. Remove diaphragm from support plate and lay both
parts aside. Cleaning of Parts
9. Position power piston, tube down, in a tool, 1. Use denatured alcohol to clean thoroughly all metal
fabricated from a piece of wood 2" x 4" x 8" long with a brake parts. Immerse in cleaning fluid and brush with hair
1-3/8" hole in center, clamped in a vise. Do not clamp tube brush to remove foreign matter. Blow out all passages,
in vise. orifices and valve holes. Air dry and place cleaned parts on
10. Use Snap Ring Pliers J-4880 to remove snap ring clean paper or lint free clean cloth.
on air valve (fig. 5-11C). 2. If slight rust is found inside either front or rear
11. Set up Power Ram and Hydraulic Pump with J- housing assemblies, polish clean with crocus cloth or fine
9746 Press Plate. Insert power piston, tube down, in press emery paper, washing clean afterwards with specified
plate and remove air valve assembly using a 3/8" drive cleaning fluid.
extension as a remover (fig. 5-12C). CAUTION: I f there is any suspicion o f
12. Removal of air valve-push rod assembly contamination or any evidence o f corrosion,
completely flush hydraulic brake system. Failure
to clean hydraulic brake system can result in early
repetition o f trouble. Use o f gasoline, kerosene,
J-9504 anti-freeze alcohol or any other cleaner with even
a trace o f 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
1. Inspect all rubber parts. Wipe free of fluid and
carefully inspect each rubber part for cuts, nicks 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. Re-use rubber parts only if a fairly new
unit is disassembled for some particular trouble and only
then if there is no doubt that the parts are in equal-to-new
condition. Badly damaged items or those which would take
extensive work or time to repair should be replaced. In case
Fig. 5-3C-- Separating Housings W ith Tool J - 9 5 0 4 of doubt, install new parts for safety.
 BRAKES 5-13

PUSH ROD
R EA C T I O N R E T A I N E R — 7
REACTION LEVERS- 7 /
REACTION BUMPER-7 / /

L O C K RI NG
" O " R I NG

S N A P RI NG
R E A C T I O N PLATE
P O W E R PI STON
AI R V A L V E S P RI NG
AI R V A L V E ^
S P R I N G RETAI NER

S UP PO RT PLATE
O* ’ R I NG

FLOATING CO N T R O L
V A L V E A SS E M B L Y

AI R FILTER
AI R S I LE N C E R
RETAINER CLIP
DIAPHRAGM J A M NUT
CLEVIS

Fig. 5-5C--Power Piston Assem bly - Exploded V iew

2. Inspect in accordance with Inspection Table: (The 4. Position new "O" ring on air valve in second groove
table is organized by power brake unit groups.) from push rod end.
5. On reassembly of power piston, floating control
Assembly
Be certain that all rubber parts are clean at reassembly. valve assembly must be replaced with a new one since the
Rewash in specified cleaning fluid if there is any doubt of force required to remove it distorts component parts.
cleanliness. Be careful during rebuild process that no grease 6. Place floating control valve on push rod-air valve
or mineral oil comes in contact with rubber parts of power assembly so flat face of valve will seat against valve seat on
brake unit. Lubricate rubber parts with Delco approved air valve.
lubricant or equivalent. 7. Wipe a thin film of Power Brake Lube (or equivalent)
on large O.D. of floating control valve and on "O" ring on
Front Housing Group air valve.
1. Install a new vacuum check valve using a new 8. Press air valve-push rod assembly, air valve first,
grommet. onto its seat in tube of power piston.
2. Place new front housing seal in housing so flat 9. Place floating control valve retainer over push rod
surface of cup lies against bottom of depression in housing. so flat side seats on floating control valve.
Power Piston Group 10. Start floating control valve and its retainer into
1. Place new "O" ring in groove on the master cylinder power piston tube. Press the floating control valve to seat
piston rod. Wipe a thin film of Power Brake Lube or in the tube, by placing J-21601-01 Floating Control Valve
equivalent on "O" ring. Retainer Installer on top of retainer and pushing down by
2. Master cylinder piston rod is now inserted through hand (fig. 5-13C).
the reaction retainer so round end of piston rod protrudes 11. After floating control valve is seated, position push
from end of the tube on reaction retainer. rod limiter washer over push rod and down onto floating
3. Place J-21524 power piston wrench in a vise. control valve. Air filter element can now be stretched over
Position power piston on wrench with three lugs fitting into end of push rod and pressed into power piston tube.
notches in power piston. 12. Assemble power piston diaphragm to diaphragm
5-14 BRAKES

LOCK RING

Fig. 5-6C~Removing Lock Ring From Power Piston

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. tube of power piston. The flange of diaphragm will fit into
14. With power piston still positioned on holding tool groove on power piston (fig. 5-IOC).
in vise, coat bead of diaphragm that contacts power piston 16. Press down and rotate support plate clockwise,
with Power Brake Lube (or equivalent). until lugs on power piston come against stops on support
15. Holding support plate by metal, with locking tangs plate (fig. 5-IOC).
down, place support plate and diaphragm assembly over 17. This assembly can now be turned over and placed,
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
in a vise.
18. With Snap Ring Pliers J-4880, assemble snap ring
into groove in air valve.
REA CTIO N
19. Place air valve spring retainer on snap ring.
RET AINER

R EA CTIO N
LEVERS

POWER
R EA CTIO N
PLATE

Fig. 5-9C--Positioning Pow er Piston on S upport Plate

Fig. 5-7C~Re moving Reaction Retainer Remover
 BRAKES 5-15

3/8"
EXTENSION

POWER
PISTON

J-9746

SUPPORT
PLATE

OWER
P IS TO N

S U P P O R T PLATE
REMOVER AND
Fig. 5-1 2C~Removing A ir Valve Assem bly
INSTALLER J -2 1 5 2 4
* -m

k 22. Position reaction plate (with numbered side up) on

top of reaction levers. Press down on plate until large ends
Fig. 5-1 OC-Removing S up po rt Plate 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
Assemble reaction bumper into groove in end of air valve. assembly is now assembled to the power piston.
20. Position air valve return spring, large end down, 24. With round end of piston rod up, and with reaction
on spring retainer. retainer held toward top of piston rod, place small end of
21. The three reaction levers are now placed into piston rod in hole in center of reaction plate. Line up ears
position with ears on wide end in slots in power piston. The on reaction retainer with notches in power piston and push
narrow ends will rest on top of air valve return spring. 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 lock
ring is seated under lug with raised divider.
Be sure both ends of lock ring are securely under large
lug.
S N A P R IN G

POW ER P ISTO N

Rear Housing Group

1. Place a new power piston bearing in 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
A IR V A L V E ASSEMBLY

Fig. 5-1 1C--Removing Power Piston Snap Ring Brake Lube (or equivalent) and lay assembly aside.
5-16 BRAKES

INSPECTION CHART

Part Inspect For Corrective Action

Power Piston and Support 1. Cracks, distortion , 1. Clean up or replace.

Plate and Reaction chipping, damaged lever
Retainer seats, pitted or rough
holes.

2. Worn seal surfaces 2. Replace

(tubes).

3. Rough or uneven floating 3. Replace

valve seat.

4. Open passages and flo w 4. Clean

holes.

Reaction Levers or Plates 1. Cracks, d istortion , tears 1. Replace

and heavy wear.

Floating C ontrol Valve 1. Deterioration o f rubber 1. Replace

or warped valve face.

A ir Valve - Push Rod 1. A ir valve: scratches, 1. Do not repair - Replace.

Assembly dents, d isto rtio n , or
corrosion o f I.D. or O.D.
A ll seats to be smooth
and free o f nicks and
dents.

2. Push rod must move freely 2. If w orn, replace air valve -

in air valve, b ut must not push rod assembly.
pull out.

Front and Rear Housings 1. Scratches, scores, pits, 1. Replace, unless easily repaired
dents, or other damage
affecting rolling or seal­
ing o f diaphragm or other
seals.

2. Cracks, damage at ears, 2. Replace, unless easily repaired

damaged threads on studs.

3. Bent or nicked locking 3. Replace, unless easily repaired

lugs.

4. Loose studs. 4. Replace or repair.

A ir Filters 1. D irty 1. Replace

 BRAKES 5-17

UNSTAKED TAB SOCKET

INSTALLER
J-21601

POWER
PISTON

Fig. 5-1 5C--Staking Housing Tabs

a. Straight Mounting Bracket - Place Spanner

Wrench J-9504 over studs on rear housing, and attach with
nuts and washers-draw nuts down tight to eliminate
Fig. 5-13C—Installing Floating Control Valve Assembly
bending or damaging of studs.
b. Tilt Mounting Bracket Position Tool J-22893
inside tilted mounting bracket. Place Spanner Wrench J-9504
4. Attach base of Holding Fixture J-22805 to front on top of J-22893 and tighten nuts and washers to bolts
housing with nuts and washers and draw down tight to provided, securing Spanner Wrench.
eliminate bending or damaging of studs. Clamp base in a c. Press down on spanner wrench and twist rear
vise. Place power piston return spring over the insert in the housing clockwise in relation to front housing until fully
front housing. locked. Do not break studs loose in rear housing or put
5. Lubricate the I.D. of the support plate seal, the pressure on power piston tube when locking housings.
reaction retainer tube and the beaded edge of the diaphragm 8. Remove Spanner Wrench J-9504. Remove unit from
with Power Brake Lube (or equivalent). vise and remove Holding Fixture J-22805 from the front
6. Place the rear housing assembly over the front housing.
housing assembly and align the scribe marks of the two 9. Push felt silencer over push rod to seat against end
housings so they will match when in locked position. of power piston tube. Snap ring retainer is now placed on
push rod so it can hold silencer against power piston tube.
7. Assemble front and rear housings as follows:

A - S T A K E D TA B S
2 PL ACE S 180°
APART

B - O PT IO N AL
STAKING
L O C A T IO N S

Fig. 5-1 4C~Housing Locking Tabs Fig. 5-16C--Gaging Master Cylinder Push Rod
5-18 BRAKES

Plastic boot is now pushed to seat against rear housing. housing. This dimension must be correct to insure proper
Raised tabs on side of boot will locate in holes in center of clearance in master cylinder between primary cup and
brackets. compensating port.
10. Using a 1/8" diameter rod (or similar tool), stake Make check as follows:
the front and rear housing in two places 180° apart (figs.
5-14C and 5-15C). 1. Place gage over piston rod in a position which will
CAUTION: The interlock tabs should not be used allow gage to be slipped to left or right without contacting
for staking a second time. Stake two o f the studs.
remaining tabs. When all tabs have been staked
once, the housing must be replaced. The center section of gage has two levels. The piston
rod end should always touch the longer section of gage
Gaging of Power Brake Unit which extends into front housing. The piston rod end should
The following gaging operation is necessary only when never touch the shorter section of gage (fig. 5-16C).
a major structural part such as front or rear housing, power
piston assembly, master cylinder piston or master cylinder 2. Any variation beyond these two limits must be
assembly is replaced with a new part. The gage measures compensated for by obtaining the service adjustable piston
how far the master cylinder push-rod projects from front 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 5-2D) Rear Housing Group
1. Scribe a line across front and rear housings to 1. Remove the air filter element from location within
facilitate reassembly. the diaphragm plate extension.
CAUTION: To prevent chipping o f the plastic
2. Remove the front housing seal (fig. 5-2D); pulling diaphragm plate, exercise extreme caution when
the piston rod from the front housing will also remove the removing the air filter retainer. Use a small
seal assembly. Remove the piston rod. screwdriver or other suitable tool, and pry at
3. Attach base of Holding Fixture J-22805 to front several peripheral locations until the retainer is
housing with nuts and washers and draw down tight to freed.
eliminate bending or damage to studs. Clamp base in bench 2. Separate the diaphragm plate assembly from the rear
vise with power section up (fig. 5-2A). housing and lay the rear housing aside.
CAUTION: Be sure to align tool so that the check 3. Disassemble diaphragm plate assembly (fig. 5-2D).
valve in the front housing is not damaged. a. Remove rolling diaphragm from the groove in the
4. Loosen locknut and remove push rod clevis and diaphragm plate hub.
locknut, if so equipped. CAUTION: Care should be used in handling the
5. Remove the mounting bracket from the rear diaphragm o f the diaphragm plate assembly. The
housing, if so equipped. diaphragm should be protected from grease, oil,
6. Remove the dust boot retainer, dust boot and foreign matter and from nicks, scratches and
silencer from the diaphragm plate extension. gouges.
7. The edge of the rear housing contains twelve lances. b. Hold the diaphragm plate so that the push rod is in
Four of these lances (one in each quadrant) are deeper than its normal (horizontal) installed position, depress the push
the other lances (fig. 5-3D). The metal that forms the four rod slightly (approximately 1/16 inch), and rotate piston so
deep lances must be partially straightened so that the lances the air valve lock will fall from its location in the diaphragm
will clear the cutouts in the front housing. If the metal tabs plate hub. Remove the air valve-push rod assembly from the
that form the deep lances crack or break during diaphragm plate. Remove the reaction disc from its location
straightening, the housing must be replaced. in the diaphragm plate bore (insert the piston rod or other
suitable tool through diaphragm plate extension and push
8. Place Spanner Wrench J-9504 over studs on rear disc from its seat). Exercise care so as not to chip surface
housing and attach with nuts and washers. Draw nuts down of passages in the diaphragm plate.
tight to eliminate bending or damaging of studs (fig. 5-2A). NOTE: Perform Step 4 only if seal is defective and a
9. Press down on Spanner Wrench J-9504 and rotate new seal is available. Do not reuse seal once it has been
the rear housing clockwise to separate the two housings. If removed from the unit.
the rear housing cannot be readily loosened, tap the rear 4. Support outer surface of rear housing on blocks of
housing lightly with plastic hammer. wood or other suitable material (stud side up) and drive out
10. Remove Tool J-9504 from the rear housing. seal with a punch or a thin blade screwdriver. Discard seal.
CAUTION: Care must be exercised not to damage Front Housing Group
or loosen studs in the rear housing. Also, take care 1. Remove check valve from grommet and then remove
that no pressure is brought to bear on plastic grommet from front housing; discard valve and grommet.
diaphragm plate tension. 2. Remove front housing and holding fixture from vise;
11. Lift the rear housing assembly from the unit. then remove holding fixture from front housing.
 BRAKES 5-19

1. Master Cylinder 9. Air Valve 17. Valve Return Spring

2. Vacuum Check Valve 10. Front Housing Seal 18. Mounting Stud
3. Grommet 11. Poppet Valve 19. Air Valve Lock Plate
4. Diaphragm 12. Poppet Valve Spring 20. Diaphragm Lip
5. Diaphragm Plate 13. Poppet Retainer 21. Front Housing
6. Rear Housing 14. Dust Boot 22. Front Housing Seal
7. Diaphragm Spring 15. Valve Push Rod 23. Piston Rod
8. Reaction Disc 16. Filter and Silencers

Fig. 5-1D--Bendix Single Diaphragm Unit (Typical)

5-20 BRAKES

paper, washing clean afterwards. Dirt is the major cause of

1 2 3 4 5 6 trouble and wear in service. Be sure to keep parts clean until
re-assembly. Re-wash at re-assembly if there is any occasion
to doubt cleanliness-such as parts dropped or left exposed
for eight hours or longer.
CAUTION: I f there is any suspicion o f
contamination or any evidence o f corrosion,
completely flush the vehicle hydraulic brake
system. Failure to clean the hydraulic brake
system can result in early repetition o f trouble.
Use o f gasoline, kerosene, anti-freeze, alcohol or
7 8 9 10 11 12 13 14
any other cleaner, with even a trace o f 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.
15 16 Inspecting Metal Parts
1. Rear Housing Mounting 8. A ir Valve Lock BADLY DAMAGED ITEMS, OR THOSE WHICH
Brackets 9. Diaphragm Plate WOULD TAKE EXTENSIVE WORK OR TIME TO
2. Push Rod Boot 10. Reaction Disc REPAIR, SHOULD BE REPLACED. In case of doubt,
3. Foam and Felt A ir 11. Piston Rod
install new parts. Do not rely on the brake unit being
4.
Filter-Silencers
Rear Housing
12. Diaphragm Return
Spring overhauled at an early or proper interval. New parts will
5. Rear Housing Seal 13. Front Housing provide more satisfactory service, even if the brake unit is
6. Diaphragm 14. Front Housing Seal allowed to go beyond the desired overhaul period.
7. Air Valve Push Rod 15. Grommet
Assembly 16. Check Valve Assembly (Figs. 5-1D and 5-2D)
1. Be careful during the rebuild procedure that no
Fig. 5-2D~Bendix Power Booster Components (Typical) 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
Cleaning silicone lubricant provided in the service repair kit.
Use clean brake fluid to thoroughly clean all reusable Front Housing Group
1. Install new check valve grommet in front housing
brake parts. Immerse in the cleaning fluid and brush metal with beveled edge of grommet inside of housing. Dip new
parts with hair brush to remove foreign matter. Blow out check valve in clean denatured alcohol and install in
all passages, orifices and valve holes. Air dry and place grommet—check valve stem is to be outside of housing.
cleaned parts on clean paper or lint free clean cloth. If slight 2. Position and secure Holding Fixture J-22805 to
rust is found inside either the front or rear half housing mounting studs, and place tool and front housing in a vise.
assemblies, polish clean with crocus cloth or fine emery Be sure to align tool so that check valve is not damaged.
NOTE: If either or both of the housings are 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. 5-4D) 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.
NOTE: 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.
 BRAKES 5-21

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
Fig. 5-4D--lnstalling Rear Housing Seal
rod clevis.
8. Install mounting bracket to the rear shell, if so
c. Install the rolling diaphragm in the groove of equipped.
diaphragm plate. CAUTION: See "Caution" on Page 1 o f this
d. Apply silicone lubricant to surface of reaction disc section.
and position disc in center bore of diaphragm plate. Use 9. Remove power cylinder from vise and remove
piston rod to seat disc in bore. Make sure disc is fully seated Holding Fixture J-22805.
before removing piston rod. 10. Apply silicone lubricant sparingly to the piston rod,
NOTE: If reaction disc is not fully seated, it will result keeping lubricant away from rounded end of rod. Guide
in an erroneous push rod height adjustment. piston rod into center bore of the diaphragm plate until it
3. Apply silicone lubricant to I.D. of rear housing seal is fully seated against reaction disc.
and diaphragm bead contact surface of rear housing. Install 11. Install front housing seal. Press seal into front
diaphragm plate assembly in rear housing. housing until seal is bottomed in recess of housing.
4. Place air filter element over push rod and into
diaphragm plate extension. Install filter retainer. Gaging
1. Place the power head assembly in a padded vise
Final Assembly (front housing up). Do not clamp tight.
1. Attach base of Holding Fixture J-22805 to front 2. Remove the front housing seal to assure that no
housing with nuts and washers and draw down tight to vacuum is in the power head while gaging.
eliminate bending or damage to studs. Clamp base in bench 3. Insert the master cylinder piston rod, flat end first,
vise with power section up (fig. 5-2A). into the piston rod retainer.
CAUTION: Be sure to align tool so that the check 4. Press down on the master cylinder piston rod (with
valve in the front housing is not damaged. approximately a 40-50 pound load) to be sure it is properly
2. Place Spanner Wrench J-9504 over studs on rear seated.
housing and attach with nuts and washers. Draw nuts down 5. Place Gage J-22647 over the piston rod in a position
tight to eliminate bending or damaging of studs. which will allow the gage to be slipped to the left or right
3. Place diaphragm plate return spring in front housing without contacting the studs (fig. 5-5D).
and position rear housing assembly on front housing (small 6. The center section of the gage has two levels. The
end of spring downward). Position rear housing so that piston rod should always contact the longer section (lower
when housings are locked, scribe marks on front and rear level) of the gage. The piston rod should never contact the
housings will be in alignment. shorter section (higher level) of the gage. Move gage from
4. Press down on Spanner Wrench J-9504 and rotate side to side to check piston rod height.
the rear housing counterclockwise to assemble the two 7. Any variation beyond these two limits must be
housings. compensated for by obtaining the service adjustable piston
CAUTION: Bend lances in on the rear housing. I f rod and adjusting the self-locking screw to meet the gaging
the tangs crack or break during this operation it specifications.
will be necessary to replace that half o f the 8. Wipe a thin film of silicone lubricant on the I.D. of
housing. the front housing seal and position seal in the depression in
5. Remove Tool J-9504 from the rear shell. the housing.
5-22 BRAKES

BENDIX HYDRAULIC BRAKE BOOSTER (HYDRO-BOOST)

UNIT REPAIR
a hammer and chisel to cut the bracket nut that secures the
W A R N IN G : The accumulator contains mounting bracket to the power section (cut the nut at the
compressed gas. Always use proper tools open slot in the threaded portion of the housing). Be careful
and follow recommended procedures or to avoid damage to the threads on the booster hub. Spread
personal injury may result. Do not apply the nut and remove it from the power section. Then remove
heat to accumulator. Do not attempt to the mounting bracket.
repair an inoperative accumulator, always 2. Remove the pedal rod boot (if equipped) by pulling
replace with a new accumulator. Dispose of it off over the pedal rod eyelet.
an inoperative accumulator by drilling a 3. Place Tool J-24569 around the pedal rod and resting
1/16" diameter hole through the end of the on the input rod end as shown in Figure 5-2E.
accumulator can opposite the "O " ring.
4. Place a punch (or similar tool) through the pedal rod
from the lower side of Tool J-24569. Push the punch on
The Bendix Hydraulic Brake Booster utilizes the through to rest on the higher side of the tool. Lift up on the
hydraulic pressure supplied by the power steering pump to punch to shear the pedal rod retainer; remove the pedal rod.
provide power assist for brake applications. The dual master 5. Remove the remnants of the rubber grommet from
cylinder is mounted to the output push rod end of the the groove near the end of the pedal rod and from the groove
booster. inside the input rod end.
The procedures below include removal of the mounting 6. With a small screwdriver, pry the plastic guide out
bracket even though it is not necessary to remove the of the output push rod retainer. Disengage the tabs of the
bracket for overhaul of the internal assembly. spring retainer from the ledge inside the opening near the
master cylinder mounting flange of the booster. Remove the
Disassembly (Fig. 5-1E) retainer, the piston return spring and output rod from the
1. Secure the booster in a vise (bracket end up) and use opening (fig. 5-3E).

SPOOL RETURN SPRING

Fig. 5-1E--Bendix Hydro-Boost Explode-T ypical

 BRAKES 5-23

minimum), depress the accumulator. Insert a punch into the

hole in the housing and remove retaining ring with a small
7. Place the booster cover in a vise equipped with soft screwdriver, (fig. 5-6E).
jawed devices. Remove the five screws that secure the 14. Slowly back off the clamp until tension on the
booster housing to the cover. accumulator is released; remove accumulator and "O" ring.
8. Remove the booster assembly from the vise and
while holding the unit over a pan, separate the cover from 15. If accumulator valve was determined to be faulty,
the housing. Remove the "figure eight" seal from the remove valve using a small diameter wire tool (fig. 5-5E).
housing cover; discard the seal. Remove the dump valve by catching the tool under the pin
9. Remove the input rod and piston assembly, the spool guide near the center of the valve, then remove two function
assembly and spool spring from the booster housing. valves and seat (fig. 5-8E).
Compare spool valve condition to Figure 5-4E. If spool
valve is defective, the complete unit must be replaced. 16. Return hose fitting "O" ring can be removed if
10. Inspect power piston. If scratches big enough to be leaking.
felt with a fingernail are present, the input rod and piston
must be replaced. 17. Push spool valve plug in and use a small
11. Remove the input rod seals from the input rod end, screwdriver to remove retaining ring (Fig. 5-9E).
and the piston seal from the piston bore in the housing; 18. Remove spool valve plug and "O" ring.
discard the seals.
12. Place the accumulator retaining cap Tool J-26889 19. Remove the tube seats using No. 4 easy-out as
over the master cylinder stud and install the nut as shown shown in Figure 5-10E.
in Figure 5-6E.
13. Using Tool J-22269-01 or a large "C" clamp (6"

ACCUM ULATOR H O U S IN G
VALVES

SHARP EDGE G R O U N D
O N E N D W ILL MAKE
T O O L M ORE EFFECTIN

W IRE DIAM ETER APPRO X. .0 4 0

Fig. 5-3E--Output Rod, Spring and Retainer Fig. 5-5E--Removing Accum ulator Valves
5-24 BRAKES

J-22269-01 OR
6" C CLAMP

Fig. 5-8E~Accumulator Valves

Fig. 5-6E~Compressing Accum u la to r W ith J-2 6 8 8 9

Discoloration of the spool or bore, particularly in the
grooves, is not harmful and is no cause for replacement.
Cleaning and Inspection 3. If the valve spool or the valve spool bore has nicks
or scoring that can be felt with a fingernail, particularly on
CAUTION: Be sure to keep parts clean until the lands, the entire booster should be replaced as an
reassembly. Wash at reassembly if there are any assembly.
parts dropped or left exposed for eight hours or NOTE: The clearance between the spool valve and the
longer. Lubricate all seals and metal friction spool valve bore of the housing assembly is important.
points with power steering fluid. Whenever the Because of this, the valve spool valve and the housing
booster is disassembled and all disturbed seals and assembly make up a selective assembly. The spool valve
damaged tube inserts should be replaced. A ll o f is selected to match the spool valve bore.
these parts are included in a kit. I f any o f the 4. Inspect the piston for scratches, nicks, etc. If
accumulator valve components are damaged or scratches on the outside diameter can be felt with a
lost, replace all the valve components. fingernail, the input rod and piston must be replaced.
1. Clean all metal parts in a suitable solvent. Be careful Assembly
to avoid losing small parts. 1. Install tube seat with Tool J-6217 as shown in Figure
2. Inspect the valve spool and the valve spool bore in 5-1 IE.
the housing for corrosion, nicks, scoring or other damage. 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
bore. The lip of the seal must be toward the rear (away from

Fig. 5-7E--Accumulator Installation Fig. 5-9E~Spool Valve Plug Removal

 BRAKES 5-25

Fig. 5-10E~Removing Tube Seat

8. Lubricate the piston and Piston Installing Tool with

the master cylinder mounting flange). Be sure the seal is clean power steering fluid. Hold the large end of the tool
fully seated in the housing. against the piston (fig. 5-13E), and slide the tool and piston
into the piston bore and through the piston seal. Remove
5. Lubricate the input rod end, NEW input rod seals piston installing tool.
and Seal Installer with clean power steering fluid. Slide the 9. If removed, install return hose fitting with new "O"
seals on the tool with the lip of the cups toward the open ring.
end of the tool (fig. 5-12E). 10. If accumulator valve was removed, install new seat
6. Slide the tool over the input rod end and down to into the valve bore. The seat can be forced to the bottom
the second groove; then slide the forward seal off the tool by installing the two function valve (fig. 5-8E).
and into the groove. Assemble the other seal in the first NOTE: Make certain the check valve seat is cup side
groove. Be sure that both seals are fully seated. up when in bore.
NOTE: Only one seal is used on JD3 and JD5 11. If removed, insert new dump valve over the two
applications. function valve making certain that the dump valve plunger
7. The piston counterbore on JF9 applications is of a is held in place until installation is complete.
different diameter than on JB8. Remove the pilot portion
of Tool J-24551. 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. lbs.

Fig. 5 -1 3E--lnstailing Input Rod and PistonAssembly into

Booster (Typical)
5-26 BRAKES

CAUTION: See "Caution" on Page 1 o f 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 of the pedal rod to seat the grommet in the groove inside
accumulator seal. Install seal and accumulator in housing the housing.
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" NOTE: When the grommet is fully seated, the pedal
minimum) depress the accumulator making certain that the rod will rotate freely with no binding.
accumulator is compressed straight (fig. 5-6E).
18. Snap the retaining ring into the housing groove by 25. Slide the boot on the pedal rod and assemble the
pushing it down all the way around with a small large end of the boot onto the hub of the power section.
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
Tool J-24554 and a torque wrench (fig. 5-15E), tighten the
nut to 110 ft. lbs.
CAUTION: See "Caution" on Page 1 o f 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 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
 BRAKES 5-27

SP E C IA L TOOLS

1. J-4880 Snap Ring Pliers 13. J-23175 Control Valve Installer

2. J-21524 Power Piston Remover and Installer 14. J-23188 Secondary Bearing Protector
3. J-21601 Power Brake Retainer and Installer 15. J-24551 Piston Installers
4. J-22657 Bushing Retainer Socket J-25083
5. J-22647 Height Gauge 16. J-24553 Input Rod Seal Installers
6. J-22677 Power Cylinder Seal Installer J-28485
7. J-22733 Seal Installer and Protector J-28497
8. J-28458 Power Piston Seal Protector 17. J-24554 Socket
9. J-22805 Power Cylinder Holding Fixture 18. J-24569 Pedal Push Rod Remover
10. J-22839 Front Plate Holding Fixture 19. J-9504 Power Cylinder Spanner Wrench
11. J-22893 Booster Separating Adapter 20. J-26889 Accumulator Compressor
12. J-23101 Power Piston Holding Tool

Fig. 5-1 7 E -S p e cia l Tools

 A U T O M A T IC TR A N S M IS S IO N (200J7A-1

SECTION 7A

A U T O M A T IC T R A N S M IS S IO N
UNIT REPAIR (OVERHAUL)
CONTENTS

THM 200 Transmission..................................... (200)7A-1

CBC 350 Transmission....................................... (350)7A-1
THM 400 Transmission..................................... (400)7A-1

THM 200 TRANSM ISSION

INDEX

Disassembly................................................................... 7A-1 Rear Gear Parts........................................................ 7A-15

Removal of Converter.............................................. 7A-1 Low and Reverse Clutch......................................... 7A-19
Teflon Seals............................................................... 7A-1 Front Gear Parts........................................................7A-22
External Parts........................................................... 7A-2 Front Unit Parts........................................................7A-25
Front Unit Parts....................................................... 7A-5 Forward and Direct Clutch..................................... 7A-28
Front Gear Parts....................................................... 7A-7 Pump Assembly.........................................................7A-32
Rear Gear Parts........................................................ 7A-9 External Parts ........................................................... .7A-36
Manual Shaft and Parking Pawl............................ 7A-10 Control Valve Assembly...........................................7A-39
Inspection and Reassembly......................................... 7A-12 Bushing Replacement................................................... 7A-45
Case............................................................................ 7A-12 Specifications.................................................................. 7A-50
Manual Shaft and Parking Pawl............................ 7A-13 Special Tools................................................................. .7A-51
DISASSEMBLY
Removal of Converter
1. With transmission in cradle of portable jack, remove scored, etc.), or do not rotate freely in their groove, and
J-21366 and then converter assembly by pulling straight out. replacement is necessary, do the following:
2. Install Holding Fixture, J-8763-02 on transmission 1. Remove and discard old angle cut seal rings; full
and place into Holding Fixture, J-3289-20, with manual circle rings must be cut off.
shaft facing bench and oil pan side up (Fig. 7A-1A). 2. Inspect seal ring groove for burrs or damage.
CAUTION: Do not over-torque fixture holding
screw.
NOTE: 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.
CAUTION: Do not use solvents on neoprene seals,
composition-faced clutch plates or thrust washers.
Teflon Seals
If any teflon seal rings are damaged (distorted, cut, Fig. 7 A - 1 A-Transmission Holding Fixture
(2 0 0)7 A-2 A U T O M A T IC TR A N SM IS S IO N

T.V. EXHAUST VALVE LIFTER

THROTTLE LEVER &

BRACKET ASSEMBLY

THROTTLE LEVER TO
CABLE LINK

Fig. 7A-2A~Teflon Oil Seal Rings Fig. 7A-4A--Removing Throttle Valve and Bracket Assembly

EXTERNAL PARTS - REM O VAL

3. When installing angle cut seal rings, do not over­
stretch. Make sure cut ends are in same relation as cut (Fig. 2. Remove oil screen and discard gasket (Fig. 7A-3A).
7A-2A). Also, make sure rings are seated in the grooves to
prevent damage to the rings during reassembly of mating CAUTION: The two oil screen attaching bolts are
part over rings. Retain with petrolatum. about 10mm (3/8") longer than the control valve
4. New angle cut or full circle teflon seal rings may assembly attaching bolts, and they are not
appear to be distorted after being installed. Once exposed interchangeable.
to normal transmission oil temperatures, the new seal rings 3. Control Valve Assembly:
will return to their normal shape and fit freely in their bores. a. Remove throttle lever and bracket assembly (Fig.
5. The teflon seal rings allow for a free fit in their bores 7A-4A). Do not bend throttle lever link.
after operation. The free fit of the rings in their bores does
not indicate leakage during operation. NOTE: T.V. exhaust valve lifter and spring may
separate from throttle lever and bracket assembly.
Snap Rings b. Remove manual detent roller and spring assembly
(Fig. 7A-5A).
Do not over expand snap rings when removing or c. Remove remaining control valve assembly attaching
installing. bolts.
Thrust Washer Surfaces CAUTION: Do not drop manual valve.
The thrust washers and thrust bearings will polish the d. Holding manual valve with finger, remove control
surfaces they protect. This is not to be considered a damaged valve assembly, spacer plate, and gaskets together, to
part because of this condition. prevent the dropping of 4 check balls, located in the control

MANUAL DETENT i
OIL SCREEN ROLLER & SPRING!
ASSEMBLY

Fig. 7A-5A~Removing Manual Detent Roller and Spring

Fig. 7A-3A--Removing Oil Screen Assembly
 A U T O M A T IC TR A N S M IS S IO N (200)7A-3

CONTROL VALVE ASSY

MANUAL VALVE

VALVE BODY
SPACER PLATE

Fig. 7A-6A~Removing Control Valve Assembly from Case Fig. 7 A-9A-R em ovin g Govenor Cover Retaining Ring

valve assembly (Fig. 7A-6A).

e. Lay control valve assembly down with spacer plate
side up and discard gaskets.
4. Remove 1-2 accumulator spring (Fig. 7A-7 A).
5. Remove 5th check ball located in case (Fig. 7A-8A).
6. Governor Assembly:
CAUTION: 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).
NOTE: Governor assembly may come out with cover.
Fig. 7 A-7A-R em oving 1-2 A ccum ula to r Spring CAUTION: Do not use any type o f pliers to
remove governor assembly.
c. Remove governor assembly from case. It may be

« 5th CHECK BALL

(T.V. EXHAUST)

Fig. 7A-8A--Removing 5th Check Ball Fig. 7 A - 10 A -R e m o v in g Governor Cover

(2 0 0)7 A-4 A U T O M A T IC TR A N SM IS S IO N

APPLY AIR PRESSURE

HERE TO REMOVE
INTERMEDIATE SERVO INTERMEDIATE!
SERVO PISTON IDENTIFICATION
& SEAL ASSY.

INTERMEDIATE
SERVO COVER

Fig. 7A-1 1A-Removing Intermediate Servo Retaining Ring Fig. 7A-1 4A -D irect Clutch Accumulator Port

necessary to rotate output shaft counterclockwise while

INTERMEDIATE removing the governor.
7. Intermediate Servo Assembly:
a. Using small screwdriver, remove intermediate servo
cover retaining ring (Fig. 7A-11A).
b. Using pliers, remove intermediate servo cover and
discard seal rings; cover seal ring may be located in case
(Fig. 7A-12A).
c. Remove intermediate servo piston and band apply
pin assembly (Fig. 7A-13A).
NOTE: If intermediate servo cover and seal assembly
can not be removed easily, place shop towels and hand
over cover and case. Apply air pressure into the direct
clutch accumulator port (Figs. 7A-14A and 7A-15A).
8. Check for proper intermediate band apply pin as
Fig. 7A-1 2A--Removing Servo Cover and Seal
follows:

APPLYING AIR PRESSURE

TO REMOVE
INTERMEDIATE SERVO

Fig. 7A -15A -A p ply Air Pressure to Remove Intermediate

Fig. 7 A - 1 3A--Removing Intermediate Servo Servo
 A U T O M A T IC TR A N S M IS S IO N (2 0 0)7 A-5

Fig. 7A-19A~Checking Front Unit End Play

CAUTION: Make sure the tapered pin end is

properly located against the band apply lug. Also,
Fig. 7A-1 6A--Checking for Proper Intermediate Band Appiy
Pin
make sure the band anchor pin is properly located
in the case and band anchor lug.
a. Install J-25014-2 in intermediate servo bore and c. Install dial indicator J-8001 and position dial
retain with intermediate servo cover retaining ring, aligning indicator point (Fig. 7A-16A) on top of J-25014-2 zero post
ring with gap at case slot (Fig. 7A-16A). and set dial indicator to zero.
b. Install pin J-25014-1 into J-25014-2 (Fig. 7A-16A).
NOTE: 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-
25014-1.
INTERMEDIATE BAND APPLY PIN CHART

DIAL INDICATOR TRAVEL APPLY PIN IDENTIFICATION NOTE: If band selection pin does not register between
the high and low limits, look for possible problem with
0 - 2.16 mm (0 - .086")
2.16 mm - 2.88 mm (.086" - .114")
2 Rings
Wide Band the intermediate band, direct clutch or case.
e. Apply 12 N*m (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.
Fig. 7A-1 7A -lnterm ediate Band Apply Pin Selector Chart
NOTE: 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 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
Fig. 7A-18A--lnstalling Tools on Rear End of Case of turbine shaft (Fig. 7A-19A).
(2 0 0)7 A-6 A U T O M A T IC TR A N SM IS S IO N

FRONT UNIT END PLAY CHART

THICKNESS IDENTIFICATION

Number and/or Color

1.66-1.77mm (0.065' -0.070” ) 1 TURBINE SHAFT &

2
1.79-1.90mm
1.92-2.03mm
(0.070'
(0.076'
-0.075")
-0.080") 3 Black
FORWARD CLUTCH
2.05-2.16mm (0.081' -0.085") 4 Light Green ASSEMBLY
2.18-2.29mm (0.086' -0.090") 5 Scarlet
2.31-2.42mm (0.091' -0.095") 6 Purple
2.44-2.55mm (0.096' -0.100") 7 Cocoa Brown
2.57-2.68mm (0.101' -0.106") 8 Orange
2.70-2.81mm (0.106' -0.111") 9 Yellow
2.83-2.94mm (0.111' -0.116") 10 Light Blue
2.96-3.07mm (0.117' -0.121") 11
3.09-3.20mm (0.122' -0.126") 12 DIRECT CLUTCH
3.22-3.33mm (0.127' -0.131") 13 Pink
3.35-3.46mm (0.132' -0.136") 14 Green
HOUSING
3.48-3.59mm (0.137' 0.141") 15 Gray

Fig. 7 A -2 0 A -F ro n t Unit End Play Washer Chart Fig. 7 A -23A-R em ovin g Forward and Direct Clutch
Asspmhlies

PUMP SEAL

INTERMEDIATE
BAND

Fig. 7A-2 1A -R em ovin g Oil Pump Seal Fig. 7 A -24A-R em ovin g Intermediate Band Assembly

INTERMEDIATE BAND
ANCHOR PIN

Fig. 7A-22 A ~ R e m ov ing Pump Assembly Fig. 7A-25A--Removing Interm ediate Band Anchor Pin
 A U T O M A T IC TR A N S M IS S IO N (200)7A-7

f. Mount dial indicator and clamp assembly on bolt,

positioning indicator point against cap nut of J-24773.
g. 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").
NOTE: 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). Fig. 7A-26A~Locatio n of Front Selective W asher
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.
c. Using J-24773 tool, remove pump assembly, pump
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.
NOTE: 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.
4. Remove intermediate band assembly (Fig. 7A-24A).
5. Remove band anchor pin (Fig. 7A-25A). Fig. 7A -2 7 A -C h e ckin g Rear Unit End Play

FRONT GEAR PARTS

Removal thickness is required to bring end play within
1. Remove output shaft to turbine shaft front selective specifications, select proper washer from the chart
washer (Fig. 7A-26A). shown in Fig. 7A-28A.
e. Remove dial indicator and clamp assembly (Fig. 7A-
NOTE: This washer may be stuck to the end of the 27A). Do not remove J-25013 tools.
turbine shaft.
2. Check Rear Unit end play as follows: NOTE: It may be necessary to tighten J-25013
a. Loosen J-25013-5 adjusting screw on output shaft adjusting screw on output shaft to remove snap ring.
and push output shaft downward (Fig. 7A-18A).
b. Install gauge clamp on case as shown (Fig. 7A-27A). REAR UNIT END PLAY CHART
c. Install dial indicator J-8001 and plunger extension
J-7057. Position extension against end of output shaft and THICKNESS IDENTIFICATIO N
set dial indicator to zero (Fig. 7A-27A).
d. Move output shaft upward by turning adjusting Number and/or Color

screw on J-25013-5 until the white or scribed line on sleeve 2.90- 3.01mm (0.114 '-0.119'') 1 Orange
J-25013 begins to disappear; then read end play. (Rear unit 3.08- 3.19mm (0.121 '-0.126'') 2 White
end play should be 0.10-0.63mm.) (.004"-.025".) 3.26 3.37mm
3.44- 3.55mm
(0.128 '-0.133'')
(0.135' '-0.140")
3 Yellow
4 Blue

NOTE: Selective washer controlling this end play is

3.62- 3.73mm (0.143' '-0.147” ) 5 Red
3.80- 3.91mm (0.150' '-0.154") 6 Brown
located between the front internal gear thrust washer 3.98- 4.09mm (0.157' '-0.161") 7 Green
and output shaft snap ring. If more or less washer 4.16- 4.27mm
4.34- 4.45mm
(0.164' '-0.168") 8 Black
(0.171' '-0.175") 9 Purple

Fig. 7 A -28A--Rear Unit End Play W a s h e r Chart

(2 0 0 )7 A-8 A U TO M A TIC TRAN SM IS S IO N

INPUT
DRUM

REAR SELECTIVE
WASHER &
IDENTIFICATION

THRUST
WASHER

■FRONT
" in t e r n a l
GEAR

Fig. 7A-29A~Removing O utput Shaft to Selective Washer Fig. 7A-32A--Removing Input Drum and Rear Sun Gear
Snap Ring

3. Using snap ring pliers, remove output shaft to b. Remove rear selective washer and thrust washer
selective washer snap ring (Fig. 7A-29A). from front internal gear.
4. Front Internal Gear: 5. Remove front carrier assembly and the front internal
a. Remove front internal gear, rear selective washer and gear to front carrier roller bearing assembly (Fig. 7A-30A).
thrust washer.
NOTE: 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
FRONT CARRIER
carrier thrust bearing assembly (Fig. 7A-31A).
NOTE: 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).
ROLLER THRUST b. Remove the 4 tanged input drum to reverse clutch
RING ASSY. housing thrust washer from rear of input drum or from
reverse clutch housing.
8. Low and Reverse clutch housing assembly:
a. Using a No. 14 sheet metal screw, remove housing
to case cup plug and seal by turning screw 2 or 3 turns and
Fig. 7A-30A~Removing Front Carrier and Roller Thrust pulling straight out. Discard cup plug and seal (Fig. 7A-
Bearing 33A).

FRONT SUN GEAR

THRUST BEARING ASSY. SEAL

CUP PLUG

Fig. 7A-3 1A-Removin g Thrust Bearing Assembly and Front

Sun Gear Fig. 7 A-33A~Rem oving Cup Plug and Seal
 A U T O M A T IC T R A N S M IS S IO N (200)7A-9

Fig. 7 A -34A-R em ovin g Low and Reverse Housing to Case Fig. 7A-36A--Proper Location of Low and Reverse Housing to
Snap Ring Case Spacer

NOTE: If cup plug will not remove, grind

approximately 20mm (3/4") from end of 6.3mm (No.
4) easy out to remove cup plug. Then use No. 14 sheet
metal screw to remove seal.
b. Remove low and reverse clutch housing to case
beveled snap ring (Fig. 7A-34A).
NOTE: The flat side of the ring should have been
against the low and reverse clutch housing with beveled
side up.
c. Using J-25012, remove low and reverse clutch
housing assembly by moving J-25012 back and forth (Fig.
7A-35A).
d. Remove low and reverse clutch housing to case
spacer ring (Fig. 7A-36A).
REAR GEAR PARTS Fig. 7A-37A~Removing Rear Unit Parts
Removal

NOTE: Make sure governor has been removed at this a. Remove roller clutch and rear carrier assembly off
time. output shaft.
1. Grasp output shaft and lift out remainder of rear unit b. Remove the 4 tanged rear carrier to rear internal
parts and lay down in a horizontal position (Fig. 7A-37A). gear thrust washer off the end of the rear carrier, or inside
2. Roller clutch and rear carrier assembly. the rear internal gear (Fig. 7A-38A).

Fig. 7 A-35A --Removing Low and Reverse Clutch Housing Fig. 7 A - 3 8 A - R e m o v in g Thrust Washers
(20 0)7 A-10 A U T O M A T IC TRAN SM IS S IO N

REAR OIL SEAL

OUTPUT SHAFT

Fig. 7A-39A--Removing Rear Internal Gear Fig. 7 A-40A~Removing Rear Oil Seal

3. Remove low and reverse clutch plates off output to vertical position with rear end up.
shaft. 6. If necessary, remove rear oil seal (Fig. 7A-40A).
4. Rear internal gear:
a. Remove rear internal gear to rear sun gear roller M A N U A L SHAFT AND PARKING PAW L
thrust bearing assembly off rear internal gear. PARTS
b. Remove gear internal gear off output shaft (Fig. 7A- Removal
39A). 1. Turn transmission to horizontal position, oil pan side
5. Turn transmission to horizontal position and remove up.
J-25013-5 and J-25013-1 tools from case. Turn transmission 2. If necessary, remove manual shaft and parking
linkage as follows:

Fig. 7A-4 1A - M a n u a l Shaft and Parking Shaft Parts

 A U T O M A T IC T R A N S M IS S IO N (2 0 0)7A -1 1

INSIDE DETENT LEVER ^

PARK
BRACKET

MANUAL SHAFT

Fig. 7A-42A~Removing Manual Shaft Nut Fig. 7 A -4 5A -R em oving Parking Pawl Bracket Bolt

a. Remove hex nut which holds inside detent lever to necessary, pry out manual shaft seal using screwdriver (Fig.
manual shaft (Fig. 7A-42A). 7A-44A).
b. Remove parking brake actuator rod and inside e. Remove parking lock bracket (Fig. 7A-45A).
detent lever assembly. f. Remove parking pawl shaft retaining pin (Fig. 7A-
c. Rmeove manual shaft retaining pin from case and 46A).
slide manual shaft out (Fig. 7A-43A). g. Using 6.3mm (No. 4) easy out, remove parking pawl
d. Inspect manual shaft to case seal for damage. If cup plug and discard (Fig. 7A-47A).

RETAINING IDENTIFICATION
PIN GROOVE

PIN GROOVE

Fig. 7A-43A~Removing Manual Shaft from Case Fig. 7 A -4 6A -R em oving Parking Pawl Shaft Pin

MANUAL SHAFT
SEAL PAR KING
PAWL CUP P PLUG I
6.3mm (#4)
EASY OUT

Fig. 7 A-44A ~Rem oving Manual Shaft Seal From Case Fig. 7A-47A--Removing Parking Pawl Shaft Cup Plug from
Case
(2 0 0 )7 A-12 A U T O M A T IC TR A N SM IS S IO N

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.
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.
4. Inspect reverse clutch lugs, governor bore,
intermediate servo bore, speedometer bore and snap ring
grooves for damage.
5. Inspect reverse clutch seal and intermediate band
anchor pin bores for damage.
6. Inspect vent assembly in case for damage. Do not
Fig. 7 A-48A~Removing Parking Pawl Shaft from Case remove unless replacement is required.
7. Inspect for damaged or stripped bolt holes. If any
NOTE: Grind approximately 20mm (3/4") from end threaded holes require heli-coils or equivalent, install these
of 6.3mm (No. 4) easy out to remove cup plug. to renew the threads.
h. Using sheet metal screw or 4mm (No. 3) easy out, 8. Turn transmission to vertical position, rear end up.
remove parking pawl shaft (Fig. 7A-48A). 9. Inspect cooler line connectors for damage. Do not
i. Remove parking pawl and return spring. remove unless replacing.

Fig. 7A-49A--Oil Passages - Bottom of Case

 A U T O M A T IC TR A N S M IS S IO N (200)7A -13

LINE REVERSE DRIVE

J-21426

REAR OIL
SEAL

Fig. 7A-5 1A - ln s ta llin g Rear Oil Seal

13. 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. lbs.).
Fig. 7A-50A--0M Passages, Front of Case
M A N U A L SHAFT A N D PARKING PAW L
10. Inspect case bushing for damage or scoring. PARTS (Fig. 7A -52A )
11. If removed, install a new oil seal, using J-21426
(Fig. 7A-51A). Inspection
12. If vent was removed, apply Loctite Primer "T", or 1. Align actuator rod tangs with hole in inside detent
equivalent, to the outside diameter of the vent that locates lever and separate.
in the case and Loctite 35, or equivalent, to the vent hole 2. Inspect parking actuator rod for damage, or broken
in the case. Install vent, using a rubber or plastic hammer. retainer lugs.

Fig. 7 A - 5 2 A ~ M a n u a l Shaft and Parking Shaft Parts

(200)7A -14 A U T O M A T IC TR A N SM IS S IO N

Fig. 7 A -5 3 A -ln s ta llin g Manual Shaft Seal Into Case Fig. 7 A -5 5 A -ln s ta llin g Parking Pawl Cup Plug

3. Inspect parking actuator spring for damage. 4. Align parking pawl and return spring with case shaft
4. Inspect actuator for free fit on actuator rod. bore.
5. Inspect parking pawl for cracks or damage. 5. Install parking pawl shaft, tapered end first.
6. Inspect parking pawl return spring for deformed end 6. Using 10mm (3/8") rod, install new parking pawl
or coils. shaft cup plug, open end out, past retaining pin hole (Fig.
7A-55A).
7. Inspect parking pawl shaft for damage. 7. Install parking pawl shaft retaining pin.
8. Inspect parking bracket for cracks or wear. 8. While holding the parking pawl toward center of
9. Inspect inside detent lever for cracks or loose pin. transmission, install parking bracket. Torque bolts to 20.0-
10. Inspect manual shaft for damaged threads and the 27.0 N-m (15-20 ft. lbs.).
flats for raised edges. File down any raised edges. 9. Install parking actuator rod into inside detent lever
on pin side, locating lever between actuator rod tangs.
Reassembly
10. Install parking actuator rod and inside detent lever
1. Turn transmission to horizontal position, oil pan side with detent lever pin toward center of transmission and
up. actuator plunger between parking pawl and parking bracket
2. If removed, install new manual shaft seal with lip (Fig. 7A-56A).
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 CAUTION: File any burrs or raised edges o ff the
toward inside of case and parking pawl return spring under manual shaft that could damage the seal during
pawl tooth with spring ends toward inside of case (Fig. 7A- installation o f the shaft.
54A). Make sure spring ends locate against case pad.

Fig. 7 A - 5 4 A —Installing Parking Pawl Fig. 7 A-56A--lnstalling Parking Pawl Rod

 A U T O M A T IC T R A N S M IS S IO N (2 0 0)7 A-15

RETAINING IDENTIFICATION
PIN GROOVE SPEEDOMETER
DRIVE GEAR CLIP

PIN GROOVE

I
OUTPUT SHAFT

Fig. 7 A-57A--lnstalling Manual Shaft Into Case Fig. 7A-59A~lnstalling Speedometer Drive Gear and Clip

11. Install manual shaft, small identification ring 4. Inspect governor drive gear for rough or damaged
groove first, through case. Install manual shaft to case teeth.
retaining pin, indexing with larger groove on manual shaft 5. Inspect speedometer drive gear for rough or
(Fig. 7A-57A). damaged teeth and also the clip for damage.
12. Aligning inside detent lever with flats on manual 6. If necessary to replace speedometer drive gear,
shaft, install inside detent lever on shaft. proceed as follows:
For nylon gear,
13. Install hex nut on manual shaft and torque to 27.0-
34.0 N-m (20-25 ft. lbs.). a. Depress speedometer drive gear clip.
b. Remove gear and clip, tapping gear lightly with
REAR GEAR PARTS plastic hammer.
Output Shaft (Fig. 7A-58A)
NOTE: Make sure speedometer drive gear is located
NOTE: The service output shaft has one speedometer so speedometer driven gear will mesh with it.
drive gear clip hole at the front speedometer gear c. Place speedometer drive gear clip with the tanged
location which is about 6.3mm (1/4") diameter and end in the correct hole in the output shaft (Fig. 7A-59A).
opposite this hole is another clip hole which is about d. Align the slot of the speedometer drive gear with the
4.0mm (5/32"). The shaft also has the same size holes clip and install the gear.
at the rear speedometer gear location.
1. Inspect journals and snap ring grooves for wear or For steel gear, (models PA, CO, CR, CS, CY),
damage. a. Remove steel gear, using J-21427-01 and suitable
2. Inspect lubrication passages for being plugged or puller such as J-8433. (Fig. 7A-60A)
damaged. b. Position front end of shaft on a block of wood to
3. Inspect splines for damage. prevent damaging the front end.

J-8433

SPEEDOMETER
DRIVE GEAR

J-21427-01

Fig. 7 A - 5 8 A ~ O u tp u t Shaft Fig. 7A-60 A ~ R e m ov ing Steel Gear

(2 0 0)7 A-16 A U T O M A T IC TRAN SM ISSIO N

J-28578

ESL-------SPEEDOMETER
DRIVEGEAR

J
OUTPUT SHAFT
■'ff-

— x
Fig. 7 A-6 1A—Insta11ing Steel Gear Fig. 7 A -6 3 A -ln s ta llin g Rear Internal Gear on Output Shaft

c. Position gear, larger chamfered inside diameter first, 5. Install rear internal gear to rear sun gear roller thrust
over rear end of output shaft. bearing assembly by placing the small diameter race over
d. Using J-28578 or J-6133, drive the gear to 156 mm the output shaft (Fig. 7A-64A).
(6-5/32") from end of output shaft to rear face of gear. (Figs.
7A-61A, 7A-62A) Roller Clutch and Rear Carrier Assembly
7. If necessary, remove rear internal gear to output Inspection
shaft snap ring. If damaged, replace with a new snap ring
(Fig. 7A-58A). 1. Remove roller clutch race. Inspect race and spline
for scoring or wear (Fig. 7A-65A).
Rear Internal Gear 2. Remove roller clutch assembly and inspect roller
bearings cage and springs for damage or wear (Fig. 7A-
1. Inspect rear internal gear, splines, teeth and bearing 65A).
surface for wear, cracks or damage. 3. Remove and inspect rear carrier to roller clutch
2. Inspect parking pawl lugs for cracks or damage. thrust washer for signs of scoring or excessive wear.
3. Install rear internal gear, hub end first, on output 4. Inspect 4 tanged rear carrier to rear internal gear
shaft, as shown in Fig. 7A-63A. thrust washer for being scored or distorted tangs (Fig. 7A-
4. Thoroughly clean, air dry and inspect closely, the 65A).
rear internal gear to rear sun gear roller thrust bearing 5. Inspect rear carrier for damage.
assembly for pitted or rough conditions. 6. Inspect roller clutch cam ramps for damage.

STEEL END OF THRUST BEARING ASSY. REAR INTERNA L

(INSIDE DIAM ETER RACE GEAR
AG AINST GEAR)

OUTPUT SHAFT

Fig. 7 A -6 2 A -P o s itio n in g Steel Gear Fig. 7A-64A--lnstalling Thrust Bearing Assembly

 A U T O M A T IC TR A N S M IS S IO N (200)7A -17

ROLLER CLUTCH THRUST THRUST

WASHER WASHER
RACE

ROLLER CLUTCH
REAR C A RR IER

Fig. 7A-65A~Roller Clutch and Rear Carrier-Exploded

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). THRUST WASHER
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). REAR CARRIER

Fig. 7 A -6 7 A -ln s ta llin g Thrust W asher Into Rear Carrier

REAR CARRIER

FEELER
GAGE

Fig. 7 A - 6 6 A - C h e c k i n g Rear Carrier Pinion End Play Fig. 7A-68A--lnstalling Roller Into Cage
(2 0 0 )7 A-18 A U T O M A T IC TR A N SM IS S IO N

REAR CARRIER REAR IN TER N AL GEAR

ROLLER CLUTCH REAR CARRIER

Fig. 7A-69A--lnstalling Roller Clutch Into Rear Carrier Fig. 7A -72A~ ln sta lling Rear Carrier Into Rear Internal Gear

3. Install roller clutch assembly into roller clutch cam 6. Install roller clutch and rear carrier assembly into
(Fig. 7A-69A). rear internal gear (Fig. 7A-72A).
4. Install roller clutch race, spline side out and rotate 7. Install J-25013-1, open end first, into rear end of
clutch race counterclockwise into position (Fig. 7A-70A). case. Bolt J-25013-5 on end of case (Fig. 7A-73A).
5. Install 4 tanged rear carrier to rear internal gear 8. Turn case to vertical position, pump end up.
thrust washer. Align tangs into slots of rear carrier and 9. Install rear unit parts into case and into J-25013-1
retain with petrolatum (Fig. 7A-71A). sleeve (Fig. 7A-74A) indexing rear internal gear parking
pawl lugs to pass by parking pawl tooth.

ROLLER CLUTCH REAR CARRIER

RACE

Fig. 7A-70A--lnstalling Roller Clutch Race Fig. 7A-73A--lnstalling Tools on Rear End of Case

Fig. 7A-7 1A -ln s ta llin g Thrust W a s he r Fig. 7A-7 4 A ~ ln sta lling Rear Unit Parts
 A U T O M A T IC TR A N S M IS S IO N (200)7A-19

L O & REVERSE LO & REVERSE

CLUTCH L 0 8t REVERSE CLUTCH LO & REVERSE
HOUSING L O & REVERSE CLUTCH APPLY SPRING STEEL CLUTCH
ASSEMBLY PISTON SEALS RING RETAINER PLATE

RING TO CASE PISTON RELEASE RING COMPOSITION

(HOUSING SPACER ASSEMBLY SPRING FACED PLATE
TO CASE)

Fig. 7 A -7 5 A - L o w and Reverse Clutch Housing-Exploded Vie w

10. Using J-25013-5 adjusting screw (Fig. 7A-73A) and Low and Reverse Clutch Housing Assembly
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. (Fig. 7A-75A)

NOTE: Make sure speedometer drive gear is visible

through speedometer gear bore. If drive gear is not Disassembly
visible, it may be located on wrong journal of shaft. 1. Compress low and reverse clutch spring retainer,
remove snap ring and retainer and inspect for damage or
LOW AND REVERSE CLUTCH distortion (Fig. 7A-76A).
Inspection
Inspect low and reverse clutch composition-faced and
steel clutch plates for signs of wear or burning.

Fig. 7A-76A~Removing or Installing Low and Reverse Clutch

Spring Retaining Snap Ring
(2 0 0 )7 A-20 A U T O M A T IC T R A N SM IS S IO N

'mMrnm

WAVE RELEASE LO & R EV ER S E

SPRING C LU TC H H O U S IN G

LO &
C LUTCH PISTON CLUTCH IN N E R SEAL
(LIP UP)

Fig. 7A-77A~Removing or Installing Low and Reverse Clutch Fig. 7 A-79 A-R e m ovin g or Installing Low and Reverse Clutch
Wave Release Springs Inner Seal

2. Remove waved spring (Fig. 7A-77A). 7. Inspect low and reverse clutch housing to case spacer
3. Remove low and reverse clutch piston. ring for damage.
4. Remove outer and inner piston seals (Figs. 7A-78A Reassembly
and 7A-79A). 1. Install clutch apply ring on low and reverse clutch
5. Remove clutch apply ring. piston.
Inspection 2. Install new outer and inner seals on piston with lips
1. Inspect low and reverse clutch housing for damage, facing away from clutch apply ring side.
plugged feed hole. 3. Install seal protector J-25011.
2. Inspect low and reverse clutch housing bushing for
damage or scoring. NOTE: Apply transmission fluid to all clutch seals
3. Inspect low and reverse clutch splines and snap ring before reassembly.
groove for damage or burrs. Remove any burrs on splines
or snap ring groove. CAUTION: Flat screwdriver surface area must be
4. Inspect low and reverse clutch piston and clutch smooth to prevent damaging outer seal.
apply ring assembly for distortion, cracks or damage. 4. Using flat edged small screwdriver, or piston
installing tool shown in Fig. 7A-107A, install low and
NOTE: The apply ring is identified by a number reverse clutch piston, while rotating and pushing down into
located on the ring. See Fig. 7A-82A. place (Fig. 7A-80A).
5. Inspect low and reverse clutch spring retainer for 5. Remove seal protector J-25011.
damage. 6. Install waved release spring (Fig. 7A-77A).
6. Inspect waved spring for damage. 7. Install retainer, cupped faced down.

LO & R EVERSE
CLU TC H PISTON LO & REVERSE J-25011 L O & REVERSE
C LUTCH O UTER SEAL CLUTCH HOUSING CLUTCH PISTON
(LIP UP)

Fig. 7A-78A--Removing or Installing Low and Reverse Clutch Fig. 7A-8 0 A ~ ln sta lling Low and Reverse Clutch Piston
Outer Seal
 A U T O M A T IC T R A N S M IS S IO N (200)7A-21

LO& REVERSE
CLUTCH HOUSING
TO CASE SPACER

Fig. 7A-8 1A - P r o p e r Location of Low and Reverse Housing to Fig. 7 A - 8 3 A -ln s ta llin g Low and Reverse Clutch Housing
Case Spacer

8. Compress retainer and install snap ring (Fig. 7A- 3. Install low and reverse clutch housing assembly
76A). aligning reverse clutch housing feed hole to reverse clutch
case feed passage, using J-25012 (Fig. 7A-83A).
Installation
1. Oil and install the lo and reverse clutch plates into If the low and reverse clutch housing does not seat past
the case, starting with a flat steel and alternating the case snap ring groove, proceed as follows:
composition-faced and flat steel clutch plates. (See Clutch a. Remove tool J-25012.
Plate Usage Chart, Fig. 7A-82A). b. Using rear sun gear and input drum as a tool, install
2. Install low and reverse clutch housing to case spacer input drum and rear sun gear in case.
ring in case (Fig. 7A-81A).

MODELS DIRECT CLUTCH FORWARD CLUTCH LOW & REV. CLUTCH

COMP. COMP. FLA T COMP.

F LA T STEEL PLATE FACED APPLY RING W A V E D PLATE F LA T STEEL PLATE FACED APPLY R ING STEEL FACED APPLY RING
PLATE PLATE PLATE PLATE

NO. THICKNESS NO. I.D. ‘ W ID TH NO. THICKNESS NO. THICKNESS NO. I.D . ♦W ID TH NO. N O ./TY PE I.D . ‘ W ID TH

2.324mm 16.99m m 1.585m m 1,969mm 1 7.50m m 4 -/ 24.34m m

PA, PY 4 4 1 1 2 3 0 5 5
(.09 1") (.6 6 9 ") (.0 6 2 ") (.0 7 7 ") (.6 8 9 ") G RO OVED (.9 5 8 ")

2.324m m 2 1,44mm 1.585mm 1,969m m 17.50m m 4-/■ 24.34m m

BR, CX 3 3 2 1 2 3 0 5 5
(.0 9 1 ") (.8 4 4 ") (.0 6 2 ") (.0 7 7 ") (.6 8 9 ") G RO O VED (.9 5 8 ")

2.324m m 16.99m m 1.585m m 1,969m m 13.51 mm 5 -/N O N - 2 0 .14mm

CS 4 4 1 1 3 4 8 6 4
(.0 9 1 ") (.6 6 9 ") (.0 6 2 ") (.0 7 7 ") (.5 3 2 ") G RO OVED (.7 9 3 ")

BZ, OW 5 2.324m m 5 9 12.50mm 1 1,585mm 3 1,969m m 13.51 mm 5 -/N O N - 20.14m m

4 8 6 4
(.0 9 1 ") (.4 9 2 ") (.0 6 2 ") (.0 7 7 ") (.5 3 2 ") G RO O VED (.7 9 3 ")

PG, PH,
CO, CR, 2.324m m 12.50m m 1,585m m 1.969m m 13.51 mm 6 -/N O N - 1 5.94mm
5 5 9 1 3 4 8 7 3
CY, BA, (.0 9 1 ") (.4 9 2 ") (.0 6 2 ") (.0 7 7 ") (.5 3 2 ") G RO O VED (.62 8")
OS, OT

NOTE: THE D IR E C T A N D FO R W AR D CLU TC H F L A T STEEL CLUTC H PLATES A N D TH E FO RW AR D

CLUTC H W A V E D STEEL PLATE SH O U LD BE ID E N T IF IE D BY T H E IR THIC KNESS.

THE D IR E C T A N D FO RW AR D PR O D UC TIO N IN S T A L L E D C O M P O S IT IO N -FA C E D CLUTCH

PLATES MUST NO T BE IN T E R C H A N G E D . FOR SE RVIC E, D IR E C T A N D FO R W AR D CLUTCH
USE TH E SAME C O M P O S IT IO N -FA C E D PLATES.

A L L LOW A N D REVERSE CLU TC H C O M P O S IT IO N -FA C E D PLATES AR E S E R V IC ED W ITH

TH E G R O O VE D C O M P O S IT IO N -FA C E D PLATES.

* M EASURE TH E W ID TH OF THE CLU TC H APPLY RING FOR PO SITIVE ID E N T IF IC A T IO N .

Fig. 7A-82A--Clutch Plate Usage and Apply Ring Idneitification

(2 0 0 )7 A-22 A U T O M A T IC TR A N SM IS S IO N

INPUT
DRUM NOTE: 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 past 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.
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. 7 A - 8 4 A -ln s ta llin g Input Drum and Rear Sun Gear (Fig. 7A-85A).
2. Inspect rear sun gear bushing for damage or scoring.
3. If necessary, remove input drum to rear sun gear
c. Rotate rear sun gear back and forth, tapping lightly snap ring and remove sun gear from input drum.
with input drum, to align roller clutch race and low and 4. Inspect input drum for damage.
reverse clutch hub splines (Fig. 7A-84A). 5. Inspect 4 tanged input drum to low and reverse
d. Remove tool (input drum and rear sun gear). clutch housing thrust washer for scoring or distorted tangs.
6. If damaged, replace rear sun gear to input drum snap
ring.
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.
7A-84A).
Front Sun Gear
1. Inspect front sun gear splines and teeth for damage
or wear.
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).

REAR SUN
GEAR

THRUST
WASHER

INPUT
DRUM

Fig. 7 A -8 6 A -ln s ta llin g Thrust Washer Fig. 7 A - 8 7 A - F r o n t Sun Gear Identification

 A U T O M A T IC TR A N S M IS S IO N (200)7A-23

4. Thoroughly clean, air dry and inspect front sun gear FRONT SUN
to front carrier thrust race and thrust bearing for pitted or GEAR
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).
NOTE: This thrust bearing requires only 1 thrust race.
Front Carrier Assembly THRUST BEARING &
RACE ASSEMBLY
Inspection (NEEDLE BEARINGS
1. Inspect front carrier for damage (Fig. 7A-90A). AGAINST GEAR)

2. Inspect pinions for damage, rough bearings or tilt.

3. Check pinion end play. Pinion play should be
0.24mm-0.69mm (0.009" to 0.027")(Fig. 7A-90A). Fig. 7A-89A~ln sta lling Thrust Bearing Assembly Again st

4. Thoroughly clean, air dry and inspect closely, front

Front Sun Gear

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). FRO NT CA R R IER
2. Install front carrier and thrust bearing assembly
(Fig. 7A-93A).
Front Internal Gear and Thrust Washer
1. Inspect forward clutch hub for worn splines and for
lubrication holes.
2. Inspect internal gear for cracks or damage.
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. FEELER
GAGE
6. Install thrust washer on front internal gear and
retain with petrolatum (Fig. 7A-92A).
7. Install front internal gear and thrust washer. Fig. 7 A -9 0 A -C h e c k in g Front Carrier Pinion End Play

THRUST BEARING ASSY.

(INSIDE DIAM ETER RACE
L AGAINST CARRIER)

FRONT CARRIER
'FRONT SUN
GEAR

Fig. 7 A - 8 8 A - ln s t a llin g Front Sun Gear Fig. 7A-9 1A--Installing Thrust Bearing Assembly Onto Front
Carrier
(2 0 0 )7 A-24 A U T O M A T IC TRAN SM IS S IO N

-SNAP J-25013-5
RING!

REAR SELECTIVE
WASHER &
IDENTIFICATION

THRUST
WASHER
J-25013-1
FRONT
INTERNAL
GEAR

Fig. 7A -9 2 A -ln sta llin g O utput Shaft to Selective Washer Fig. 7 A -9 4 A -ln s ta llin g Tools on Rear End of Case
Snap Ring

Rear Selective Thrust Washer Check Rear Unit End Play

1. Inspect selective washer for scoring or damage (Fig. 1. Loosen J-25013-5 adjusting screw on output shaft
7A-92A). and push output shaft downward (Fig. 7A-94A).
CAUTION: Do not install clamp assembly on any
CAUTION: The rear selective thrust washer m ust machined case surfaces.
be installed with the identification number toward 2. Install gauge clamp on case as shown in Fig. 7A-
the front o f the transmission. 95A.
2. Install rear selective washer. 3. Install dial indicator J-8001 and plunger extension
J-7057. Position extension against end of output shaft. Set
3. Inspect output shaft to selective thrust washer snap dial indicator to zero (Fig. 7A-95A).
ring for damage or distortion. 4. Move output shaft upward by turning the adjusting
screw on J-25013-5 until the white or scribed line on sleeve
NOTE: It may be necessary to move output shaft J-25013-1 begins to disappear (Fig. 7A-94A) and read end
upward by turning the adjusting screw on J-25013-5 to play. Rear unit end play should be 0.10-0.64mm
install output shaft to selective washer snap ring. (.004"-.025").
4. Install snap ring on output shaft (Fig. 7A-92A).
NOTE: Selective washer controlling this end play is
CAUTION: Make sure snap ring is fully seated in located between the front internal gear thrust washer
output shaft groove. and output shaft snap ring. If more or less washer

FRONT CARRIER

ROLLER THRUST
EARING ASSY.

Fig. 7 A - 9 3 A - ln s ta llin g Front Carrier and Roller Thrust Fig. 7 A -9 5 A -C h ec kin g Rear Unit End Play
Bearing
 A U T O M A T IC T R A N S M IS S IO N (200)7A-25

REAR UNIT END PLAY CHART

THICKNESS IDENTIFICATION

Number and/or Color

2.90- 3.01mm (0.114 '-0.119") 1 Orange

3.08 - 3.19mm (0.121' '-0.126'') 2 White
3.26- 3.37mm (0.128' '-0.133” ) 3 Yellow
3.44- 3.55mm (0.135' '-0.140'') 4 Blue
3.62 - 3.73mm (0.143' '-0.147” ) 5 Red
3.80- 3.91mm (0.150' '-0.154” ) 6 Brown
3.98- 4.09mm (0.157' '-0.161") 7 Green
4.16- 4.27mm (0.164' '-0.168” ) 8 Black
4.34- 4.45mm (0.171' '-0.175” ) 9 Purple

Fig. 7A-96A~Rear Unit End Play Washer Thickness Chart Fig. 7 A -9 7 A -L o c a tio n of Front Selective W asher

thickness is required to bring end play within

specifications, select proper washer from the chart SNAP RING
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.
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).
DIR
FRONT UNIT PARTS CLUTCH
HOUSING
Direct Clutch Housing Assembly (Fig. 7A-98A)
1. Remove snap ring (Fig. 7A-99A).
2. Remove the clutch backing plate from the direct Fig. 7A -9 9A -R em oving or Installing Direct Clutch Snap Ring
clutch housing.

D IR E C T D IR E C T D IR E C T FLA T D IR E C T
CLUTCH C LU TCH CLU TCH STEEL C LU TC H
PISTON APPLY R E T A IN E R PLATE B AC KING
SEALS RIN G & SPRING PLATE

C O M P O S ITIO N ­ SNAP
D IR E C T D IR E C T C LU TCH SPRING R IN G FAC ED PLATE R IN G
CLU TCH PISTON ASSEMBLY G U ID E
H O U SING

Fig. 7A-98A--Direct Clutch Assembly - Exploded

(2 0 0)7 A-26 A U T O M A T IC TRAN SM IS S IO N

J-23327

D IR E C T
CLUTCH
HOUSING
D IR E C T
C LU TC H C EN T E R SEAL
SNAP H O U SIN G (LIP UP)
RING

Fig. 7 A - 10OA-Removing or Installing Direct Clutch Inner Fig. 7A-1G3A--Removing or Installing Center Seal of Direct
Snap Ring 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.
DIR 9. Inspect release spring retainer for being collapsed.
CLUTCH CLUTCH OUTER SEAL 10. Inspect release springs for being collapsed.
PISTON (LIP UP) 11. Remove release spring guide and inspect for
damage.
Fig. 7A -101 A-Removing Direct Clutch Piston Outer Seal 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
piston unless the piston or apply ring requires replacement.
NOTE: 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
DIRECT damage.
CLUTCH CLUTCH INNER SEAL 20. Inspect direct clutch bushings for damage or
PISTON (LIP UP) scoring.

Fig. 7A-102A--Rem oving Direct Clutch Piston Inner Seal

 A U T O M A T IC TR A N S M IS S IO N (200)7A-27

DIRECT DIR
CLUTCH CLUTCH INNER SEAL CLUTCH "CLUTCH OUTER SEAL
PISTON (LIP UP) PISTON (LIP UP)

Fig. 7 A - 10 4 A - ln s ta llin g Direct Clutch Piston Inner Seal Fig. 7A -10 5 A - ln s ta llin g Direct Clutch Piston Outer Seal

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
DIRECT
CLUTCH
lip facing up. HOUSING
4. Install seal protector J-25010 (Fig. 7A-105A).
CAUTION: Use extreme care when installing
direct clutch piston past larger direct clutch snap
ring groove. Groove could cut outer seal on piston.
5. Oil seals and install direct clutch piston (Fig. 7A- J-25010

106A). D IR E C T
C L U TC H
PISTOM

NOTE: 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. Fig. 7 A - 10 6 A - ln s ta llin g Direct Clutch Piston

6. Remove seal protector J-25010.

7. Install release spring guide with the omitted rib over

Fig. 7 A - 107A--Piston Installing Tool

(2 0 0 )7 A-28 A U T O M A T IC T R A N SM IS S IO N

the check ball in the piston, as shown in Fig. 7A-108A.

8. Install retainer and spring assembly.
NOTE: Models BR, CX, PA and PY use a direct
OMITTED clutch retainer and spring assembly which contains
RIB (16) release springs. All other models use a retainer and
spring assembly with (10) release springs.
REL
ASSEMBLY CAUTION: Retainer could locate in snap ring
GUIDE
DIRECT CLUTCH groove and forcing retainer to compress springs,
PISTON could damage retainer plate when installing.
9. Using J-23327 tool, compress retainer and spring
Fig. 7 A - 10 8 A - ln s ta llin g Release Spring Guide 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.
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. 7A-99A).
NOTE: 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.
Fig. 7 A - 1 0 9 A -ln s ta llin g Clutch Plates into Direct Clutch
Housing

FORWARD
TURBINE FORWARD FORWARD CLUTCH WAVED FORWARD
SHAFT CLUTCH CLUTCH RETAINER & STEEL CLUTCH
SEAL HOUSING PISTON SPRING PLATE BACKING
RINGS ASSEMBLY ASSEMBLY ASSEMBLY PLATE

THRUST FORWARD FORWARD SNAP COMPOSITION FLAT SNAP

WASHER CLUTCH CLUTCH RING FACED STEEL RING
(DIRECT TO PISTON APPLY PL^TE PLATE
FORWARD SEALS RING
CLUTCH)

Fig. 7A-1 1 0 A -F o r w a r d Clutch Assembly - Exploded Vie w

 A U T O M A T IC TR A N S M IS S IO N (2 0 0)7 A-29

J-25024

SNAP
THRUST RING
WASHER

J 23327 1
FORWARD
CLUTCH % 1 T fl H f l 1 , f J-25018
ASSEMBLY A' M I * , i
FORWARD
CLUTCH 'N id i#
HOUSING 1u '

Fig. 7A-1 1 1A-Removing or Installing Forward Clutch to Fig. 7A-1 13 A -R em o vin g or Installing Forward Clutch Release
Direct Clutch Thrust Washer Spring Snap Ring

2. Remove and inspect forward clutch to direct clutch 12. Inspect release spring retainer for distortion.
thrust washer for damage (Fig. 7A-111A). 13. Inspect release springs for being collapsed.
3. Place forward clutch down with turbine shaft 14. Remove forward clutch piston.
through hole in work bench. 15. Remove forward clutch outer and inner piston seals
4. Remove snap ring and inspect for damage (Fig. 7A- and discard (Figs. 7A-114A and 7A-115A).
112A).
5. Remove backing plate from the forward clutch
housing. FORWARD CLUTCH PISTON
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 and J-25018. CLUTCH OUTER SEAL
11. Remove retainer and spring assembly from (LIP UP)
housing.
Fig. 7A-1 1 4A -R em ovin g or Installing Outer Piston Seal

SNAP
RING

CLUTCH
BACKING
PLATE
CLUTCH INNER SEAL
(LIP UP)
FORWARD
CLUTCH
ASSEMBLY

FORWARD CLUTCH PISTON

Fig. 7A-1 12A~Removing or Installing Snap Ring from

Forward Clutch Housing Fig. 7A-1 1 5 A -R em o v in g or Installing Inner Piston Seal
(2 0 0)7 A-30 A U T O M A T IC TR A N SM IS S IO N

FORWARD EXHAU ST
CLUTCH CHECK 16. Do not remove the clutch apply ring from the
HOUSING BA L L
piston unless the piston or apply ring requires replacement.
17. Inspect the forward clutch piston and clutch apply
ring assembly for cracks or damage.
NOTE: The apply ring is identified as shown in Fig.
LUBE 7A-82A.
HOLE 18. Inspect forward clutch housing for cracks, opened
oil passages or other damage (Fig. 7A-116A).
19. Check for free operation of check ball.
UP
PLUG 20. Inspect forward clutch housing snap ring groove
for damage or burrs.
FORWARD CLUTCH 21. Inspect turbine shaft for open oil passages on both
FEED HOLE ends of shaft and journals for damage.
22. Inspect cup plug for damage. If cup plug is
Fig. 7A-1 1 6A--Forward Clutch Housing damaged or missing, proceed as follows:
a. Use 4mm (No. 3) easy out (grind to fit) and remove
cup plug.
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
7A-115A).
CAUTION: Use extreme care when installing
forward clutch piston past large forward clutch
snap ring groove. Groove could cut outer seal on
piston.
FORWARD CLUTCH 3. Lubricate seals and install forward clutch piston
PISTON (Fig. 7A-117A).
FORWARD CLUTCH;^
HOUSING
NOTE: To make the piston easier to install, insert tool
between the inner seal and shaft; rotate tool around the
Fig. 7 A - 1 1 7A~lnstalling Forward Clutch Piston 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.
CAUTION: 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).
DIRECT NOTE: An arbor press and J-23327-1 and J-25018 can
CLUTCH
PISTON be used to compress the retainer and spring assembly.
6. Remove J-23327-1 and J-25018.
DIRECT 7. Oil and install the forward clutch plates into the
CLUTCH forward clutch housing, starting with the waved steel plate
HOUSING

Fig. 7A-1 1 8 A--I n sta 11i n g Forward Clutch Piston

 A U T O M A T IC T R A N S M IS S IO N (2 0 0)7 A-31

FORW ARD
C LU TC H
H O U S IN G

D IR E C T
C LU T C H
H O U SIN G

Fig. 7A - 1 19 A —Installing Clutch Plates Into Forward Clutch Fig. 7A-1 21 A--lnstalling Forward Clutch Assembly
HOusing

and alternating composition- faced and flat steel clutch 2. Install intermediate band, locating band apply lug
plates. (See Fig. 7A-119A, and Clutch Plate Usage Chart and anchor pin lug in case slots (Fig. 7A-125A).
Fig. 7A-82A).
8. Install backing plate, chamfered side up. Forward and Direct Clutch
9. Install snap ring (Fig. 7A-112A). Installation
1. Position direct clutch assembly, clutch plate end up,
over hole in bench.
NOTE: Make sure composition clutch plates turn
freely. NOTE: Align direct clutch composition-faced clutch
10. Install forward to direct clutch thrust washer and plate teeth one above the other to make the forward
retain with petrolatum (Fig. 7A-111A). clutch assembly easier to install.
2. Install forward clutch assembly into direct clutch.
11. If removed, install new turbine shaft seal rings, Hold direct clutch housing and rotate forward clutch back
making sure cut ends are assembled in the same relationship and forth until the forward clutch is seated (Fig. 7A-121A).
as cut and rings are seated in their groove. Retain with
petrolatum. (See Fig. 7A-120A for correct way to position NOTE: When the forward clutch is seated, it will be
cut ends.) 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.
Intermediate Band Assembly 3. Grasp direct and forward clutch assemblies to
1. Inspect band for burning, flaking or damage. prevent their separation and position on bench, with the
turbine shaft up.

FORWARD
CLUTCH
HOUSING

DIRECT S liiti'
CLUTCH —
HOUSING

Fig. 7A-1 22A--Forward Clutch Properly Seated in Direct

Clutch
(2 0 0 )7 A-32 A U T O M A T IC TRAN SM IS S IO N

PUMP BODY
PUMP COVER

THRUST WASHER

PUMP OIL
SEAL RINGS

CHEC
BALL
PRESSURE REGULATOR SPRING
PRESSURE REGULATOR GUIDE
PRESSURE REGULATOR VALVE
V A LV E BORE PLUG
RETAINER RING

Fig. 7A - 12 3 A - ln s ta llin g Direct and Forward Clutch Fig. 7 A - 1 2 6 A -P u m p Assembly - Exploded V ie w

Assemblies

4. Install J-25021 as shown in Fig. 7A-123A. NOTE: The direct clutch housing will be
5. Install direct and forward clutch assemblies, using approximately 33.34mm (1-5/16") from the pump face
J-25021, and rotate into position (Fig. 7A-123A). in case when correctly seated. See Fig. 7A-124A.
6. Remove J-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.

Fig. 7 A - 12 4 A - D ir e c t and Forward Clutch Assemblies Properly

Installed

THRUST
WASHER

PUMP ASSEMBY

INTERMEDIATE
BAND

Fig. 7 A - 1 2 7 A-Removin g or Installing Thrust W asher from

Fig. 7A-1 2 5 A -lnstallin g Interm ediate Band Assembly Pump
 A U T O M A T IC T R A N S M IS S IO N (200)7A-33

PUMP BODY

PUMP
DRIVEN
GEAR
PUMP DRIVE GEAR
(ID EN TIFIC A TIO N MARKS ON
TANGS UP)

Fig. 7 A -1 2 8 A Removing or Installing Pressure Regulator Fig. 7A-1 2 9 A -R e m ovin g Pump Drive Gear
Valve

Pressure Regulator Pump Body

Inspection Inspection
1. To prevent the pump from turning while removing 1. Remove the 7.14mm (.281") check ball from the
the pressure regulator valve, place a bolt or screwdriver pump body or pump cover and keep it separated from the
through a hole in the pump and bench (Fig. 7A-128A). five 6.35mm (.250) check balls used in the case and control
valve assembly.
2. Using small screwdriver, push on bore plug, 2. Remove drive gear and driven gear from pump body
compressing pressure regulator spring; and using snap ring (Fig. 7A-129A).
pliers, remove retaining ring (Fig. 7A-128A). 3. Inspect drive and driven gears fro scoring, galling
3. Release valve spring tension slowly and remove valve or damage.
train.
4. Inspect pressure regulator valve for nicks or damage. NOTE: Driven gear identification marks should have
5. Inspect spring and guide for damage or distortion. been against the pump body gear pocket. (See Fig. 7A-
6. Inspect pressure regulator valve for free operation 133A for identification.) The drive gear has 1
in bore. identification mark on each drive tang (Fig. 7A-129A).
This side should be facing away from the pump body
Do not drop the check ball that is in gear pocket.
CAUTION:
the pump, as the pump body and pump cover are 4. Inspect drive and driven gear pocket and crescent
separated. for scoring or damage.
7. Remove pump cover to pump body attaching bolts 5. Inspect pump body face for nicks and overall
and separate pump cover from pump body. flatness.
6. Inspect for open oil passages (Fig. 7A-130A).

VOID
CONVERTER
CONVERTER TO COOLER
FEED

LINE

PUMP
INTAKE

SEAL DRAIN
BACK HOLE

REVERSE DRIVE 3RD/REVERSE

PUMP BODY

Fig. 7 A - 1 3 0 A - P u m p Body Assembly

(2 0 0 )7 A-34 A U T O M A T IC T R A N SM IS S IO N

J-25016

PUMP BODY
SEAL

Fig. 7A -1 31 A ~lnstallin g Seal Into Pump Body Fig. 7 A - 134A--Checking Pump Body-to-Gear End Clearance

7. Inspect for damaged bolt hole threads. 11. Install driven pump gear with identification mark
8. Inspect for open drainback hole. down against gear pocket of pump body (Figs. 7A-132A and
9. Inspect bushing for scores or nicks. 7A-133A).
10. If removed, coat outside of seal body with non­ 12. Install drive gear with identification marks on drive
hardening sealing compound; support pump body, oil seal tangs up (Fig. 7A-129A).
side up, and using J-25016, install new pump body oil seal 13. Pump body face to gear face clearance should be
(Fig. 7A-131A). 0.020-0.055mm (,0007"-.0021") (Fig. 7A-134A).
14. Place the check ball into the check ball pocket in
PUMP DRIVEN GEAR the pump body and retain it with petrolatum. (See Fig. 7A-
(IDENTIFICATION
130A for ball location).
Pump Cover
Inspection
1. Inspect for open oil passages (Figs. 7A-135A and
7A-136A).
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
a 7.92mm (5/16") diameter rod on the larger plugs. Stake
top of hole two places, directly opposite each other, to retain
plug.
PUMP BODY 3. Inspect pump cover face for nicks and overall
flatness.
Fig. 7A-132A--ln stalling Pump Driven Gear

BLEED

CONVERTER VOID
TO COOLER
CONVERTER
FEED
FROM
COOLER
TO LUBE

DIRECT
CLUTCH
OIL PRESSURE
LINE CONTROL
BOOST ORIFICE
PUMP
INTAKE SEAL DRAIN
BACK HOLE
3RD/REVERSE LINE
DRIVE REVERSE
PUMP COVER

Fig. 7 A - 1 3 3 A - P u m p Driven Gear Identification Fig. 7 A -13 5 A --P u m p Cover Assembly

 A U T O M A T IC TR A N S M IS S IO N (2 0 0)7 A-35

Fig. 7A-136A~Pum p Cover Oil Passages Fig. 7 A - 13 8 A -ln s ta llin g Pump Assembly

4. Inspect for chips in pressure regulator bore. 8. If removed, install 3 new oil seal rings, making sure
5. Inspect stator shaft for damaged splines or damaged cut ends are assembled in the same relationship as cut (Fig.
bushings. 7A-120A). Also, make sure rings are seated in the grooves
6. Inspect orifice plug (see Fig. 7A-135A). If the plug to prevent damage to the rings during reassembly of mating
requires replacement, place new plug, orifice end first, into part over rings Retain with petrolatum.
plug hole from the rough casting side. Drive the plug flush 9. Install pump to case seal ring, chamfered side out,
to .25mm (.010") below top of hole, rough casting side. making sure the ring is not twisted.
Stake the top of hole two places to retain the plug. 10. Install pump to direct clutch thrust washer and
retain with petrolatum (Fig. 7A-127A).
Reassembly 11. Remove holding bolt or screwdriver.
1. Place pump body over hole in bench. 12. Install new pump to case gasket on pump and retain
2. Assemble pump cover to pump body with attaching with petrolatum.
bolts, finger tight. 13. Install 2 pump to case alignment pins in case as
3. Align pump cover and pump body using J-25015 shown in Fig. 7A-138A.
(Fig. 7A-137A) and place bolt or screwdriver through pump
to case bolt hole and bench. NOTE: Before installing pump, make sure
4. Torque pump cover attaching bolts to 20.0-27.0 intermediate band anchor pin lug is aligned with band
N-m (15-20 ft. lbs.). anchor pin hole in case.
5. Remove J-25015. 14. Install pump assembly and finger start pump to case
6. Install pressure regulator spring, guide, valve with bolts and new washers, except one bolt hole (Fig. 7A-139A),
stem end out, and bore plug, hole side out (Fig. 7A-126A). which will be used to make the front unit end play check.
7. Compress pressure regulator valve spring by pushing
on bore plug with small screwdriver and install retaining NOTE: If turbine shaft cannot be rotated as pump is
ring (Fig. 7A-128A). being pulled into place, the forward or direct clutch

Fig. 7 A - 1 3 7 A -A lig n in g Pump Cover and Pump Body Fig. 7A-1 3 9 A - C h e c k i n g Front Unit End Play
(2 0 0 )7 A-36 A U T O M A T IC TRAN SM IS S IO N

NOTE: 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 anJ new washer,
torquing bolt to 20.0-27.0 N-m (15-20 ft. lbs.).
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
Fig. 7A-1 4 0 A - F r o n t Unit End Play W asher Thickness Chart
Governor Assembly
housings have not been installed properly to index with Inspection
all the clutch plates. This condition must be corrected 1. Inspect governor cover for damage, scored or worn
before pump is pulled fully into place. bore, or plugged oil passage.
15. Replace 2 alignment pins with 2 bolts and new 2. Wash in cleaning solvent and blow out oil passage.
washers. 3. Inspect governor driven gear for nicks or damage.
16. Torque pump to case bolts to 20.0-27.0 N*m (15-20 4. Inspect governor shaft seal ring for cuts, damage and
ft. lbs.). free fit in groove.
5. Inspect for free operation of governor weights.
NOTE: Make sure turbine shaft rotates freely. 6. Inspect for damaged, mispositioned, or tilted
Check Front Unit End Play (Fig. 7A -139A ) springs. (Models BR and CX use one spring; all other
1. Install 278mm (11") bolt and locking nut as shown models use two.)
in Fig. 7A-139A. 7. Inspect for presence of 2 check balls.
2. Push turbine shaft downward. 8. Inspect shaft for damage.
3. Install J-25022 on J-24773 tool and locate on end of 9. Inspect governor washer for damage.
turbine shaft (Fig. 7A-139A). 10. If damaged, cut seal ring off governor shaft.
4. Mount dial indicator on bolt and position indicator
point against cap nut of J-24773. CAUTION: Do not damage seal ring when
5. Move output shaft forward by turning the adjusting removing seal.
screw on J-25013-5 until the white or scribed line on sleeve Installation
J-25013-1 begins to disappear, then set dial indicator to 1. If removed, install new seal ring on shaft and place
zero. seal ring end into governor cover to size seal; lubricate with
6. Pull turbine shaft upward, and read end play. Front petrolatum.
unit end play should be 0.56mm-1.30mm (.022"-.051"). 2. Lubricate with petroiaturm and install 2 new seal
rings on governor cover.
CAUTION: The governor cover seal rings must be
FRONT UNIT END PLAY CHART well lubricated with petrolatum to prevent
damage or cutting o f the rings. Also, make sure
THICKNESS IDENTIFICATION 2 check balls are in the governor before
Number and/or Color installation.
1.66-1.77mm (0.065"-0.070") 1
3. Install governor assebmly, seal ring end first, into
cover.
1.79-1.90mm (0.070"-0.075") 2
1.92-2.03mm (0.076” -0.080") 3 Black
2.05-2.16mm (0.081” -0.085") 4 Light Green
2.18-2,29mm (0.086"-0.090") 5 Scarlet
2.31-2.42mm (0.091"-0.095") 6 Purple

Do not use any type o f hammer to

2.44- 2.55mm (0.096" 0.100” ) 7 Cocoa Brown
2.57-2.68mm (0.101 "-0 .106” ) 8 Orange CAUTION:
2.70-2.81mm (0.106” -0. I l l " )
2.83-2.94mm (0.111"-0.116” )
9 Yellow
install governor assembly and cover into case.
Damage to case, governor or cover could result.
10 Light Blue
2.96-3.07mm (0.117"-0.121” ) 11
3.09-3.20mm (0.122''-0.126") 12
3.22-3.33mm (0.127” -0.131") 13 Pink
3.35-3.46mm (0.132"-0.136") 14 Green
3.48-3.59mm (0.137"-0.141") 15 Gray

Fig. 7A-1 4 1A -lns tallin g Tools on Rear End of Case

 A U T O M A T IC TR A N S M IS S IO N (2 0 0)7 A-37

GOVERNOR COVER INTERMEDIATE SNAP INTERMEDIATE

SERVO COVER RING SERVO PISTON WASHER

GOVERNOR GOVERNOR TO
ASSEMBLY CASE WASHER

O” RING SEALS Fig. 7A-1 44 A~lnterm edia te Servo-Exploded

NOTE: Governor shaft is not aligned with case hole,

Fig, 7A-1 42A--lnstalling Governor and Cover Assembly if retaining ring cannot be installed.
5. Install governor retaining ring. Align ring gap with
4. Install governor and cover assembly, aligning an end showing in case slot.
governor shaft with shaft hole in case (Fig. 7A-142A). Intermediate Band Anchor Pin
Rotate governor and cover assembly and output shaft
slightly. The governor cover fits tight in the bore the last 1. Inspect anchor pin for damage.
1.5mm (1/16"). 2. Install anchor pin, stem end first, making sure stem
locates in hole of intermediate band lug (Fig. 7A-143A).
Intermediate Servo Piston Assembly (Fig. 7A-
144A)
INTERMEDIATE BAND
ANCHOR PIN Inspection

NOTE: Production transmissions may be built with

either two or zero oil seal rings on the band apply pin.
All service band apply pins will have two oil seal rings.
1. Inspect pin 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 spring.
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:
Fig. 7 A - 143 A - ln s ta llin g Intermediate Band Anchor Pin

MODEL SERVO COVER SERVO PISTON

IDENTIFIED BY IDENTIFIED BY
CAST NO. ON COVER CAST NO. ON COVER

BR, CX, PA, PY, CS 8628696 8630131

BZ, OW, PG, CO, OS 8630085 8630083

PH, CR, CY, BA, OT 8628133 8628111

Fig. 7A-1 4 5 A -l n te r m e d i a t e Servo Cover and Piston Usage Chart

(2 0 0)7 A-38 A U T O M A T IC TR A N SM IS S IO N

c. Install dial J-8001 and position dial indicator point

on top of J-25014-2 zero post, and set dial indicator to zero.
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.
NOTE: 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
Make sure J-25014-2 gauge plate is pulled
backwards and seated squarely against the retaining
ring.
e. Apply 12 N-m (100 in. lbs.) of torque to hex nut on
side of gauge. Slide dial indicator over gauge pin J-25014-1
Fig. 7A-1 4 6 A -ln te rm e d ia te Band Apply Gages (Fig. 7A-146A). Read dial indicator and see Fig. 7A-147A
for proper size.
a. Install J-25014-2 in intermediate servo bore and NOTE: Dial indicator travel is reversed, making the
retain with intermediate servo cover retaining ring, aligning indicator readings backwards. On an indicator that
ring with gap at case slot (Fig. 7A-146A). ranges from 0-100, a 5mm (.020") travel will read 2mm
b. Install pin J-25014-1 into J-25014-2. (.080"), a 1.5mm (.060") travel will read 1mm (.040").
The identification ring is located on the band end of
CAUTION: Make sure the tapered pin end is the pin.
properly located against the band apply lug. Also, f. Remove retaining ring and band apply pin gauges.
make sure the band anchor pin is properly located If new apply pin or replacement of piston is required,
in the case and band anchor lug. proceed as follows:
Disassembly
1. Using J-22269-01, compress intermediate servo
piston spring (Fig. 7A-148A).
INTERMEDIATE BAND APPLY PIN CHART
2. Using small flat edge screwdriver, remove
DIAL INDICATOR TRAVEL APPLY PIN IDENTIFICATION intermediate pin to piston snap ring.
0 - 2.16 mm (0 .086") 2 Rings 3. Remove J-22269-01 and separate band apply pin,
2.16 mm - 2.88 mm (.086" 114") Wide Band
spring and washer from intermediate servo piston.
Reassembly
1. Install washer on snap ring end of band apply pin
(Fig. 7A-144A).
2. Install spring on washer.
3. Install band apply pin, spring end first through
Fig. 7A-1 4 7 A -ln te rm e d ia te Band Apply Pin Chart
intermediate servo piston.
4. Using J-22269-01, compress intermediate servo
piston spring (Fig. 7A-148A).
5. Using small pliers, install intermediate servo pin to
piston snap ring. Remove J-22269-01.
6. If removed, install new intermediate servo piston,
inner and outer seal rings. Make sure cut ends are assembled
in the same relationship as cut (Fig. 7A-120A). Make sure
rings are seated in the grooves to prevent damage to the
rings. Retain with petrolatum.
7. Lubricate with petrolatum and install new seal ring
J-22269-01 on intermediate servo cover.
CAUTION: The intermediate servo cover seal
SNAP RING rings must be well lubricated with petrolatum to
prevent damage or cutting o f ring.

Fig. 7A - 1 48 A -R e m ov in g Intermediate Servo Piston from

A pp ly Pin
 A U T O M A T IC T R A N S M IS S IO N (2 0 0)7 A-39

INTERMEDIATE INTERMEDIATE
SERVO COVER SERVO PISTON
CUP PLUG

SEAL

“0 " RING SEAL

OIL SEAL RINGS
Fig. 7A-1 49 A -ln s ta llin g Intermediate Servo Piston into Cover Fig. 7A-1 5 1A - ln s ta llin g Low and Reverse Clutch Housing to
Case Cup Plug and Seal

8. Install intermediate servo piston assembly into 2. Place cup plug, with smaller hole end first, into hole
intermediate servo cover (Fig. 7A-149A). in case. Using a 10mm (3/8") diameter by 150mm (6")
9. Install intermediate servo assembly into case, metal rod and hammer, drive plug until it seats against the
tapping lightly with non-metal or plastic hammer if seal.
necessary (Fig. 7A-150A).
Control Valve Assembly
CAUTION: Make sure the tapered end o f the band
apply pin is properly located against the band Disassembly
apply lug.
NOTE: As each valve train is removed, place the
10. Install servo retaining ring. Align ring gap with an individual valve train in the order that it is removed
end showing in case slot. and in a separate location relative to its position in the
Low and Reverse Clutch Housing to Case Cup valve body. None of the valves, bushings or springs are
interchangeable; some coiled pins are interchangeable.
Plug and Seal (Fig. 7A-151A) Remove all coiled pins by pushing through from
1. Install new seal, making sure it seats against the the rough cast surface side of the control valve
housing. assebmly, except the 2 pins which retain the throttle
valve and throttle valve plunger.
1. Remove the 4 check balls.

INTERMEDIATE SERVO
COVER
INTERMEDIATE SERVO
PISTON ASSY.

"O" RING SEAL

7A-1 5 0 A - ln s ta llin g Intermediate Servo Piston and Cover

Assembly
(2 0 0)7 A-40 A U T O M A T IC TR A N SM IS S IO N

43 44 45 46

1. M A N U A L VALVE 17. RETAINING COILED PIN 33. THROTTLE V A L V E

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 V A L V E 20. DIRECT CLUTCH EXHAUST VALVE 36. THROTTLE V A L V E SPRING
5. 2-3 SHIFT VA L V E 21. REVERSE BOOST VAL V E 37. THROTTLE V A L V E PLUNGER
6. 2-3 THROTTLE VALVE 22. REVERSE BOOST SPRING 38. THROTTLE V A L V E PLUNGER BUSHING
7. 2-3 THROTTLE VALVE SPRING 23. REVERSE BOOST BORE PLUG 39. RETAINING COILED PIN
8. 2-3 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 VA L V E 43. CHECK BA L L #4
12. LO OVERRUN CLUTCH V A L V E 28. 1-2 ACCUMULATOR V A L V E SPRING 44. CHECK BALL # 3
13. 1-2 SHIFT VA L V E 29. SHIFT T.V. VALVE 45. CHECK B A L L # 2
14. 1-2 THROTTLE VALVE 30. SHIFT T.V. SPRING 46. CHECK B A L L #1 (Note: 5th Check
15. 1-2 THROTTLE VAL V E SPRING 31. RETAINING COILED PIN Ball Is In The Case)
16. 1-2 THROTTLE VALVE BUSHING 32. SHIFT T.V. BORE PLUG

Fig. 7 A - 152A~Control Valve Assembly - Exploded Vie w

2. Position control valve assembly as shown in Fig. 7A- NOTE: The 2-3 throttle valve spring and 2-3 throttle
152A. valve may be inside the 2-3 throttle valve bushing.
3. Remove 1-2 accumulator piston. 6. From next bore down, remove coiled pin. Remove
4. Remove manual valve from upper bore. 1-2 throttle valve bushing, 1-2 throttle valve spring, 1-2
throttle valve and 1-2 shift valve.
CAUTION: Some o f the coiled pins in the control
valve assembly have pressure against them. NOTE: The 1-2 throttle valve spring and the 1-2
Therefore, hold a shop towel over the bore while throttle valve may be inside the 1-2 throttle valve
removing the pin, to prevent possibly losing a bore bushing.
plug, spring, etc. 7. From next bore down, remove coiled pin and bore
5. Remove coiled pin from upper right bore. Remove plug. Remove reverse boost spring and reverse boost valve.
2-3 throttle valve bushing 2-3 throttle valve spring, 2-3 8. Check the operation of the shift T.V. valve in the
throttle valve and 2-3 shift valve. next bore down, by moving the valve against the spring. If
 A U T O M A T IC T R A N S M IS S IO N (200)7A-41
d. Prying on end of the rod with a large screwdriver,
remove small screwdriver and remove shift T.V. plug, shift
T.V. spring and 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.
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") alien 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 pin,
intermediate boost spring and intermediate boost valve.
11. From next bore down, remove coiled pin, low
SHIFT SHIFT TV overrun clutch spring and low overrun clutch valve.
TV PLUG VALVE 12. From next bore down, remove coiled pin, direct
clutch exhaust spring and direct clutch exhaust valve.
Fig. 7A-1 53A~Removing Shift T. V. Plug 13. From next bore down, remove coiled pin, valve bore
it is necessary to remove the valve, proceed as follows: (Figs. plug, 1-2 accumulator valve and 1-2 accumulator valve
7A-153A and 7A-154A). spring.
a. Remove coiled pin and place valve body on shop
towel with rough casting surface up. Inspection
b. Using needle nose pliers, compress the shift T.V. 1. Wash control valve body, valves, springs, and other
spring by pushing on the shift T.V. valve; hold valve with parts in clean solvent and air dry.
small screwdriver. 2. Inspect 1-2 accumulator piston for damage.
c. Place 6.3mm (1/4") rod, 9.5mm (3/8") long, against 3. Inspect 1-2 accumulator piston seal for damage and
the end of the shift T.V. valve. free fitting groove. Do not remove seal unless replacing.
4. Inspect valve for scoring, cracks and free movement
in their bores.
S CR EW DRIVER 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. Inspect bore plugs for damage.
Reassembly

NOTE: 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
SHIFT TV coiled pins (black finish) that retain the throttle valve
PLUG
6.3 MM (1 /4 ") D IA . ROD
and throttle valve bushing, with the tapered end first.
Coiled pins do not fit flush on rough casting face. Make
9.5 MM (3 /8 ” ) LONG

Fig. 7A-1 54A--Removing Shift T.V. Plug 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,
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,
ALLEN longer stem end out, direct clutch exhaust spring and coiled
WRENCH 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
Fig. 7A-1 55A--Removing Inner Coiled Retaining Pin
lands of this valve (Fig. 7A-155A). Install the detent pin (on
(2 0 0 )7 A-42 A U T O M A T IC T R A N SM IS S IO N

C O N TR O L
VALVE
ASSY.

1-2 T H R O T T L E
V A L V E B U SHING

1 - 2 A C C U M U LA TO R
SPRING
PIN SLOT ID E N T IF IC A T IO N

Fig. 7 A - 156A~lnstall 1-2 Throttle Valve Bushing Fig. 7A-1 5 8 A - ln s ta llin g 1-2 A ccum ula to r Spring

models BR and CX only) into the shift T.V. spring and valve bushing and 2-3 throttle valve, stem end first, into the
install these 2 parts into the bore. Install the throttle valve bushing. Install these 3 parts, valve end first, into the bore,
plunger, stem end first, into the throttle valve plunger aligning bushing so pin can be installed in the pin slot (Fig.
bushing and install these 2 parts into tffe bore, valve end 7A-157A).
first. Install outer coiled pin from rough cast surface side,
aligning pin with slot in bushing. 11. Install manual valve with the inside detent lever pin
groove to the right.
7. In next bore up, if removed, install shift T.V. valve,
larger outside diameter stem end out, shift T.V. spring and 12. If removed, install new seal ring on 1-2 accumulator
coiled pin. Then, using plastic hammer, install new shift piston.
T.V. plug flush with rough casting surface.
13. Oil and install 1-2 accumulator piston, spring
8. In next bore up, install reverse boost valve, stem end pocket side out, into 1-2 accumulator piston bore of valve
out, reverse boost spring. Install bore plug, hole side out and body.
coiled pin.
Control Valve Assembly
9. In next bore up, install 1-2 shift valve, longer stem
end out, making sure valve is seated at the bottom of the Installation
bore. Install 1-2 throttle valve spring into the 1-2 throttle
valve bushing and 1-2 throttle valve, stem end first, into the NOTE: When installing a NEW control valve
bushing. Install these 3 parts, valve end first, into the bore, assembly, always be sure to use one with the same
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

Fig. 7A-1 57A--lnstalling 2-3 Throttle Valve Bushing Fig. 7A-1 5 9 A - T y p i c a l Valve Body Spacer Plate
 A U T O M A T IC T R A N S M IS S IO N (20 0)7 A-43

MANUAL VALVE

DETENT LEVER
[PIN

i 5th CHECK BALL [GUIDE PINS

(T.V. EXHAUST)

Fig. 7A-1 60A--lnstalling 5th Check Ball Fig. 7A-1 6 1A - ln s ta llin g Control Valve Assembly Using Guide
Pins

casting number as the original. 6. Install 4 check balls into ball seat pockets in control
1. Inspect 1-2 accumulator spring for damage. valve assembly and retain with petrolatum. (See Fig. 7A-
2. Install 1-2 accumulator spring into case (Fig. 7A- 162A for check ball location.)
158A). 7. Place the control valve assembly to spacer plate
3. Inspect control valve assembly and spacer plate for gasket marked "VB" on the control valve assembly.
damage (Fig. 7A-159A). 8. Place the valve body spacer plate on the gasket
marked "VB".
NOTE: The size of the 5 check balls used in the case 9. Place the spacer plate to case gasket marked "C" on
and control valve assembly is 6.35mm (.250"). The size the spacer plate.
of the check ball used in the pump is 7.14mm (.281"). 10. Insert 2 control valve assembly to case attaching
Do not interchange. bolts through the control valve assembly, gaskets and spacer
4. Install 5th check ball in case as shown (Fig. 7A- plate; and install these parts, aligning the manual valve with
160A). the detent lever pin (Fig. 7A-161A).
5. Install 2 guide pins as shown in Fig. 7A-161A.

IN T E R M E D IA T E LIN E RN D I RN D
BOOST

R E V E R S E BO OST

PUMP IN T A K E

PART TH R O TTLE

LIN E BO OST

4 CH EC K B A LLS
(N O TE: 5TH C H E C K
B A L L IN C A S E )

D IR E C T D IR E C T C LU T C H TV EXH AU ST
C LU T C H A CC U M U LA T O R

Fig. 7A- 162A--Location of Four Check Balls

(2 0 0 )7 A-44 A U T O M A T IC TRAN SM IS S IO N

MANUAL DETENT
ROLLER & SPRING
ASSEMBLY
jmm ■

T.V. EXHAUST VALVE LIFTER J

THROTTLE LEVER &

BRACKET ASSEMBLY
iiiiiiiin i i
THROTTLE LEVER TO
CABLE LINK

Fig. 7 A - 1 63A--lnstalling Manual Detent Roller and Spring Fig. 7A-1 6 5 A - ln s ta llin g Throttle Valve and Bracket Assembly
Assembly

NOTE: Make sure check balls, 1-2 accumulator piston c. Install link on throttle lever making sure link is
and manual valve do not fall out. hooked as shown (Fig. 7A-165A).
11. Start control valve assembly to case attaching bolts, d. Install throttle lever and bracket assembly, locating
except the throttle lever and bracket assembly and the oil slot in bracket with coiled pin, aligning lifter through valve
screen attaching bolts. body hole and link through T.V. linkage case bore. Retain
with bolt.
CAUTION: The (2) oil screen attaching bolts are 15. Torque all control valve assembly to case attaching
about 10mm (3/8") longer than the control valve bolts to 13.0-17.0 N-m (9-12 ft. lbs.).
assembly attaching bolts, and they are not
interchangeable. Oil Screen
12. Inspect inside manual detent roller and spring 1. Thoroughly clean, air dry and inspect oil screen
assembly for damage. assembly.
13. Remove guide pins and replace with bolts and 2. Install new oil screen gasket on screen and retain
inside manual detent roller and spring assembly, locating with petrolatum.
the tang in the control valve assembly, and the roller on the 3. Install oil screen assembly and attaching bolts (Fig.
inside detern lever (Fig. 7A-163A). 7A-166A). Torque bolts to 13.0-17.0 N-m (9-12 ft. lbs.).
14. Throttle lever and bracket assembly. Oil Pan
a. Inspect throttle lever and bracket assembly for 1. Clean and inspect oil pan for damage.
damage (Fig. 7A-164A).
b. If removed, install spring on top of lifter, then lifter 2. Install new oil pan to case gasket on case.
spring first into throttle bracket. 3. Install oil pan and retaining bolts. Torque bolts to
14.0-18.0 N-m (10-13 ft. lbs.).

OIL SCREEN

,TV EXHAUST VALVE

LIFTER SPR'NG
THROTTLE
LEVER = \ v T V EXHAUST
TO CABLE VALVE LIFTER
LINK

Fig. 7A-1 6 4 A - T h r o t t l e Lever and Bracket Assembly Fig. 7A-1 66A--lnstalling Oil Screen
 A U T O M A T IC TR A N S M IS S IO N (2 0 0)7 A-45

J 8092

J-25019-2

PUMP
C O VE R

SPEEDOMETER DRIVEN
GEAR ASSEMBLY

Fig. 7A-1 6 7 A -R e m ov in g and Installing Sper Driven Gear - Fig. 7A - 16 9 A - ln s ta llin g Pump Cover Bushing - Front
Typical

Speedometer Driven Gear (Fig. 7A-167A) 5. Place transmission in cradle or transmission jack.
Remove holding fixture, J-8763-02 from transmission.
Inspection
1. Remove speedometer driven gear from housing and BUSHING REPLACEMENT
inspect for damage.
2. Inspect housing for damage and "O" ring for damage PUM P COVER BUSHINGS
or cuts.
3. If damaged, remove and discare "O" ring. Front Bushing
1. Using tool J-24036 with Slide Hammer, J-7004-1,
Reassembly remove bushing (Fig. 7A-168A).
1. If removed, install new "O" ring on housing. 2. Using tool J-25019-2 with Driver Handle J-8092,
2. Install speedometer driven gear into housing. drive or press new bushing into place until tool bottoms
3. Install speedometer driven gear assembly into case (Fig. 7A-169A).
(Fig. 7A-167A).
4. Install speedometer retainer and attaching bolt, align Rear Bushing
slot in speedometer driven gear housing with retainer. 1. Using tool J-25019-14 with Slide Hammer J-7004-1,
Torque bolt to 8.0-14.0 N-m (6-10 ft. lbs.). remove bushing (Fig. 7A-170A).

J-7004 1

J 24036

PUMP
COVER

Fig. 7A-1 6 8 A -R e m o v in g Pump Cover Bushing - Front Fig. 7 A - 1 7 0 A -R e m o v in g Pump Cover Bushing - Rear
(200)7A-46 A U T O M A T IC TRAN SM IS S IO N

D IR E C T
/C L U T C H
HO USING

Fig. 7 A - 171 A—Insta 11i ng Pump Cover Bushing - Rear Fig. 7 A - 17 4 A -R e m ovin g Direct Clutch Housing Bushing -
Front

2. Using tool J-25019-6 with Driver Handle J-8092, PUM P BODY BUSHING
drive or press new bushing until tool bottoms (Fig. 7A- 1. Place pump body with the machined face down, on
171A). 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
J-8092 (Fig. 7A-173A).
J-25019-4 DIRECT CLUTCH HOUSING
Front Bushing
PUMP
BODY 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.
Fig. 7A-1 72 A -R e m ovin g Pump Body Bushing

12 J-8092

J 25019 9
PUMP
BODY
D IR E C T
CLU TC H
HO U SIN G

Fig. 7A-1 7 3 A —I nsta lling Pump Body Bushing Fig. 7A-1 7 5 A--Installing Direct Clutch Housing Bushing -
Front
 A U T O M A T IC TR A N S M IS S IO N (200J7A-47

J-8092

J-25019-4
J-8092
D IR E C T
^CLUTCH J-250193
HOUSING
FRONT
INTERNAL
GEAR

Fig. 7 A - 1 7 6A--Removing Direct Clutch Housing Bushing - Fig. 7 A - 1 7 8A--Removing Front Internal Gear Bushing
Rear

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-177A).
J-8092
FRONT INTERNAL GEAR BUSHING
1. Using tool J-25019-3 with Driver Handle J-8092, J-25019-9

remove bushing (Fig. 7A-178A).

2. Using tool J-25019-9 with Driver Handle J-8092, FRONT
IN TER N AL
drive or press new bushing into place until tool bottoms GEAR
(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. ^'9 7A-1 7 9 A - ln s ta llin g Front Internal Gear Bushing

J-8092 J-7004-1

J-25019-6
25019-14
D IR E C T
CLUTCH
HO USING

REAR SUN GEAR

a*
Fig. 7A-1 7 7 A -l n s ta l l i n g Direct Clutch Housing Bushing - Rear Fig. 7A-1 80A--Removing Rear Sun Gear Bushing
(2 0 0)7 A-48 A U T O M A T IC TRAN SM IS S IO N

W J-7004-1

J-8092

J-25019-2
J-25019-16
REAR SUN GEAR

REAR
CARRIER

Fig. 7A-1 8 1A--lnstalling Rear Sun Gear Bushing Fig. 7A-1 84A~Removing Rear Carrier Bushing

3. Using tool J-25019-2 with Driver Handle J-8092,

drive or press new bushing into place until tool bottoms
(Fig. 7A-181A).
LO AND REVERSE CLUTCH HOUSING
BUSHING
J-7004-1 1. Using tool J-25019-16 with Slide Hammer J-7004-1,
remove bushing (Fig. 7A-182A).
J-25019 16
2. Place lo and reverse clutch housing with splined hub
between two blocks of wood to prevent damaging the
splines.
LO & REVERSE
3. Using tool J-25019-8 with Driver Handle J-8092,
CLUTCH
HOUSING 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,
remove bushing (Fig. 7A-184A).
Fig. 7A-1 82A--Removing Lo and Reverse Clutch Housing 2. Using tool J-25019-7 with Driver Handle J-8092,
Bushing drive or press new bushing into place until tool bottoms
(Fig. 7A-185A).

J-25019-8

& REVERSE J-25019-7

LUTCH
HOUSING
REAR
CARRIER

Fig. 7A-1 8 3 A - ln s ta llin g Lo and Reverse Clutch Housing Fig. 7 A - 1 85A--lnstalling Rear Carrier Bushing
Bushing
 A U T O M A T IC T R A N S M IS S IO N (200J7A-49

J-8092
CASE BUSHING J-21424-9

1. Using tool J-21424-9 with Driver Handle J-8092,

remove bushing (Fig. 7A-186A). CASE

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).
Fig. 7A-1 86A--Rem oving or Installin g Case Bushing

GROUP 4.169 GROUP 4.158 GROUP 4.159

GROUP 4.176

TURBINE SHAFT TO FRONT INT. GEAR

OUTPUT SHAFT SEL. TO FRONT CARRIER
THRUST WASHER THRUST BEARING ASSY
REAR CARRIER TO
GROUP 4.176 GROUP 4.176 LO RACE
THRUST WASHER REAR SUN GEAR TO
GROUP 4 180 REAR INT. GEAR
THRUST BEARING ASSY
GROUP 4.159

PUMP COVER REAR SUN

BUSHING (REAR) GEAR BUSHING
GROUP 4.226 GROUP 4.159

PUMP COVER
BUSHING (FRONT) FRONT INTERNAL CASE BUSHING

HM 160A-8/76

Fig. 7A-1 8 7 A -B u s h in g Locations

(200)7A -50 A U T O M A T IC TR A N SM IS S IO N

SPECIFICATIONS
TU RB O -HYDRAM ATIC "2 00 "
................................24 N-m (18 ft. lbs.)
................................24 N-m (18 ft. lbs.)
................................ 24 N-m (18 ft. lbs.)
................................ 15 N-m (11 ft. lbs.)
................................15 N-m (11 ft. lbs.)
Bottom Pan Attaching Bolts .................................................................. ................................16 N-m (12 ft. lbs.)
................................ 48 N-m (35 ft. lbs.)
Transmission to Engine Mounting Bolts.............................................. ................................34 N-m (25 ft. lbs.)
................................ 11 N-m (8 ft. lbs.)
................................31 N-m (23 ft. lbs.)
Speedometer Driven Gear Attaching Bolts.......................................... ................................11 N- m (8 ft. lbs.)
Detent Cable Attaching Screw .............................................................. ................................ 9N- m (6 tt. lbs.)
Oil Cooler Line to Transmission Connector........................................ ................................37 N-m (25 ft. lbs.)
Oil Cooler Line to Radiator Connector................................................ ................................ 27 N-m (20 ft. lbs.)
Linkage Swivel Clamp Nut .................................................................... ................................ 41 N-m (30 ft. lbs.)
Shifter Assembly to Sheet Metal Screws ............................................ ................................ 10 N-m (8 tt. lbs.)
Converter Bracket to Adapter N u ts...................................................... ................................ 17 N-m (13 ft. lbs.)
Catalytic Converter to Rear Exhaust Pipe N u ts ................................ ................................ 23 N-m (17 ft. lbs.)
Exhaust Pipe to Manifold N u ts.............................................................. ................................ 16 N- m (12 ft. lbs.)
Rear Transmission Support B olts.......................................................... ................................ 54 N • m (40 ft. lbs.)
Mounting Assembly to Support Nuts ................................................ ................................ 29 N-m (21 ft. lbs.)
Mounting Assembly to Support Center N u t...................................... ................................44 N-m (33 ft. lbs.)
Adapter to Transmission Bolts ............................................................ ................................44 N • m (33 ft. lbs.)
 A U T O M A T IC T R A N S M IS S IO N (200J7A-51

SP E C IA L TOOLS

1. J25015 Oil Pump Body and Cover Alignment Band 14. J25022 End-Play Checking Fixture Adapter
2. J25016 Front Oil Pump Seal Installer 15. J-23327 Clutch Spring Compressor
3. J25020-01 Converter Stator and Turbine End-Play Checking Fixture 16. J22269-01 Direct Clutch Spring Compressor
4. J25023 Reverse Clutch Selective Shim Group 17. J21426 Rear Oil Seal Installer
5. J25012 Reverse Clutch Housing Installer and Remover 18. J25024 Forward Clutch Spring Compressor
6. J25018 Forward Clutch Spring Compressor 19. J21427-01 Speedo Gear Puller
7. J25019 Bushing Service Set 20. J24773 Gaging Fixture
8. J25014 Intermediate Band Apply Pin Gauge 21. J8092 Driver Handle
9. J25021 Turbine Shaft and Direct Clutch Installer 22. J7004 Slide Hammer
10. J25025 Alignment Pin and Stud Set 23. J8001 Dial Indicator Set
11. J25013 Output Shaft and Rear U nit Support Fixture 24. J8433 Puller
12. J25010 Direct Clutch Seal Protector 25. J8763-02 Holding Fixture and Base
13. J25011 Reverse Clutch Seal Protector J3289-20

Fig. 7 A - S T - T H M 2 0 0 , Special Tools

 A U T O M A T IC TR A N S M IS S IO N (3 5 0)7 A-1

SECTION 7 A

A U T O M A T IC T R A N S M IS S IO N
UNIT REPAIR (OVERHAUL)
C B C 350 TRANSM ISSION
INDEX

Transmission Disassembly and Reassembly.............. 7A-3 Low and Reverse Roller Clutch Support.............. 7A-28
Disassembly (Transmission)...................................... 7A-3 Disassembly............................................................. 7A-28
Converter Inspection................................................... 7A-3 Inspection................................................................ 7A-30
Converter End Clearance Check.............................. 7A-4 Assembly................................................................. 7A-30
Removal of Extension, Speedometer Driven Gear Governor Assembly................................................. 7A-30
Oil Pan and Screen.............................................. 7A-4 Disassembly............................................................. 7A-31
Removal of Valve Body and Linkage.................... 7A-6 Inspection................................................................ 7A-31
Removal of Oil Pump and Internal Case Governor Driven Gear Replacement................... 7A-31
Components.......................................................... 7A-9 Reassembly.............................................................. 7A-31
Valve Body................................................................ 7A-16 Bushing Replacement................................................ 7A-31
Disassembly............................................................. 7A-16 Extension Housing Bushing.................................... 7A-31
Inspection................................................................ 7A-16 Output Shaft Bushing.............................................. 7A-32
Reassembly.............................................................. 7A-16 Case Bushing............................................................. 7A-32
Oil Pump.................................................................... 7A-17 Stator Shaft Front Bushing..................................... 7A-32
Disassembly............................................................. 7A-17 Stator Shaft Rear Bushing....................................... 7A-33
Inspection................................................................ 7A-17 Input Ring Gear Bushing........................................ 7A-33
Assembly................................................................. 7A-17 Sun Gear Bushing..................................................... 7A-33
Direct Clutch and Intermediate Overrun.............. Reaction Carrier Bushing........................................ 7A-33
Roller Clutch......................................................... 7A-21 Direct Clutch Bushing............................................. 7A-33
Disassembly............................................................. 7A-21 Transmission Assembly............................................. 7A-34
Inspection................................................................ 7A-23 Transmission Internal Components....................... 7A-34
Reassembly.............................................................. 7A-23 Speedometer Drive Gear and Extension................ 7A-35
Forward Clutch......................................................... 7A-24 Manual Linkage...................... .................................7A-35
Disassembly............................................................. 7A-24 Intermediate Servo Piston,.......................................
Inspection................................................................ 7A-25 Valve Body, Oil Pan and Gasket.........................7A-35
Reassembly.............................................................. 7A-26 Governor and Vacuum Modulator........................ 7A-36
Sun Gear and Sun Gear Drive Shell..................... 7A-27 Intermediate Clutch Accumulator......................... 7A-36
Disassembly............................................................. 7A-28 Specifications............................................................... 7A-37
Inspection................................................................ 7A-28 Special Tools............................................................... 7A-38
Assembly................................................................. 7A-28
 (3 5 0 )7 A-2
CONVERTER INTERMEDIATE INTERMEDIATE FORWARD
ASSEMBLY CLUTCH OVERRUN BAND CLUTCH

LOW AND
REVERSE SUN O UTPUT

AUTOMATIC
CLUTCH GEA R SHAFT

TR A N SM IS S IO N
R EA CTIO N
CARRIER

GOVERNOR

A N D REVERSE
O V E R R U N ROLLER

INPUT
SHAFT
PAR KING
PAW L

OUTPUT
CARRIER

STATOR INTERMEDIATE MANUAL

SHAFT OVERRUN SHAFT
ROLLER CLUTCH

Fig. 7A-1B--CBC 3 5 0 Sectioned V iew

 A U T O M A T IC TR A N S M IS S IO N (350)7A-3

Fig. 7A-2B~Transm ission in H olding Fixture

Fig. 7A-4B~C hecking C onverter fo r Leaks

TRANSM ISSIO N D ISA SSEM BLY AND R EA SSEM BLY

DISASSEM B LY 2. With transmission in holding fixture remove torque
1. Install Holding Fixture J-8763-02 on transmission converter assembly.
and place into Holding Tool base J-3289-20 with converter 3. Remove vacuum modulator assembly attaching bolt
facing up (fig. 7A-2B). and retainer.
4. Remove vacuum modulator assembly, "O" ring seal,
NOTE: Cleanliness is an important factor in the and modulator valve from case (fig. 7A-3B). Discard "O"
overhaul of the transmission. Before attempting any ring.
disassembly operation, the exterior of the case should
be thoroughly cleaned to prevent the possibility of dirt Inspection of Converter
entering the transmission internal mechanism. During 1. Check converter for leaks as follows (fig. 7A-4B):
disassembly, all parts should be thoroughly cleaned in a. Install Tool J-21369 and tighten.
cleaning fluid and then air dried. Wiping cloths or rags b. Apply 80 psi air pressure to tool.
should not be used to dry parts. c. Submerge in water and check for leaks.
2. Check converter hub surfaces for signs of scoring or
CAUTION: Do not use solvents which could wear.
damage rubber seals or clutch facings.

O” RING SEAL J -21371-8

VACUUM MODULATOR

Fig. 7 A -3 B -R e m o v in g Vacuum M od ulator Assembly Fig. 7 A -5 B -ln s ta llin g J-2 157 1-8
(3 5 0)7 A-4 A U T O M A T IC T R A N SM IS S IO N

E X T E N S IO N H O U S IN G
B US H IN G
J-25020

Fig. 7A-6B--Checking C onverter End Clearance

Converter End Clearance Check (Figs. 7A-5B,

7A-6B) Fig. 7A -8B -R em oving Extension Housing Bushing

1. Fully release collet end of Tool J-21371-8. REM O VAL OF EXTENSION, SPEEDOMETER
2. Install collet end of Tool J-21371-8 into converter
hub until it bottoms; then tighten cap nut to 5 ft. lbs. (fig. DRIVEN GEAR, GOVERNOR, OIL PAN AND
7A-5B). SCREEN
3. Install Tool J-21371-3 and tighten hex nut to 3 ft. 1. Remove four housing to case attaching bolts.
lbs. (fig. 7A-6B). 2. Remove extension housing form case and remove
4. Install Dial Indicator J-8001 and set it at "zero", square cut "0" ring seal from extension housing.
while its plunger rests on the cap nut of Tool J-21371 -8. 3. Remove extension housing lip seal using screw driver
5. Loosen hex nut while holding cap nut stationary. (fig. 7A-7B).
With the hex nut loosened and holding Tool J-21371-3 4. If extension housing bushing is to be replaced,
firmly against the converter hub, the reading obtained on collapse bushing (fig. 7A-8B) and refer to Figure 7A-98B
the dial indicator will be the converter end clearance. End for installation.
clearance should be less than .050". If the end clearance is 5. Install speedometer drive gear remover tool J-21427-
.050" or greater, the converter must be replaced. 01 and J-9539 bolts with J-8105 or suitable puller on output
shaft and remove speedometer drive gear. Remove retaining
clip.
6. Remove governor cover retainer with a screwdriver.
E X TE N S IO N H O U S IN G
7. Using a screwdriver and hammer, gently tap along
LIP SEAL governor cover lip (fig. 7A-9B), remove governor cover and
"O" ring seal (fig. 7A-10B). Discard seal.

Fig. 7 A -7 B -R e m o v in g Extension Housing Lip Seal Fig. 7 A -9 B -R e m ov in g Governor Cover

 A U T O M A T IC T R A N S M IS S IO N (350)7A-5

GOVERNOR COVER

GOVERNOR COVER
TO CASE " O ” RING
SEAL
Fig. 7 A - 10 B -G o ve rn o r Cover and " 0 " Ring Seal Fig. 7A-1 2B~Rem oving T ransm ission Oil Pan

CAUTION: Do not attempt to pry the screwdriver 9. Remove oil pan attaching screws (fig. 7A-12B), oil
between the case and governor cover as this could pan, and gasket. Discard gasket.
cause damage to the case. 10. Remove oil pump suction screen (strainer) to valve
8. Withdraw governor assembly from case (fig. 7A- body attaching screws (fig. 7A-13B).
11B) and check governor bore and governor sleeve for 11. Remove oil pump screen (strainer) and gasket from
scoring. valve body.

Fig. 7A-1 1 B- Removing Governor from Case Fig. 7A-1 3B--Removing Oil Pump Suction Screen (Strainer)
from Valve Body
(3 5 0)7 A-6 A U T O M A T IC TR A N SM IS S IO N

TORQUE
!VAL VE B O D Y WRENCH
ASSEMBLY

MANUAL
CONTROL
VA L V E “ S " LINK!

DETENT S PR IN G SPACER SUPPORT PLATE

A N D ROLLER
ASSEMBLY I
£»* jM
75-221

Fig. 7A-1 6B--Removing T ransfer (Spacer) S upport Plate

Fig. 7 A -14 B -D e te n t Spring and Roller Assem bly

REMOVAL OF VALVE BODY AND LINKAGE detent actuating lever (fig. 7A-15B). Refer to valve body
1. Remove detent spring and roller assembly from valve disassembly.
body. Remove valve body to case attaching bolts (fig. 7A- 3. Remove transfer plate support bolts. Remove
14B). transfer support plate (fig. 7A-16B).
2. Remove manual control valve link from range 4. Remove upper gasket, valve body transfer (spacer)
selector inner lever. Remove detent control valve link from plate and valve body transfer (spacer plate to case gasket
(fig. 7A-17B).

VALVE BODY SPACER PLATE

R A N G E SELECTOR!
IN N ER LEVER
DETENT C O N T R O L 1
VALVE WIRE

VALVE BODY SPACER PLATE

TO CASE GASKET
%
Fig. 7A-1 5B--Removing M anual C ontrol Valve Link, Valve Fig. 7A-1 7B -R em oving Valve Body Transfer (Spacer) Plate
Body and D etent A ctu a tin g Lever and Gasket
 A U T O M A T IC TR A N S M IS S IO N (3 5 0)7 A-7

CHECK BALLS

GOVERNOR
SCREEN

Fig. 7A-18B~Check Ball Four (4) Locations

Fig. 7A-20B~R em oving G overnor Feed Screen

5. Remove four (4) check balls from correct passages NOTE: on JA and JH models, there are two governor
in case face (fig. 7A-18B). feed screens.
6. Remove oil pump pressure screen from oil pump 8. Remove manual shaft to case retainer with
pressure hole in case (fig. 7A-19B). screwdriver (fig. 7A-21B).
7. Remove governor feed screen from governor feed
hole (drive oil) in case (fig. 7A-20B).

r ~
MANUAL SHAFT TO
CASE RETAINER
iS ' _

SCREWDRIVER
OIL PUMP PRESSURE SCREEN

Fig. 7 A - 1 9B -R e m o vin g Oil Pump Pressure Screen Fig. 7 A-2 1 B--Removing M an u al Shaft to Case Retainer
(3 5 0 )7 A-8 A U T O M A T IC T R A N SM IS S IO N

RANGE SELECTOR INNER

LEVER TO MANUAL SHAFT
NUT. TORQUE TO 30 LB.FT.
Fig. 7 A -22B~Loosening Nut H olding Range Selector Inner Fig. 7A -2 4B -R em oving M anual Shaft to Case Lip Seal
Lever to M anual Shaft

9. Loosen nut holding range selector inner lever to 11. Remove manual shaft to case lip seal (fig. 7A-24B).
manual shaft (fig. 7A-22B). 12. Remove parking lock; lock bracket (fig. 7A-25B).
10. Remove range selector inner lever from manual (Special Bolts).
shaft. Remove manual shaft from case. Remove inner lever
and parking pawl actuator rod from case. Disassembly inner
lever from parking pawl actuator rod (fig. 7A-23B).

j RANGE SELECTOR
!INNER LEVER

W r l ~ ^
ACTUATING ROD
MANUAL SHAFT

PARKING PAWL
ACTUATING ROD PARK LOCK LOCK BRACKET
Fig. 7 A -2 3 B -R e m o v in g M an u al Shaft and Inner Lever and Fig. 7 A -2 5 B -R e m o v in g Park Lock, Lock Bracket
Parking Pawl Ac tuator Rod from Case
 A U T O M A T IC TR A N S M IS S IO N (3 5 0)7 A-9

j
INTERMEDIATE SERVO
PISTON AND SEAL
WASHER
APPLY PIN

0
SPRING SEAT
PARKING PAWL
SPRING
h i # ................. f

Fig. 7 A -2 8B ~ ln te rm ed iate Servo Piston and Related Parts

PARKING PAWL
DISENGAGING SPRING

Fig. 7 A -26B -R em oving Parking Pawl D isengaging Spring

13. Remove parking pawl disengaging spring (fig. 7A- 15. Remove intermediate servo piston and seal ring.
26B). Remove washer, spring seat and apply pin (fig. 7A-28B).
14. Remove parking pawl shaft retaining plug, parking REMOVAL OF OIL PUMP AND INTERNAL
pawl shaft, and parking pawl (fig. 7A-27B) if replacement CASE COMPONENTS
is required. 1. Remove eight (8) pump attaching bolts with washer
NOTE: The parking pawl shafts retaining plug may be type seals (fig. 7A-29B).
removed by using a bolt extractor.

PUMP ASSEMBLY
TO CASE ATTACHING
BOLTS (8)

PARK PAWL
SHAFT

PARKING PAWL SHAFT

RETAINING PLUG
Fig. 7A-27B--Parking Pawl S haft Retaining Plug, Parking Pawl Fig. 7A-29B--R em oving Pump A tta ch in g Bolts
Shaftand Parking Pawl
(3 5 0 )7 A-10 A U T O M A T IC T R A N SM IS S IO N

INTERMEDIATE CLUTCH

aFACED
i ;tgyr'#i PLATES
mm
TIGHTEN JAM NUTS —STEEL
..................... PLATES
Fig. 7A-30B--Removing Pump from Case Fig. 7 A-32B-Rem oving Intermediate Clutch Plates

2. Install two (2) threaded slide hammers J-7004 into 4. Remove intermediate clutch drive plates and steel
threaded holes in pump body and remove pump assembly reaction plates (fig. 7A-32B).
from case (fig. 7A-30B). Discard pump gasket. 5. Remove intermediate clutch pressure plate (fig. 7A-
3. Remove intermediate clutch cushion spring (fig. 7A- 33B).
3 IB).

INTERMEDIATE CLUTCH
CUSHION SPRING

INTERMEDIATE CLUTCH
PRESSURE PLATE k
Fig. 7A-3 1 B-Removing Interm ediate Clutch Cushion Spring Fig. 7A-33B--Removing Interm ediate Clutch Pressure Plate
 A U T O M A T IC TR A N S M IS S IO N (3 5 0)7 A-11

INPUT RING GEAR

i V _

INTERMEDIATE OVERRUN FRONT INPUT RING

BRAKE BAND GEAR THRUST WASHER
Fig. 7A-34B-Removing Intermediate Overrun Brake Band Fig. 7A-36B-Rem oving 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).
7. Pull outward on the input shaft to remove the direct
and forward clutch assemblies from case (fig. 7A-35B). NOTE: Washer has 3 tangs.
9. Remove input ring gear to output shaft snap ring
(fig. 7A-37B).

INPUT RING GEAR

OUTPUT SHAFT

SNAP RING

FORWARD AND DIRECT!

CLUTCH ASSEMBLIES
Fig. 7A-35B--Removing Direct and Forward Clutch Fig. 7 A - 3 7 B - R e m o v in g Input Ring Gear to Output Shaft Snap
Assemblies Ring
(3 5 0)7 A-12 A U T O M A T IC TRAN SM IS S IO N

Fig. 7A-38B~Removing Input Ring Gear Fig. 7 A-40B--Removing Output Carrier Assembly

10. Remove input ring gear (fig. 7A-38B). 12. Remove output carrier assembly (fig. 7A-40B).
11. Remove input ring gear rear (output carrier) thrust 13. Remove sun gear drive shell assembly (fig. 7A-
washer (fig. 7A-39B). 4 IB).

Fig. 7A-39B--Removing Input Ring Gear Rear Thrust W a s h e r

Fig. 7A-4 1 B -R emoving Sun Gear Drive Shell

 A U T O M A T IC T R A N S M IS S IO N (350)7A-13

RETAINING^
RING OUTPUT RING GEAR
AND SHAFT ASSEMBLY

...i

REACTION CARRIER
LOW & REVERSE CLUTCH SUPPORT ASSEMBLY
Fig. 7 A-42B-Removing Low and Reverse Clutch Support Fig. 7A-44B--Removing Reaction Carrier Assembly
Retaining Ring

14. Remove low and reverse roller clutch support to 17. Remove reaction carrier assembly from output ring
case retaining ring (fig. 7A-42B). gear and shaft assembly (fig. 7A-44B).
15. Remove low and reverse clutch support and race 18. Remove output ring gear and shaft assembly from
assembly and anti-clunk spring. case (fig. 7A-45B).
16. Remove low and reverse clutch plates and steel
reaction plates (fig. 7A-43B).

OUTPUT RING GEAR

AND OUTPUT SHAFT.yK-.
LOW AND REVERSE ASSEMBLY
CLUTCH PACK
Fig. 7A-45B--Removing Output Ring Gear and Sh aft Assembly

Fig. 7A- 43B~Rem oving Low and Reverse Clutch Pack

(350)7A-14 A U T O M A T IC TR A N SM IS S IO N

OUTPUT RING GEAR

TANGED THRUST WASHER

Fig. 7A-48B~Compressing Low and Reverse Clutch Piston
Spring Retainer

Fig. 7A-46B-Removing Output Ring Gear Torrington Bearing

NOTE: On models so equipped, also remove grease 21. Compress low and reverse clutch piston spring
pack sleeves from output shaft before taking shaft from retainer using tool J-23327 (fig. 7A-48B) and remove piston
case. retaining ring and spring retainer.
19. Remove reaction carrier-to-output ring gear 22. Remove seventeen (17) piston springs from piston
torrington bearing (fig. 7A-46B). (fig. 7A-49B).
20. Remove output ring gear to case needle bearing
assembly (fig. 7A-47B).

LOW AND REVERSE CLUTCH .1

PISTON RETURN SPRINGS (17)-
i i i r

OUTPUT
RING
GEAR
OUTPUT RING
GEAR TO CASE
NEEDLE BEARING

LOW AND REVERSE

CLUTCH P IS T O N ^
Fig. 7 A - 4 7 B - R e m o v in g Output Ring Gear to Case Needle Fig. 7A-49B--Low and Reverse Clutch Piston Springs and
Bearing Assembly Piston
 A U T O M A T IC T R A N S M IS S IO N (3 5 0)7 A-15

FI ^
APPLY AIR PRESSURE
HERE TO REMOVE LOW & REVERSE CLUTCH PISTON
REVERSE CLUTCH PISTON

CENTER SEAL

INNER SEAL

Fig. 7 A-50B-Removing Low and Reverse Clutch Piston Fig. 7A-52B-Rem oving Low and Reverse Clutch Piston Center
and Inner Seal

23. Remove low and reverse clutch piston assembly by 25. 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
24. Remove low and reverse clutch piston outer seal accumulator piston cover and remove retaining ring (fig.
(fig. 7A-51B). 7A-53B).
27. Remove intermediate clutch accumulator piston
cover and remove "O" ring seal from case.
28. Remove intermediate clutch accumulator piston
spring.

OUTER
SEAL
J-23069

REVERSE
LUTCH
PISTON
Fig. 7A-5 1 B--Removing Low and Reverse Clutch Piston Outer Fig. 7A-53B--Removing Accumulator Piston Cover Retaining
Seal Ring
(350)7A -16 A U T O M A T IC TRAN SM IS S IO N

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.
Fig. 7A -54B-lnterm ediate Clutch Accumulator Components 7. From the next bore, remove the retaining pin, spring,
seat, and the detent regulator valve.
30. Also, remove inner and outer hook type oil seal 8. Install Tools J-22269 and J-24675 on direct clutch
rings if required. accumulator piston and compress piston only enough to
remove retaining "E" ring (fig. 7A-55B).
29. Remove intermediate clutch accumulator piston
assembly (fig. 7A-54B).
CAUTION: Piston may be damaged if piston is
over compressed.
VALVE BODY DISASSEMBLY, INSPECTION, 9. Remove direct clutch accumulator piston, and metal
AND REASSEMBLY (FIG. 7A-56B) oil seal ring, and spring.
10. From the next bore down from the direct clutch
Disassembly accumulator, remove the detent actuating lever bracket bolt,
1. Position valve body assembly with cored face up and bracket, actuating lever and retaining pin, stop, spring
direct clutch accumulator piston pocket positioned as retainer, seat, outer spring, inner spring, washer and detent
shown in Figure 7A-56B. valve.

s nrwrm ©
irrmro « 1
23 24 25

r 3*2 9 GAUMAAJ <“ *

isaaaasf©
20 21 22
33 31 30 29 28
ra ss a
WVYYYYVO

'2 MAN UA L VA LV E
PRESSURE REGULATOR VA LV E
14
15
1-2 SHIFT VA LV E
1-2 SHIFT C O N T R O L VA LVE
f 27 D ETE N T V A LV E
28 WASHER
3 PRESSURE RE GU LA TO R VA LVE SPR IN G 16 1-2 SHIFT C O N T R O L VA LV E SPRING 29 DETENT V A LV E INNER SPR IN G
4 REVERSE AND MOD ULATOR B O O S T VA LVE 17 1-2 SHIFT C O N T R O L VA LV E SLEEVE 30 DETENT V A LV E OUTER SP RI NG
5 INTERMEDIATE BO O ST VA LVE 18 R E TA IN IN G PIN 31 D ET EN T VA LV E OUTER SP RI N G SE AT
6 B O O S T V A L V E SLEEVE 19 M AN UA L LOW C O N T R O L VA LV E 32 D ET EN T V A L V E SPRI NG RE TAINER

’8 RETAIN ING PIN

. 7 20 M A N U A L LO W C O N T R O L VA LV E SP RI N G 33 DETENT V A L V E STOP
2-3 SHIFT VALVE 21 PLUG 34 DETENT V A LV E A C T U A T IN G LEVER BRAC KE T
9 3 SHIFT V A LV E SPRING 22 R E TA IN IN G PIN 35 D ET EN T V A L V E A C T U A T IN G LEVER
10 3 SHIFT C O N T R O L VA LV E 23 DETENT R E G U L A T O R VALV E 36 R E T A IN I N G BOLT
11 3 SHIFT C O N T R O L VA LV E SPR IN G 24 DETENT RE GU L AT O R VA LV E SP RI NG SE AT L37 R E TA IN IN G PIN
12 3 SHIFT C O N T R O L VA LV E SLEEVE 25 DETENT RE GU L AT O R V A L V E SPRING 38 CAP
113 R E TA IN IN G PIN 26 RE TA IN IN G PIN

Fig. 7A- 56B--Valve Body ■ Exploded V ie w

 A U T O M A T IC T R A N S M IS S IO N (350)7A -17

2. Install special tools J-22269 and J-24675 and

compress spring and piston only enough to install retaining
ring.
NOTE: 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. lbs. 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.
Fig. 7A-55B~Rem oving D irect Clutch A ccum u la to r Piston 6. In the next bore up, install the 1-2 shift valve, 1-2
Retaining "E" Ring
shift control valve, control valve spring, control valve sleeve
and retaining pin.
Inspection
7. In the next bore up, install the manual low control
1. Inspect all valves for scoring, cracks and free valve, spring, plug and retaining pin.
movement in their respective bores.
2. Inspect valve body for cracks, scored bores, 8. In the top right hand bore, install the detent
interconnected oil passages and flatness of mounting face. regulator valve, spring seat, spring and retaining pin.
3. Check all springs for distortion or collapsed coils. OIL PUMP (FIG. 7A-57B)
Reassembly Disassembly
1. Install direct clutch accumulator piston spring and 1. Place pump cover and stator shaft assembly through
piston into valve body. hole in bench.

Fig. 7 A - 5 7 B - P u m p Assembly - Exploded V ie w

(3 5 0 )7 A-18 A U T O M A T IC TRAN SM IS S IO N

INTERMEDIATE CLUTCH

INTERMEDIATE

Fig. 7A -58B -R em oving Pump Cover to Pump Body Bolts Fig. 7A -60B -R em oving Interm ediate Clutch Piston Inner and
O uter Seal

2. Remove pump cover to body attaching bolts 5/16 4. Remove intermediate clutch piston inner and outer
x 18-1 1/2 (fig. 7A-58B). seals (fig. 7A-60B).
3. Remove intermediate clutch spring retainer, twenty 5. Remove two (2) forward clutch housing to pump hub
(20) intermediate clutch return springs and the intermediate hook type oil seal rings and three (3) direct clutch drum to
clutch piston assembly (fig. 7A-59B). pump hub hook type oil rings (fig. 7A-6 IB).
NOTE: 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-6 IB).

Fig. 7 A - 5 9 B - l n t e r m e d i a t e Clutch Spring Retainer, Return Fig. 7 A - 6 1 B - P u m p Hub Oil Seal Rings
Springs and Piston
 A U T O M A T IC TR A N S M IS S IO N (350)7A -19

PUMP C O V E R A N D
STATOR SHAFT
A S S E M B LY

CAUTION: Some solvents may be harmful to

rubber seals.
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
PUMP B O D Y 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 pump
Fig. 7A -62B ~ S eparating Pump Cover From Pump Body body is 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.
7. Remove pump cover and stator shaft assembly from Clearance should be .0005"-.0015" (fig. 7A-63B).
pump body (fig. 7A-62B).
8. Remove pump drive gear and driven gear. Reassembly
9. Remove pump outside diameter to case (square cut) 1. Replace hub lip seal if defective (figs. 7A-64B and
"O" ring seal. Discard seal. 7A-65B).

Inspection
1. Wash all parts in cleaning solvent and blow out all
oil passages. DO NOT USE RAGS TO DRY PARTS.
PUMP TO CONVERTER
HUB LIP SEAL

PUMP BODY

W O O D BLOCKS
Fig. 7 A -63 B ~ C h e c kin g Pump Body to Gear Face Clearance Fig. 7 A - 6 4 B - R e m o v in g Pump to Converter Hub Lip Seal
(3 5 0 )7 A-20 A U T O M A T IC T R A N SM IS S IO N

INTERMEDIATE
CLUTCH

J-21359 C OO LE R OUT
| FROM RADIATOR ]

C OO LE R IN
REVERSE TO RADIATOR )
PUMP TO | DIRECT CLUTCH
OUTER|
CONVERTER EXHAUST
CONVERTER FEED
HUB LIP SEAL PUMP LIP SEAL DRAIN
FORWARD CLUTCH
DIRECT CLUTCH

PUMP B O D Y

Fig. 7 A -6 7B -P u m p Body Oil Passages

PUMP BODY
5. Install three (3) direct clutch to pump hub hook type
W O O D BLOCKS oil seal rings. Install two (2) forward clutch to pump hub
hook type oil seal rings.
Fig. 7 A -6 5 B ~ ln sta llin g Hub Lip Seal
NOTE: If the (2) forward clutch-to-hub oil seals are
2. Place pump body on wood blocks and pry out teflon, be sure to compress the seals slightly to "set"
defective seal. Coat outer diameter of new seal with a non­ them, to insure a tight fit on the hub. Use care when
hardening sealer and install seal using seal installer J-21359 assembling the forward clutch not to damage the seals.
to seat seal fully in counterbore.
Install pump drive gear and driven gear (fig. 7A- CAUTION: Check pump cover and body oil
66B). passages to make sure they are not restricted (figs.
7A-67B and 7A-68B).
4. Install direct clutch drum housing to pump cover 6. Install intermediate clutch piston inner seal and
selective thrust washer over pump cover delivery sleeve. outer seal on piston.

EXHAUST INTERMEDIATE CLUTCH

DIRECT CLUTCH PUMP LIP SEAL DRAIN
FORWARD CLUTCH COOLER IN
TO RADIATOR )
CONVERTER FEED

- C O O L E R OUT
( FROM RADIATOR |

( DIRECT CLUTCH
OUTER'
INTERMEDIATE
CLUTCH

PUM P C O V E R A N D STATOR SH A F T A SSEM BLY

Fig. 7A-6 6 B ~ ln sta lling Pump Drive and Driven Gears Fig. 7 A -6 8 B ~ P u m p Cover Oil Passages
 A U T O M A T IC TR A N S M IS S IO N (350)7A-21

D IR E C T C L U T C H D R U M
ST E E L S E P A R A T O R
P IS T O N RETURN C U S H IO N S P R IN G
LATES
S P R IN G SEAT

D IR E C T C L U T C H
P IS T O N A S S E M B L Y R E T A IN IN G R IN G — FACED PLATE

D IR E C T C L U T C H PR ES S U R E P LA TE '

R E T A IN IN G

Fig. 7A -69B ~ D irect Clutch Assem bly - Exploded V iew

7. Install pump outside diameter to case (square cut) DIRECT CLUTCH AND INTERM EDIATE
"O" ring seal. OVERRUN ROLLER CLUTCH (FIG. 7A-69B)
8. Install intermediate clutch piston assembly into
pump cover being careful not to damage seals. Disassembly
9. Install spring retainer with attached clutch return 1. Remove intermediate overrun clutch drum front
springs, align pump body to cover, and install five (5) retaining ring and retainer (fig. 7A-70B).
attaching bolt. Tighten bolts to 18 pound-feet. 2. Remove intermediate clutch overrun outer race (fig.
10. Align pump body to cover and start bolts. 7A-70B).
3. Remove intermediate overrun roller clutch assembly
(fig. 7A-71B).
IN T E R M E D IA T E O V E R R U N
R CLUTCH ASSEM BLY
OVERRUN
RETAINING RIN

D IR E C T
CLUTCH
DRUM

DIRECT CLUTCH ASSEMBLY

Fig. 7 A-70B --Removing Overrun Clutch Retaining Ring and

Retainer Fig. 7A-7 1 B -Removin g Interm ediate Overrun Roller Clutch
(3 5 0)7 A-22 A U T O M A T IC TRAN SM IS S IO N

DIRECT CLUTCH DRUM TO STEEL

FORWARD CLUTCH H O U S IN G D LATES
NEEDLE ROLLER BEARING

LINED P L A T ES

Fig. 7A -72B ~ D irect Clutch Drum to Forward Clutch Housing Fig. 7A-7 4B -R em oving Drive and Driven Plates
Needle Roller Bearing

NOTE: Intermediate overrun roller clutch inner race 7. Using compressor tool J-23327, remove direct clutch
is a press fit. Do not remove unless replacement is piston return spring seat retaining ring, spring seat and
necessary. seventeen (17) clutch return coil springs (fig. 7A-75B).
4. Remove direct clutch drum to forward clutch
housing needle roller bearing (fig. 7A-72B). NOTE: On JA and JH models, return coil springs are
5. Remove direct clutch pressure plate to clutch drum attached to retaining ring.
retaining ring and pressure plate (fig. 7A-73B). 8. Remove direct clutch piston.
6. Remove drive plates and steel driven plates (fig. 7A-
74B).

R E T A I N I N G R IN G
PRESSURE PLATE
DIRECT CLUTCH DR UM

Fig. 7A-73 B~ Re m ov ing Direct Clutch Pressure Plate Fig. 7 A -7 5 B -C o m p re s s in g Direct Clutch Spring Seat
 A U T O M A T IC TR A N S M IS S IO N (350)7A-23

.0 2 0 " P IAN O WIRE CRIMPED

I N T O C O P P E R T U B IN G

P IS T O N

DIRECT C L U T C H H O U S I N G

Fig. 7A-76B~Rem oving D irect Clutch O uter and Inner Seals Fig. 7 A -7 8 B ~ ln sta llin g Direct Clutch Piston

9. Remove direct clutch piston outer seal and inner seal 6. Inspect roller cage for wear and roller springs for
(fig. 7A-76B). distortion.
10. Remove direct clutch piston center seal from drum
(fig. 7A-77B). Reassembly
1. Install new direct clutch piston outer seal and inner
Inspection seals.
1. Inspect drive and driven clutch plates for signs of 2. Install new direct clutch piston center seal on drum
burning, scoring or wear. with lip facing upward.
2. Inspect seventeen (17) springs for collapsed coils or 3. Install direct clutch piston into housing with aid of
signs of distortion. a feeler gage or a piece of .020" piano wire crimped into
3. Inspect piston for cracks. copper tubing (fig. 7A-78B).
4. Inspect clutch housing for wear, scoring, open oil 4. Install seventeen (17) clutch return coil springs.
passages and free operation of ball check. 5. Install piston return spring seat. Compress spring
5. Inspect roller clutch inner and outer race for seat with tool J-23327 and install retaining ring (fig. 7A-
scratches or indentations. 79B).

DIRECT
CLUTCH
DRUM

CLUTCH PISTON
CENTER SEAL
Fig. 7A-79B--lnstalling Direct Clutch Springs, Spring Se at and
Fig. 7A-77B--Removin g Direct Clutch Piston Center Seal Retaining Ring
(350)7A -24 A U T O M A T IC TRAN SM IS S IO N

C L U TC H PLATES IN CBC 350 R E T A IN IN G F O R W A R D CLUTCH

M O D ELS
Intermediate Direct Forward Low/Reverse R IN G ASSEMBLY
Drive Driven Drive Driven Drive Driven Drive Driven

AJ
3 3 4 4 4 4 5 5
5WB, 5T L , 5TM

AG
3 3 4 4 4 4 4 4
5WC

F O R W A R D C L U TC H
AN
5W L, W K, 5W Z, 5TE 2 2 3 3 4 4 4 4 PRESSURE PLATE
5K E , 5 K K

Fig. 7A -8 2B -R em oving Forward C lutch Retaining Ring and

Pressure Plate

cage direction to avoid bending spring.

Fig. 7A -80B --A utom atic Clutch Chart
9. Install intermediate clutch overrun outer race.
6. Lubricate with transmission fluid and install face NOTE: When outer race is installed, it should free
plates and steel separator plates, alternating steel and faced wheel in counterclockwise direction only.
plates. 10. Install intermediate overrun clutch retainer and
7. Install direct clutch pressure plate and retaining ring. retainer ring as shown on Figure 7A-70B.
8. Install intermediate overrun roller clutch assembly FORWARD CLUTCH (FIG. 7A-81B)
with four (4) holes toward front of transmission.
Disassembly
CAUTION: I f roller falls out during assembly 1. Remove forward clutch retaining ring and pressure
operation, reinstall roller from inside to outside plate (fig. 7A-82B).

F O R W A R D C LU TC H P IS T O N A SSEM BLY
R E T A IN IN G

FO RW AR D CLUTCH DRUM
STEEL S E P E R A T O R PLATES- R IN G
/
C U S H IO N S P R IN G '

,n

&

IN P U T S H A F T

P IS T O N R E T U R N SE A T
F A C E D P L A T E S -------
R E T A IN IN G R IN G
F O R W A R D CLUTCH PRESSURE PLATE'

Fig. 7 A-8 1 B--Forward Clutch Assembly - Exploded V ie w

 A U T O M A T IC TR A N S M IS S IO N (3 5 0)7 A-25

FO RW ARD
CLUTCH
PISTON
SEPARATOR
PLATES IN N ER SEA L

Fig. 7A-85B~R em oving Forward Clutch Piston Inner and

O uter Seals
Fig. 7A -8 3B -R em oving Forw ard C lutch, Clutch Pack

2. Remove face plates, steel separator plates and NOTE: On JA and JH models, return springs are
cushion spring (fig. 7A-83B). attached to return seat.
3. Using tool J-23327, compress piston return seat and 5. Remove forward clutch piston assembly.
remove retaining ring (fig. 7A-84B). 6. Remove the forward clutch inner and outer piston
4. Remove piston return seat and twenty-one (21) seals (fig. 7A-85B).
clutch return springs.
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.

Fig. 7 A -8 4 B -C o m p re s s in g Forward Clutch Piston Return Seat

(350J7A-26 A U T O M A T IC TR A N SM IS S IO N

.020" PIANO WIRE CRIMPED

IN T O C O P P E R T U B IN G
P IS T O N

F O R W A R D CLUTCH H O U S I N G

F O R W A R D CLUTCH
BALL CHECK
EXHAUST

F O R W A R D CLUTCH DRUM

Fig. 7A -86B ~ F orw ard Clutch Exhaust Check Ball Installin g

Piston

4. Inspect clutch housing for wear, scoring, open oil

passages and free operation of exhaust check ball (fig. 7A-
86B).
NOTE: Input shaft and clutch housing are serviced Fig. 7A -8 7 B ~ ln p u t Shaft, T eflon Seal Replacement
separately.
a. Inspect for open lubrication passages at each end. over end of J-22974 and slowly push teflon seal down taper
b. Inspect splines for damage. and onto shaft and groove. Do not leave seal on untapered
c. Inspect ground bushing journals for damage. or middle of tool as this will stretch the seal excessively.
d. Inspect shaft for cracks or distortion. After the seal is on the shaft, it must be sized. Dip end of
e. On models with a teflon seal at the end of the input input shaft in automatic transmission fluid to lubricate seal
shaft, proceed as follows: and shaft, and slowly insert seal and shaft into output shaft
• Inspect the input shaft teflon seal ring for damage. three times before final assembly of transmission. Check
See Figure 7A-87B. If the seal is cut or otherwise damaged, that seal has not been cut and is free in the groove.
it must be replaced. Some scoring and/or scuffing of the Reassembly
shaft is normal. Remove seal with a sharp pointed knife by
inserting under the seal and cutting, making sure not to 1. Install new forward clutch inner piston seal and
damage the seal land area. Install new seal using J-22974 outer piston seal.
and J-9392-01. Position J-22974 with large open end on top 2. Install the forward clutch pistons assembly with the
of input shaft chamfer. Slide teflon seal partially down tool aid of a feeler gage or a piece of .020" piano wire crimped
taper by hand. Position J-9392-01 or 9/16" box end wrench into copper tubing (fig. 7A-86B).
 A U T O M A T IC TR A N S M IS S IO N (3 5 0)7 A-27

USE
WHEN DIM. C IS
(OR EQUIVALENT)
.0160— .0520 6261072
.0 5 2 0 — .0 8 3 0 6261349
.0 8 3 0 — .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 transmission fluid and install cushion
spring face 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 7A-88B 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.
SUN GEAR AND SUN GEAR DRIVE SHELL
Fig. 7A -88B ~ D eterm ining Selective Fit fo r Forward Clutch
Pressure Plate (FIG. 7A-89B)

Fig. 7A-89B--Planetary Gear Train - Exploded V ie w

 (3 5 0 )7 A-28 A U T O M A T IC TRAN SM ISSIO N

SUN GEAR
RETAINING
RING

SUN GEAR DRIVE SHELL

Fig. 7A-90B~Rem oving Sun Gear Drive Shell Rear Retaining Fig. 7 A -92B -R em oving Sun Gear to Drive Shell Front Steel
Ring T hrust W asher

Disassembly Inspection
1. Remove sun gear to sun gear drive shell rear Check gear and sun gear shell for damage or wear.
- retaining ring (fig. 7A-90B).
2. Remove sun gear to drive shell flat rear steel thrust Reassembly
washer (fig. 7A-91B). 1. Install new sun gear to drive shell front retaining
3. Remove sun gear assembly from drive shell. ring.
4. Remove sun gear to drive shell front retaining ring 2. Install sun gear assembly into drive shell.
(fig. 7A-92B). Discard retaining ring. 3. Install sun gear to drive shell flat steel thrust washer.
5. If bushing is to be replaced, refer to Figure 7A-104B. 4. Install new sun gear to sun gear drive shell retaining
ring.

NOTE: Do not stress front and rear retaining rings at

SUN GEAR DRIVE SHELL
MX.,. installation.
SUN GEAR
LOW AND REVERSE ROLLER CLUTCH
SUPPORT (FIG. 7A-93B)

Disassembly
1. Remove low and reverse clutch to sun gear shell
thrust washer.

FLAT THRUST WASHER

Fig. 7 A-9 1 B-Removin g Sun Gear to Drive Shell Rear Steel
Thrust W a s h e r
 A U T O M A T IC T R A N S M IS S IO N (3 5 0)7 A-29

L O W A N D R EVERSE
L UTCH S U P P O R T

ROLLERCLUTCH
ASSEMBLY

IN N E R RACE

THRUST W A S H E
C A G E M U S T H A V E (4) EQ UA L LY S P A C E D
.0 9 1 LUBE H O L E S O N THIS SIDE IF ROLLER F ALLS O U T , I N S T A L L RO LLER
F R O M " O U T S ID E I N " AS S H O W N TO
A V O I D B E N D IN G S P R IN G S

Fig. 7A-93B--Low and Reverse Clutch Assem bly - Exploded V ie w

(3 5 0 )7 A-30 A U T O M A T IC T R A N SM IS S IO N

Z 2 LOW
i & REVERSE ROLLER
LOW AN D REVERSE CLUTCH ASSEMBLY
OVERRUN CLUTCH RACE
Fig. 7 A -94 B -R e m ovin g Overrun Clutch Inner Race Fig. 7A -9 6B -R em oving Overrun Roller Clutch Assem bly

2. Remove low and reverse overrun clutch inner race Inspection

from support (fig. 7A-94B).
3. Remove low and reverse clutch roller clutch 1. Inspect foller clutch inner and outer race for
retaining ring (fig. 7A-95B). scratches and identations.
4. Remove low and reverse roller clutch assembly (fig.
7A-96B). 2. Inspect rollers for wear and roller springs for
distortion.

Assembly

1. Install low and reverse roller clutch assembly to

inner race with oil holes toward rear of transmission.
2. Install low and reverse overrun clutch outer race.
L O W & REVERSE ROLLER 3. Install low and reverse clutch to cam retaining ring.
CLUTCH R E T A IN IN G R IN G
NOTE: 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 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:

Fig. 7 A - 9 5 B - R e m o v in g Overrun Roller Clutch Retaining Ring

 A U T O M A T IC TR A N S M IS S IO N (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
Disassembly exhaust slots of governor sleeve, place in arbor press, and
with a long punch, press gear out of sleeve.
1. Cut off one end of each governor weight pin and 3. Carefully clean governor sleeve of chips that remain
remove pins, governor thrust cap, governor weights, and from original gear installation.
springs. Governor weights are interchangeable from side to 4. Support governor on 3/16 inch plates installed in
side and need not be identified (fig. 7A-97B). exhaust slots of sleeve, position new gear in sleeve and, with
a suitable socket, press gear into sleeve until nearly seated.
2. Remove governor valve from governor sleeve. Be Carefully remove any chips that may have shaved off gear
careful not to damage valve. hub and press gear in until it bottoms on shoulder.
5. A new pin hole must be drilled through sleeve and
3. Perform following inspections and replace governor gear. Locate hole position 90 degrees from existing hole,
driven gear, if necessary. center punch and then, while supporting governor in press,
drill new hole through sleeve and gear using a standard (1/8
Inspection inch) drill.
1. Wash all parts in cleaning solvent, air dry and blow 6. Install split retaining pin.
out all passages. 7. Wash governor assembly thoroughly to remove any
2. Inspect governor sleeve for nicks, burrs, scoring or chips that may have collected.
galling. Assembly
3. Check governor sleeve for free operation in bore of 1. Install governor valve in bore of sleeve, large land
transmission case. end first.
4. Inspect governor valve for nicks, burrs, scoring or 2. Install governor weights and springs, and thrust cap
galling. on governor sleeve.
5. Check governor valve for free operation in bore of 3. Align pin holes in thrust cap, governor weight
governor sleeve. assemblies and governor sleeve, and install new pins. Crimp
6. Inspect governor driven gear for nicks, burrs, or both ends of pins to prevent them from falling out.
damage. 4. Check governor weight assemblies for free operation
7. Check governor driven gear for looseness on on pins.
governor sleeve. 5. Check governor valve for free movement in governor
8. Inspect governor weight springs for distortion or sleeve.
damage. BUSHING REPLACEMENT
9. Check governor weights for free operation in their
retainers. Extension Housing Bushing
10. Check valve opening at entry and exhaust (.020 Remove extension housing bushing from housing using
inch minimum). tool J-21424-9 with drive handle J-8092. Install extension
(3 5 0 )7 A-32 A U T O M A T IC TRAN SM IS S IO N

J - 2 1 4 6 5 -15
J -2 6 1 9 -4
J-8 0 9 2 ADAPTER

J-2 1 4 2 4 -9

E X T E N S IO N
H O U S IN G B O D Y PUMP

PUMP C O V E R
A N D STATOR
SHAFT ASSEMBLY
Fig. 7A-1 OOB-Removing S tator S haft Front Bushing

Using tool J-23062-1 and drive handle J-8092 with extension

Fig. 7 A -9 8 B -ln s ta llin g Extension Housing Bushing
J-21465-13, 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.
housing bushing in housing flush to .010 below seal counter Stator Shaft Front Bushing
bore surface using tool J-21424-9 with drive handle J-8092 With stator shaft properly supported, remove front
(fig. 7A-98B). bushing using tool J-21465-16 and slide hammer with
adapter J-2619-01 (fig. 7A-100B). Using tool J-21242-7 and
Output Shaft Bushing drive handle J-8092, install bushing to .250" from face (fig.
With output shaft properly supported, remove bushing 7A-101B).
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.

J-8092
DRIVE
HANDLE
J - 21 424-7

PUMP C O V E R PUMP
AN D STATOR BODY
SHAFT ASSEMBLY

Fig. 7 A - 9 9 B - R e m o v in g Output Shaft Bushing Fig. 7 A - 1 01 B—Installing Sta tor Shaft Front Bushing
 A U T O M A T IC TR A N S M IS S IO N (3 5 0)7 A-33

SUN
GEAR J-8092
DRIVE
SHELL

J-23062-3

SUN GEAR
ASSEMBLY

Fig. 7 A -10 2 B --ln sta llin g Inner and O uter S tator Shaft Bushing Fig. 7 A -1 0 4 B --ln sta llin g Sun Gear Bushings

Stator Shaft Rear Bushing Sun Gear Bushing

With stator shaft properly supported, remove front With sun gear properly supported, remove two (2) sun
bushing (fig. 7A-102B). Place tool J-21424-7 and drive gear bushing using tool J-23062-3 and drive handle J-8092
handle J-8092 with extension J-21465-13 through front of with extension J-21465-13. Using tool J-23062-3 and drive
stator shaft and drive out two (2) rear bushings. Using tool handle J-8092, install sun gear bushing to .010" below
J-23062-2 and extension J-21465-13, install inner bushing surface at either end (fig. 7A-104B).
to approximately 1-5/32" below front face and outer
bushing 3/32" below front face (fig. 7A-102B). Install new Reaction Carrier Bushing
front bushing (fig. 7A-101B). With reaction carrier properly supported, remove
bushing using tool J-23062-3 and drive handle J-8092. Using
Input Ring Gear Bushing tool J-23062-3 and drive handle J-8092, install bushing flush
With input ring gear properly supported, remove to or .010" below inside face.
bushing using tool J-23062-5 and drive handle J-8092. Using
tool J-23062-5 and drive handle J-8092, install bushing to Direct Clutch Bushing
approximately 1/16" below rear face inside gear end (fig. With direct clutch drum properly supported, remove
7A-103B). bushing (fig. 7A-105B). Using tool J-23329 and drive handle
CAPE CHISEL

BUSHING
J-8092

J-23062-5

INPUT DIRECT CLUTCH DRUM

RING GEAR

Fig. 7 A - 1 0 3 B - ln s t a llin g Input Ring Gear Su pport Bushing Fig. 7 A - 10 5 B -R e m o v in g Direct Clutch Drum Bushing
(3 5 0)7 A-34 A U T O M A T IC TR A N SM IS S IO N

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 into case.
7. Install reaction carrier assembly into output ring
gear and shaft assembly.
8. Oil and install low reverse clutch steel reaction plates
and face plates, starting with a steel plate and alternating
with face plates. Install low and reverse clutch support
retainer (anti-clunk) spring.
NOTE: Notch in steel separator plates should be
placed toward bottom of case.
9. Install low and reverse clutch support assembly with
position of notch with low and reverse clutch support
retainer (anti-clunk) spring as shown on Figure 7A-107B.
SIMP Make certain the splines on inner race of the
Fig. 7 A -106 B ~ ln sta llin g D irect Clutch Drum Bushing roller clutch align with splines on reaction carrier.
10. Install low and reverse roller clutch inner race to
sun gear shell thrust washer.
J-8092, install direct clutch drum bushing (fig. 7A-106B). 11. Install low and reverse clutch support to case snap
TRAN SM ISSIO N ASSEMBLY ring with anti-clunk spring between gap.
When servicing transmission, use only transmission oil 12. Install rear thrust washer and sun gear drive shell
or petroleum jelly as lubricants to retain bearings or races assembly.
during assembly. Lubricate all bearings, seal rings and 13. Install output carrier assembly.
clutch plates prior to assembly. 14. Install input ring gear rear thrust washer.
15. Install input ring gear.
Transmission Internal Components 16. Install new input ring gear to output shaft snap
1. Install low and reverse clutch piston assembly with ring.
notch in piston installed adjacent to parking pawl.
2. Install seventeen (17) piston return (coil) springs. 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.
LOW AND REVERSE CAUTION: Make certain forward clutch face
CLUTCH SUPPORT plates are positioned over input ring gear and the
tangs on direct clutch housing are installed into
slots on the sun gear drive shell.
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.
NOTE: Notch in steel reaction plates is installed
LOW AND REVERSE toward selector lever inner bracket.
CLUTCH SUPPORT 23. Install intermediate clutch cushion spring.
RETAINER SPRING Pump to Direct Clutch Thrust W asher 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:
Fig. 7 A - 1 0 7 B—Installing Low and Reverse Clutch Support
Assembly
 A U T O M A T IC TR A N S M IS S IO N (350)7A-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.
SIMP 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 speedometer drive gear using a heat lamp
or suitable heat method.
3. Align slot in speedometer drive gear with retaining
PUMP COVER TO DIRECT CLUTCH clip and install.
NEEDLE BEARING 4. Install extension housing to case square cut "O" ring
seal.
5. Attach extension housing to case using attaching
Fig. 7 A -1 0 8 B -P u m p Cover to Direct Clutch T orrin gton
Bearing
bolts. Torque to 25 ft. lbs.
a. Install torrington bearing, (fig. 7A-108B) oil pump 6. If necessary, install a new extension housing seal,
gasket and using guide studs from J-3387 set install oil using seal installer J-5154 or J-21426 (fig. 7A-110B).
pump. Install two pump to case bolts.
b. Move transmission so that output shaft points down. Manual Linkage
Mount a dial indicator so that plunger of indicator is resting 1. If necessary, install a new manual shaft to case lip
on end of the input shaft. J-5492 may be used to support seal using 3/4" diameter rod, seat seal in case.
the dial indicator as shown in Figure 7A-109B. Zero the 2. Install parking pawl, tooth toward the inside of case,
indicator. into case.
c. Push up on the transmission output shaft and 3. Install parking pawl shaft into case and through
observe the total indicator movement. parking pawl.
d. The indicator should read .010" to .044". If the 4. Install parking pawl shaft retainer plug. Drive into
reading is within limits, the proper selective fit washer is case using a 3/8" dia. rod, until retainer plug is .130" to
being used. If the reading is not within limits, it will be .170" below face of case, then stake in three places.
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.
NOTE: Selective fit thrust washers are available in
thicknesses of .066", .083" and .100".
25. Install new pump assembly in case gasket.

J-5154

Fig. 7A -109 B ~C he cking End Play fo r Proper T hrust W asher

Selection Fig. 7 A - 1 10 B -ln s ta llin g Extension Housing Seal
(3 5 0 )7 A-36 A U T O M A T IC TR A N SM IS S IO N

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.
NOTE: 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
1. Install governor assembly, cover and seal and
retainer wire.
2. Install vacuum modulator valve.
Fig. 7A-1 1 1B--Park Lock B racket Special Bolt Ide ntificatio n
3. Install vacuum modulator and retainer clip. Torque
bolt to 130 inch pounds.
5. Install parking pawl disengaging spring, square end
hooked on pawl. NOTE: Position retainer with tangs pointing toward
6. Install park lock bracket, torque bolts to 29 ft. lb. modulator.
(fig. 7A-111B). Intermediate Clutch Accumulator (Refer to
Figures 7A-54B and 7A-55B)
CAUTION: 290 M Bolts - 6 marks on head. 1. Install intermediate clutch accumulator piston
7. Install range selector inner lever to parking pawl assembly.
actuator rod. 2. Install intermediate clutch accumulator spring.
8. Install actuating rod under the park lock bracket and 3. Install new "O" ring seal in groove in case before
parking pawl. installing cover.
9. Install manual shaft through case and range selector 4. Install intermediate clutch accumulator cover and
inner lever. retaining ring using tool J-23069.
10. Install retaining nut on manual shaft. Torque to 30 3. Install four (4) check balls into proper transmission
ft. lbs. case pockets (fig. 7A-18B).
11. Install manual shaft to case spacer clip. 4. Install oil pump pressure screen and governor feed
screen.
5. Install valve body transfer plate and gasket assembly.
Intermediate Servo Piston, Valve Body, Oil Pan 6. Install valve body to transfer plate gasket.
and Gasket 7. Install valve body. Connect manual control valve
1. Install intermediate servo piston, apply pin, spring link to range selector inner lever. Torque bolts in random
and spring seat. sequence to 130 inch pounds.
2. Install intermediate servo piston and metal oil seal 8. Install spacer support plate, torque bolts to 130 in.
ring. lbs.
 A U T O M A T IC T R A N S M IS S IO N (3 5 0)7 A-37

SPECIFICA TIO N S
TURBO H YD R A-M ATIC- 350

TORQUE SPECIFICATIONS

Pump Cover to Pump Body.............................. 17 ft. lbs.

Pump Assembly to Case............................. 18-1/2 ft. lbs.
Valve Body and Support Plate......................130 in. lbs.
Parking Lock Bracket..................................... 29 ft. lbs.
Oil Suction Screen.......................................... 40 in. lbs.
Oil Pan to Case.................................................130 in. lbs.
Extension to Case. .......................................... 25 ft. lbs.
Modulator Retainer to C ase........................ 130 in. lbs.
Inner Selector Lever to S h aft...................... 25 ft. lbs.
Detent Valve Actuating Bracket.................... 52 in. lbs.
Converter to Flywheel B o lts........................ 35 ft. lbs.
Under Pan to Transmission Case....................110 in. lbs.
Transmission Case to Engine........................ 35 ft. lbs.
Oil Cooler Pipe Connectors to Transmission
Case (Straight Pipe Fitting).........................25 ft. lbs.
(Tapered Pipe Fitting)......................... 15 ft. lbs.
Oil Cooler Pipe to Connectors.........................10 ft. lbs.
Gearshift Bracket to Frame............................. 15 ft. lbs.
Gearshift Shaft to Swivel................................. 20 ft. lbs.
Manual Shaft to Bracket............................... 20 ft. lbs.
Detent Cable to Transmission....................... 75 in. lbs.
Intermediate Band Adjust Nut ..................... 15 ft. lbs.
(3 5 0 )7 A -3 8 A U T O M A T IC T R A N SM IS S IO N

S P EC IA L TOOLS

1. J-8763-02 Transmission Holding Fixture 16. J-5154 or Extension Housing Oil Seal
(Used w ith J-3289-20 Base) J-21426 Installer
2. J-3289-20 Transmission Holding Fixture 17. J-21359 Pump Oil Seal Installer
Base 18. J-7004 Slide Hammers (Pair) For
3. J-8092 Driver Handle (Threaded type) Pump Body removal (3/8” x 16 tread)
4. J-21465-13 Driver Handle Extension (Used w ith J-8092) 19. J-22269-01 Direct Clutch Accumulator Piston
5. J-23062-3 Sun Gear and Reaction Carrier Remover and Installer (THM 350 only)
Bushing 20. J-23069 Intermediate Accumulator Cover
6. J-23062-7 O utput Shaft Bushing Installer Remover and Installer
7. J-21465-15 Stator Shaft Front Bushing 21. J-2619-01 Slide Hammer (5 /8 " x 18
Remover (Used w ith J-8092) w ith 1/2" x 13 Adapter)
8. J-23329 Direct Clutch Bushing Installer Not Illustrated
9. J-9534-01 O utput Shaft Bushing Remover
10. J-23327 Clutch Spring Compressor J-21369 Converter Pressure Check
11. J-23062-2 Stator Shaft Rear Bushing Fixture
Installer (Both Rear) J-8001 Dial Indicator Set
12. J-23062-1 Case Bushing Remover and Installer (.001" Increments, .001" Travel)
13. J-21424-9 Extension Housing Bushing Remover and J-21427-1 Speedo Gear Remover
Installer (Used w ith J-8092) J-9539 Slide Hammer Bolts (3 /8 " - 16 Threads)
14. J-21424-7 Stator Shaft Front Bushing J-8105 Speedo Gear Remover Puller
Installer (Used w ith J-8092) J-5586 Snap Ring Pliers
15. J-23062-5 Input Ring Gear Bushing J-24367 Transmission Band Adjuster (THM 250 only)
Remover and Installer J-24675 Accumulator Piston Adapter (Used w ith J-22269-01)

Fig. 7A-ST--CBC 3 5 0 Special Tools

 A U T O M A T IC T R A N S M IS S IO N S (400)7A-1

SECTION 7A

A U T O M A T IC T R A N S M IS S IO N
THM 400 TRANSM ISSION
INDEX

Transmission Disassembly and Reassembly.............. 7A-3 Output Shaft, Rear Internal Gear,
Disassembly of Major Units...................................... 7A-3 Sun Gear and Shaft............................................. .7A41
Governor, Speedometer Driven Gear, Pan, Filter Sun Gear Shaft Bushing-Front.................................7A41
and Intake Pipe..................................................... 7A-3 Sun Gear Shaft Bushing-Rear..................................7A-41
Control Valve Assembly, Solenoid Connector, Main Shaft Inspection............................................... .7A-41
Governor Pipes and Detent Spring.................... 7A4 Front and Rear Bands Inspection..............................7A41
Rear Servo, Valve Body Spacer, Gasket Case Extension............................................................ .7A41
and Front Servo...................................................... 7A-5 Modulator and Valve...................................................7A42
Rear Band Apply Pin Selection........................... 7A-6 Manual and Parking Linkage Inspection.................7A42
Manual Linkage...................................................... 7A-7 Case Assembly Inspection..........................................7A-42
Rear Oil Seal and Case Extension......................... 7A-9 Case Assembly Bushing............................................7A-44
Front Unit End Play Checking Procedure.......... 7A-9 Converter Inspection....................................................7A44
Oil Pump and Internal Case Components............. 7A-10 Converter End Clearance Check..............................7A44
Rear End Play Checking Procedure.................... 7A-11 Assembly of Rear Unit.............................................. .7A45
Gear Unit Assembly................................................. 7A-13 Assembly of Units to Transmission Case..................7A-48
Speedometer Drive G ear......................................... 7A-15 Install Manual Linkage............................................7A-51
Governor Assembly.................................................... 7A-16 Rear Extension Assembly..........................................7A-52
Driven Gear Replacement..................................... 7A-17 Check Balls, Front Servo, Spacer and Solenoid.... 7A-53
Front Servo Parts Inspection.................................. 7A-18 Rear Servo Assembly.................................................7A-55
Rear Servo Parts Service......................................... 7A-18 Control Valve Assembly and Governor Pipes...... .7A-56
Control Valve Service................................................ 7A-19 Filter and Intake Pipe............................................. .7A-56
Oil Pump Service........................................................ 7A-22 Modulator Valve and Valve and
Forward Clutch Service............................................. 7A-25 Vacuum Modulator.....................................................7A-57
Direct Clutch and Intermediate Roller Service...... 7A-31 Governor...................................................................7A-57
Center Support Service.............................................. 7A-35 Speedometer Driven G ear.......... ............................7A-57
Reaction Carrier, Roller Clutch and Output Converter Assembly-Installation.......................... ..7A-57
Carrier Assembly.................................................. 7A-40 Specifications....................................................................7A-58
Pinion Replacement................................................. 7A-40 Special Tools................................................................... .7A-59
(4 0 0 )7 A-2 A U T O M A T IC T R A N SM IS S IO N S

Fig. 7 A -1C --TH M 4 0 0 Side Cross S ection -T ypical

 A U T O M A T IC T R A N S M IS S IO N S (400)7A-3

MODULATOR VALVE

Fig. 7A-2C -Transm ission in Holding Fixture VACUUM MODULATOR

DISASSEM BLY OF M AJO R UNITS Fig. 7A-4C--Removing Vacuum M o d u la to r and Valve

1. With transmission in cradle on portable jack, remove

converter assembly by pulling straight out.
Converter contains a large amount of oil. 4. Remove modulator assembly attaching screw and
NOTE: retainer (Fig. 7A-3C).
2. Install holding Fixture J-8763-01 on transmission so 5. Remove vacuum modulator assembly and "O" ring
that modulator assembly will be located on side of holding seal from case (Fig. 7A-4C). Discard "O" ring.
fixture nearest bench (Fig 7A-2C). 6. Remove modulator valve from transmission case
(Fig. 7A-4C).
NOTE: Do not over-torque holding screw. This will
bind center support. Removal of Governor,
3. Install fixture and transmission into holding Tool
Base J-3289-14 with bottom pan facing up (Fig. 7A-2C). 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.

RETAINER

Fig. 7A-3C--Removing M od ula tor Retainer Fig. 7 A -5C -R e m o v in g Governor Cover Attaching Screws
(400)7A-4 A U T O M A T IC TR A N SM IS S IO N S

STRAINER
ASSEMBLY

INTAKE)
PIPE

lo ca to r]
TABS

Fig. 7A-8C--Removing F ilter Assem bly and " 0 " Ring

Fig. 7A-6C--Removing S peedom eter Driven Gear Retainer

Removal of Control Valve Assembly,
Solenoid Connector, Governor Pipes, Governor
Screen Assembly, and Detent Spring Assembly
3. Remove speedometer driven gear attaching screw 1. Remove control valve body attaching screws and
and retainer (Fig. 7A-6C). detent roller and spring assembly (Fig. 7A-9C).
4. Withdraw speedometer driven gear assembly from Do not remove solenoid attaching screws.
case. NOTE:
5. Remove bottom pan attaching screws, bottom pan
and bottom pan gasket. Discard gasket. CAUTION: I f transmission is in the vehicle, the
6. Remove the filter retainer bolt (Fig. 7A-7C). front servo parts may drop out as the control valve
7. Remove filter and intake pipe assembly from case assembly is removed.
(Fig. 7A-8C) and discard filter.
8. Remove intake pipe to case "O" ring seal from intake
pipe or case and discard.

DETENT ROLLER AND

SPRING ASSEMBLY

Fig. 7 A -7 C -R e m o v in g Filter Retainer Bolt Fig. 7 A-9 C-R e m ov in g Detent Roller and Spring Assembly
 A U T O M A T IC T R A N S M IS S IO N S (400)7A-5

Fig. 7A -10C--Removing C ontrol Valve Assem bly and Governor

Pipes from Case Fig. 7A - 12C --D isconnecting Detent Solenoid W ire

2. Remove control valve assembly and governor pipes

(Fig. 7A-10C).
CAUTION: Do not drop manual valve. SER V O C O V ER

3. Remove governor screen assembly from governor

feed pipe hole in the case or from end of governor feed pipe
(Fig. 7A-11C). Clean governor screen in clean solvent and
A T T A C H IN G BO LTS

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
1. 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).
Fig. 7A-1 3C -R em oving Rear Servo Cover A tta ching Bolts

REAR SER V O
ASSEM BLY
GOVERNOR SCREEN
ASSY.

GOVERNOR FEED
PIPE HOLE

Fig. 7A-1 1C-R emoving Governor Screen Assembly Fig. 7 A - 1 4 C -R e m o vin g Rear Servo Assembly
(4 0 0)7 A-6 A U T O M A T IC TRAN SM ISSIO NS

TORQUE
WRENCH

TORQUE
WRENCH
J-21370-6

370-5

Fig. 7A -15C--Checking Rear Band A pply Pin, Except M odels Fig. 7 A -16C--Checking Rear Band A p p ly Pin, M odels CD and
CD and CL CL

b. Apply 25 ft. lb. torque and select proper pin to be Rear Band Apply Pin Selection (Models CD and
used during assembly of transmission. CL)

NOTE: Selecting proper length pin is equivalent to NOTE: There are six selective pins identified as shown
adjusting band. The band lug end of each selective in Figure 7A-17C. Selecting proper pin is equivalent
apply pin bears indentification in the form of one, two to adjusting band.
or three rings. 3. Remove rear servo accumulator spring.
c. If both steps of J-21370-5 are below the gage surface, 4. Make band apply pin selection check to determine
the long pin, identified by 3 rings, should be used. possible cause of malfunction (Fig. 7A-15C).
d. If the gage surface is between the steps, the medium Rear Band Apply Pin Selection (All Models
pin, identified by 2 rings, should be used. Except CD and CL)
e. If both steps are above the gage surface, the short a. Attach band apply pin selection Gage J-21370-5 and
pin, identified by 1 ring, should be used. J-21370-6 to transmission case with attaching screws
GAGING STEPS LOCATED ON
PIN
THREE SIDES OF TOOL PART NO.
ID E N T IF IC A T IO N
J-21370-9

THIS STEP:
c LONGEST PIN
USE PIN NO. 8627195
L
L— 'J THIS STEP: SIDES B TO C
USE PIN NO. 8627194 a n tB
O)
6I1". THIS STEP:
00 B USE PIN NO. 8624141
CM

THIS STEP: SIDES A TO B

O USE PIN NO. 8627193
O
H
A
THIS STEP:
USE PIN NO. 8624140 □EG
LOWER STEP LOWER STEP:
SHORTEST PIN USE PIN NO. 8627192

Note: The Identification Rings are .030" and .100" wide.

Fig. 7A-17C--Rear Band Apply Pin Indentification
 A U T O M A T IC T R A N S M IS S IO N S (400)7A-7

Fig. 7 A -18C~Removing Detent S olenoid and Gasket Fig. 7A -20C -R em oving Front Servo Piston, Retainer Ring, and
Pin
checking to make certain the gage pin does not bind in servo
pin hole (Fig. 7A-15C). 6. Withdraw electrical connector and "O" ring seal
a. Attach band apply pin selection gage (J-21370-9 and (Fig. 7A-19C).
J-21370-6), to transmission case (lever pivot pin to rear) 7. Remove control valve assembly spacer plate and
with rear servo cover attaching screws. gasket.
b. Attach tool attaching screws finger tight and check 8. Remove six (6) check balls from cored passages in
freeness of selective pin. Torque attaching screws to 15 foot­ transmission case.
pounds and recheck pin to make certain it does not bind.
c. Apply 25 foot-pounds torque to the lever on Tool NOTE: Mark location of balls for aid in reassembly.
J-21370-6 (Fig. 7A-16C). Selection of the proper rear band 9. Remove front servo piston, retainer ring, washer,
apply pin is determined by the relation of the flat on Tool pin, spring retainer and spring from transmission case (Fig.
J-21370-9 to the flat machined area around the hole on Tool 7A-20C).
J-21370-6.
d. Before removing gaging tool make note of the proper Remove Manual Linkage
band apply pin to be used during assembly of the
transmission as determined by the six selective pins NOTE: If necessary, remove manual linkage as
identified as shown in Fig. 7A-17C. follows:
1. Unthread jam nut holding detent lever to manual
NOTE: If the transmission is in the vehicle, be careful shaft.
when the detent solenoid is removed as it prevents the
spacer plate and gasket and check balls from dropping NOTE: Model CD transmision does not have parking
down. lock mechanism.
5. Remove detent solenoid attaching screws, detent 7A-21C). Remove manual shaft retaining pin from case (Fig.
2.
solenoid and gasket (Fig. 7A-18C).

Fig. 7 A - 1 9C~Remo ving Electrical Connector and "O" Ring

Seal Fig. 7A-2 1C -Rem o vin g Manual Shaft Retaining Pin from Case
(4 0 0)7 A-8 A U T O M A T IC TRA N SM IS S IO N S

Fig. 7A-25C--Rem oving Parking S haft Retaining S pring

MANUAL
SHAFT DETENT
LEVER
5. Remove attaching screws and parking bracket (Fig.
7A-23C).
Fig. 7A-22C--Removing Detent Lever and Jam Nut from
M anual S haft 6. Remove parking pawl return spring (Fig. 7A-24C).
NOTE: The following steps are to be completed only
3. Remove manual shaft and jam nut from case (Fig. if 1 or more of the parts involved require replacement.
7A-22C). Do not lose jam nut as it becomes free from 7. Remove parking pawl shaft retainer (Fig. 7A-25C).
manual shaft. 8. Remove parking pawl shaft cup plug by inserting a
4. Remove parking actuator rod and detent lever screwdriver, between the parking pawl shaft and the case
assembly. rib, and prying outwards (Fig. 7A-26C).
9. Remove parking pawl shaft and parking pawl (Fig.
7A-26C).

Fig. 7A -2 3C -R em o ving Parking Bracket

RETURN SPRING

PARKING
PAWL
SHAFT

Fig. 7 A -2 4 C -R e m o v in g Parking Pawl Return Spring Fig. 7A-26C--Removing Parking Pawl, Shaft and Cup Plug
 A U T O M A T IC T R A N S M IS S IO N S (400)7A-9

DIAL
Fig. 7A-27C~Rem oving Rear Oil Seal from Case Extension INDICATOR
J-8001
Fig. 7A-29C --C hecking Front U n it End Play

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). c. Mount a dial indicator on rod and index indicator
2. Remove case extension to case attaching bolts. to register with end of turbine shaft.
3. Remove case extension to case gasket (Fig. 7A-28C). d. Push on turbine shaft rearward.
4. Make front unit end play check as follows (Fig. 7A- e. Push output shaft forward.
29C): f. Set dial indicator to Zero.
a. Remove one front pump attaching bolt, and bolt g. Pull turbine shaft forward.
washer. (See Fig. 7A-29C for location). Read resulting travel or end play. Should be
b. Install a 3/8"-16 threaded slide hammer bolt or J- .003 "-.024".
9539, into bolt hole. 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.
NOTE: 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 - 2- Red
.093 - .097 - 3- Brown
.104 - .108 - 4- Green
.115 - .119 - 5- Black
.126 - .130 - 6- Purple
GASKET

Fig. 7A-28C--Case Extension and Gasket Fig. 7 A - 3 0 C - F r o n t End W a s h e r Selection Chart

(40 0)7 A-10 A U T O M A T IC TR A N SM IS S IO N S

Fig. 7A-33C ~R em oving Forw ard Clutch Assem bly and

T urbine S haft

Fig. 7A-3 1C -R em oving Front Seal

3. Install two 3/8"-16 threaded slide hammer bolts, J-

9539 with weights J-6585-01, into bolt holes in pump body
and remove pump assembly from case (Fig. 7A-32C). (See
Oil Pump and Internal Case Components illustration for location of threaded holes.)
4. Remove and discard pump to case seal and gasket.
Removal
1. If necessary to replace, pry front seal from pump 5. Remove forward clutch assembly and turbine shaft
(Fig. 7A-31C). from transmission (Fig. 7A-33C).
2. Remove pump attaching bolts. 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-34C--Removing Direct Clutch Assembly

Fig. 7A-32C--Removing Pump Assembly
 A U T O M A T IC T R A N S M IS S IO N S (4 0 0)7A -1 1

DIAL INDICATOR

J-9539

Fig. 7A-37C --C hecking Rear U nit End Play

REAR END WASHER THICKNESS

Fig. 7A-35C--Removing Front Band
Identification
Thickness Notches and/or Numeral
.074-.078 None .......................... 1
8. Remove front band assembly (Fig. 7A-35C). .082 - .086 1 Tab S id e ................... 2
9. Remove sun gear shaft (Fig. 7A-36C). .090 - .094 2 Tab S id e ................... 3
.098 - .102 1 Tab O.D......................4
Check Rear End Play as Follows (Fig. 7A-37C) .106-.110 2 Tabs O.D.................... 5
a. Install J-9539 or a 3/8"-16 threaded bolt into an .114-.118 3 Tabs O.D.................... 6
extension housing attaching bolt hole (Fig. 7A-37C).
b. Mount a dial indicator on bolt and index with end
of output shaft. Fig. 7A-38C--Rear End W asher T hickness Chart
c. Move output shaft in and out to read end play. End If a different washer thickness is required to bring end
play should be from .007"-.019". Selective washer play within specification, it can be selected from the chart
controlling this end play is a steel washer having 3 lugs that shown in Fig. 7A-38C.
is located between output shaft thrust washer and rear face
of transmission case. 10. Remove center support to case bolt (Fig. 7A-39C),
using a 3/8" 12-point thin wall deep socket.

CENTER S U PP O R T BOLT

Fig. 7 A-36C~Rem oving Sun Gear Shaft Fig. 7A-39C--Removing Center Support Bolt
(400)7A -12 A U T O M A T IC TRA N SM IS S IO N S

Fig. 7A-40C~Rem oving Interm ediate Backing Plate and

Clutch Plates

11. Remove intermediate clutch backing plate to case

snap ring.
12. Remove intermediate clutch backing plate, as Fig. 7A -42C -R em oving Center S u p po rt and Gear U nit from
shown in Fig. 7A-40C. Case

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. 15. Remove entire gear unit assembly by lifting with
b. (CB, CL and CD models) Remove three (3) gear assembly installing and removing Holding Tool J-
composition, and three (3) steel clutch plates. 21795 with J-9539 slide hammer (Fig. 7A-42C).
14. Remove center support to case retaining snap ring 16. Remove shaft to case thrust washer from rear of
(Fig. 7A-41C). output shaft or inside case.
17. Place gear unit assembly, with output shaft facing
down through hole in work bench.
18. Remove rear unit selective washer from
transmission case (Fig. 7A-43C).

Fig. 7 A-4 1 C -R e m o v in g Center Support to Case Retaining

Snap Ring Fig. 7A-43C--Removing Selective W a s he r
 A U T O M A T IC T R A N S M IS S IO N S (400)7A-13

Fig. 7 A-44C--Removing Center S up po rt to Case Spacer

Fig. 7A-46C--Rem oving Center Support Assem bly

19. Remove center support to case spacer (Fig. 7A-
44C).
20. Remove rear band assembly (Fig. 7A-45C).
Disassembly of Gear Unit Assembly
NOTE: One race may have been removed with center
NOTE: CL Model (spur gears) disassembly procedure
support.
is identical as illustrated. 4. Remove reaction carrier and roller clutch assembly
1. Remove center support assembly (Fig. 7A-46C).
2. Remove center support to reaction carrier thrust
washer (Fig. 7A-47C).
3. Remove center support to sun gear races and thrust THRUST WA SH ER

bearing.

ORIFICE PLUG

Fig. 7A-45C--Remo ving Rear Band Fig. 7A-47C--Removing Center Su pport Thrust W a s h e r
(4 0 0)7 A-14 A U T O M A T IC TRAN SM IS S IO NS

S N A P R IN G
ROLLER CLUTCH
ASSEMBLY

REACTION
CARRIER

SUN
GEAR
PLASTIC GEAR
RING

OUTPUT Fig. 7A-50C--Removing O utput Shaft to Carrier Snap Ring

CARRIER

9. Remove "O" ring from output shaft of models that

Fig. 7A-48C--Removing Reaction C arrier and Roller Clutch use an "O" ring.
from O utpu t C arrier
10. Remove output shaft to output carrier snap ring
(Fig. 7A-50C).
11. Remove output shaft.
(Fig. 7A-48C). Lift roller clutch assembly out of carrier. 12. Remove output shaft to rear internal gear thrust
5. Remove front internal gear ring from output carrier bearing and two (2) races.
assembly. 13. Remove rear internal gear and mainshaft (Fig. 7A-
6. Remove sun gear (Fig. 7A-49C). 51C).
7. Remove reaction carrier to output carrier thrust
washer.
8. Turn assembly over and place main shaft through
hole in work bench. REAR INTER NAL GEAR

M AINSHAFT

Fig. 7A-49C--Removing Sun Gear Fig. 7A-5 1 C-Removin g Rear Internal Gear and M ainshaft
 A U T O M A T IC T R A N S M IS S IO N S (400)7A -15

SPEEDOMETER DRIVE
G E A R CL IP

IN T E R N A L G E A R

Fig. 7A -5 4 C ~ ln sta llin g Speedom eter Drive Gear Clip

SNAP R IN G
M A IN SHAFT

Fig. 7A -52C -R em oving Rear Internal Gear to Main Shaft

Snap Ring

NOTE: Do not drop bearings. Speedometer Drive Gear Replacement

If removal and installation or replacement of the
14. Remove rear internal gear to sun gear thrust speedometer drive gear is necessary, proceed as follows:
bearing and two (2) races.
Nylon Speedometer Drive Gear
15. If necessary, remove rear internal gear to mainshaft 1. Depress clip and slide speedometer drive gear off
snap ring, to remove mainshaft (Fig. 7A-52C). 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.
NOTE: 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,
NYLON
SPEEDOMETER
DRIVE G E A R discard the retaining clip and refer to Step "2" of steel
speedometer drive gear installation.
NOTE: 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

Fig. 7A-53C--Removing Nylon Speedom eter Drive Gear

(400)7A -16 A U T O M A T IC TRAN SM IS S IO NS

Fig. 7A-57C--Governor--Exploded

serviced as a complete assembly. However, the driven gear

Fig. 7A-55C--Rem oving Steel Speedom eter Drive 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
output shaft, and remove speedometer drive gear (fig. 7A- operation. In such cases, proceed as follows:
55C).
2. Install new steel speedometer drive gear and drive Disassembly
to location 5-21/32" below end of output shaft for all 1. Cut off one end of each governor weight pin and
models. (Fig. 7A-56C). remove pins, governor thrust cap, governor weights, and
GOVERNOR ASSEM BLY springs. Governor weights are interchangeable from side to
All components of governor assembly, with exception side and need not be identified. (Fig. 7A-57C).
of driven gear, are a select fit and each assembly is 2. Remove governor valve from governor sleeve. Be
calibrated. The governor, including the driven gear, is 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
IN STALLER galling.
3. Check governor sleeve for free operation in bore of
transmission case.
4. Inspect governor valve for nicks, burrs, scoring or
SP E E D O M E T E R
DR IV E G E A R
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. 7 A-56C~lnstalling Steel Sp eedometer Drive Gear

 A U T O M A T IC T R A N S M IS S IO N S (400)7A-17

Fig. 7A-60C ~R em oving G overnor Gear Retaining Pin

Fig. 7A-58C --C hecking Valve O pening W ith W eights O utw ard

10. Check valve operating at entry (.020" minimum) with care in the following manner:
with a feeler gage, holding governor as shown with governor 1. Drive out governor gear retaining split pin using
weights extended completely outward (Fig. 7A-58C). small punch (Fig. 7A-60C).
11. Check valve opening at exhaust (.020" minimum) 2. Support governor on 7/64 inch plates installed in
with a feeler gage, holding governor as shown with governor exhaust slots of governor sleeve, place in arbor press, and
weights completely inward (Fig. 7A-59C). with a long punch, press gear out of sleeve.
3. Carefully clean governor sleeve of chips that remain
Governor Driven Gear Replacement from original gear installation.
To facilitate governor repair in the field, a governor 4. Support governor on 7/64 inch plates installed in
driven gear and replacement pins are available for service exhaust slots of sleeve, position new gear in sleeve and, with
use. The service package contains a nylon driven gear, two a suitable socket, press gear into sleeve until nearly seated.
governor weight retaining pins and one governor gear Carefully remove any chips that may have shaved off gear
retainer split pin. Replacement of gear must be performed 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 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
Fig. 7 A-59C--Checking Valve Opening With W e ig h t Inward sleeve.
(4 0 0)7 A-18 A U T O M A T IC TRA N SM IS S IO N S

Fig. 7A -61C ~Front Servo A ssem bly-E xploded V iew

Front Servo Parts Inspection

Rear Servo Assembly

NOTE: See Fig. 7A-61C. Do not remove the teflon oil Disassembly
seal ring from the front servo piston unless the oil seal 1. Remove rear accumulator piston from rear servo
ring requires replacement. For service, the oil seal ring piston (Fig. 7A-62C-A).
is aluminum. 2. Remove "E" ring retaining rear servo piston to servo
1. Inspect servo pin for damage. pin (Fig. 7A-63C).
2. Inspect piston and oil ring for damage.
3. Check fit of servo pin in piston and case bore.
SERVO PISTON

E” R IN G
S E R VO P IS T O N

S E R V O P IN

ACCUMULATOR PISTON
Fig. 7A-62C--Removing Rear Accum ulator Piston from Rear Fig. 7A-63C--Removing Retaining "E" Ring from Rear Servo
Servo Piston Pin
 A U T O M A T IC T R A N S M IS S IO N S (400)7A-19

RETAIN IN G
“E” R IN G

SERVO PIS TON \

SERVO PIN

Fig. 7A-64C--Rear Servo and A ccum u la to r A ssem b ly-E xp lod ed V iew

3. Remove rear servo piston and seal from servo pin CONTROL VALVE, DISASSEM BLY,
(Fig. 7A-64C). (Exploded view.) INSPECTION A N D RE ASSEM BLY (Fig. 7A-67C)
4. Remove washer, spring, and spring retainer.
Disassembly
Inspection
1. Position control valve assembly with cored face up
NOTE: See Fig. 7A-64C. Do not remove the teflon oil
and accumulator pocket nearest operator.
seal rings from the rear accumulator piston, unless the 2. Remove manual valve from upper bore.
oil seal rings require replacement. If the teflon inner 3. Install Special Tools J-22269 and J-24675, on
oil seal ring (small diameter) requires replacement, for accumulator piston and remove retaining ring (Fig. 7A-
service, use the aluminum oil seal ring. 65C).
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.
1. 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
1. Install spring retainer cup side down, spring and ACCUMULATOR
washer on servo pin. PISTON
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.
Fig. 7 A-65C--lnstalling Compressor Tool to Front Accum ulator
Piston
(4 0 0 )7 A-20 A U T O M A T IC T R A N SM IS S IO N S

Inspection

NOTE: 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.
1. 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 and J-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 CC, 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
4. Remove front accumulator piston and spring (Fig. hammer until flush with cast surface of valve body.
7A-66C). b. (Models CB, CD, CJ, and CL) Install 1-2
5. On the right side adjacent to the manual valve, accumulator valve stem end out, into bore. Place bore plug
remove the 1-2 valve train as follows: 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
a. (Models CG, CJ and CP) Remove retaining pin, 1-2 surface of valve body.
modulator bushing, 1-2 valve spring, 1-2 modulator valve, c. (Models CA, CF, CG, CM and CT) Install the 1-2
and 1-2 shift valve. accumulator valve, stem end out, and 1-2 accumulator
secondary spring. Install the bore plug and compress spring
b. (All other models) Remove retaining pin, 1-2 until grooved retaining pin can be inserted from the cast
modulator bushing, 1-2 regulator valve, 1-2 regulator surface side of the valve body. Install retaining pin with the
spring, 1-2 detent valve and 1-2 shift valve. 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.
6. From next bore down, remove retaining pin, 2-3 shift Compress spring and secure with small screwdriver (Fig.
valve spring, 2-3 modulator valve bushing, 2-3 modulator 7A-68C).
valve, 3-2 intermediate spring, and 2-3 shift valve. 5. Install detent regulator valve, wide land first.
6. Install detent valve, narrow land first.
NOTE: Model CC does not use a 2-3 shift valve spring. 7. Install bore plug (hole out), depress spring by
7. From next bore down remove retaining pin, bore pressing in on plug, install retaining pin, and remove
plug, spring, spacer, and 3-2 valve. screwdriver.
8. At other end of assembly, top bore, remove retaining 8. In lower right hand bore, install 3-2 valve.
pin and bore plug, detent valve, detent regulator valve, 9. Install 3-2 spring, spacer, bore plug (hole out) and
spring and spacer. retaining pin.
9. From the next bore down, remove the 1-2 10. In next bore up, install the 2-3 shift valve, open end
accumulator valve train as follows: out, into the bore and install 3-2 intermediate spring.
a. (Model CP, CC, and CK) Remove the grooved 11. Install 2-3 modulator valve into bushing and install
retaining pin, bore plug, 1-2 accumulator valve and spring. both parts into valve body bore.
b. (Models CB, CD, CJ, and CL) Remove the grooved 12. Install 2-3 valve spring and retaining pin.
retaining pin, bore plug, 1-2 accumulator valve. NOTE: Model CC does not use a 2-3 shift valve spring.
c. (Models CA, CF, CG, CM and CT) Remove the 13. In next bore up, install 1-2 valve, stem end out.
grooved retaining pin, bore plug, 1-2 accumulator 14. Install parts as follows:
secondary spring and 1-2 accumulator valve.
 A U T O M A T IC TR A N S M IS S IO N S (40 0)7 A-21

r' 9a 10a
MODELS CJ, CP & CG

10 111 12 13

l-A U l -
22 23

|/
20 22 23
MODEL CC

114 15 29 16
1 MODELS CM, CT, CG, CF & CA
i— J
1. Manual Valve 9. 1-2 Detent Valve 15. Bore Plug 22. 2-3 Modulator
2. Retaining Pin 9a. 1-2 Modulator Valve 16. 1-2 Accumulator Bushing
3. Bore Plug 10. 1-2 Regulator Valve Valve 23. Retaining Pin
4. Detent Valve Spring 17. 1-2 Primary 24. 3-2 Valve
5. Detent Regulator 10a. 1-2 Mod. Valve Spring Accumulator Spring 25. Spacer
Valve 11. 1-2 Regulator Valve 18. 2-3 Shift Valve 26. 3-2 Valve Spring
6. Spacer 12. 1-2 Modulator 19. 3-2 Intermediate 27. Bore Plug
7. Detent Regulator Bushing Spring 28. Retaining Pin
Valve Spring 13. Retaining Pin 20. 2-3 Modulator Valve 29. 1-2 Accumulator
8. 1-2 Shift Valve 14. Retaining Pin 21. 2-3 Shift Valve Valve Sec. Spring
Spring

* LATER DESIGN

Fig. 7A -6 7 C -C o n tro l Valve A ssem bly-E xploded V ie w

a. (Models CG, CJ and CP) Install the 1-2 valve spring

and 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
retaining pin.
16. Install manual valve with detent pin groove to the
right.

Fig. 7A-68C--lnstalling Detent Regulator Valve and Detent

Valve
(4 0 0)7 A-22 A U T O M A T IC TRA N SM IS S IO N S

RETAINING
PIN

BORE PLUG

PUMP COVER

Fig. 7A -69C -R em oving Pump Regulator Valve Snap Ring

Fig. 7 A-7 1C -ln s ta llin g Pressure Regulator Retaining Pin and

Bore Plug
Oil Pump Disassembly, Inspection and
Assembly
Disassembly
1. Place oil pump assembly in hole in bench or holding 7. Remove pump cover from body.
fixture, J-6116 with J-21364 adapter.
2. Compress regulator boost valve bushing against 8. Remove retaining pin and bore plug from pressure
pressure regulator spring and remove snap ring, using J- regulator bore (Fig. 7A-71C).
5403 pliers (Fig. 7A-69C). 9. Remove hook type oil rings from pump cover.
3. Remove regulator boost valve bushing and valve. 10. Remove pump to forward clutch housing selective
4. Remove pressure regulator spring. washer.
5. Remove regulator valve, spring retainer and 11. Mark drive and driven gears for reassembly in same
spacer(s), if present (Fig. 7A-70C). position and remove from the pump body. See Fig. 7A-72C.
6. Remove pump cover to body attaching bolts.

PUMP DRIVE GEAR

(TANGS UP)

PUMP
PUMP DRIVEN
BODY GEAR

Fig. 7A-70C--Removing Pressure Regulator Valve Fig. 7 A -7 2 C -ln s ta llin g Pump Drive Gear
 A U T O M A T IC T R A N S M IS S IO N S (400)7A-23

VENT
CONVERTER

COOLER
RETURN
PUMP COVER

TO
COOLER

INTAKE
SEAL DRAIN
BACK HOLE
REVERSE
FOR IDENTIFICATION™
SQUARED OFF PRESSURE
REG. BOSS.
MODULATOR OR
INTERMEDIATE

Fig. 7A-73C--Pressure Regulator Valve Id e n tifica tio n

Fig. 7A-75C--Pum p Body Oil Passages

Inspection of Pump Body and Pump Cover 7. Check bushing for scores or nicks. If replacement
is necessary, proceed as follows:
NOTE: A solid type pressure regulator valve must only a. Using Tool J-21465-17 and driver Handle J-8092
be used in a pump cover with a squared off pressure remove bushing.
regulator boss. See Fig. 7A-73C. A pressure regulator b. From front side of pump, using J-21465-17 and
valve with oil holes and orifice cup plug may be used driver Handle J-8092 install new bushing flush to .010"
to service either type pump cover. below gear pocket face.
1. Inspect drive and driven gear pocket and crescent 8. Inspect pump attaching bolt seals for damage,
for scoring, galling or other damage. replace if necessary.
2. Place pump gears in pump body and check pump
body face to gear face clearance (should be .0008" - .0035") 9. Inspect pump cover face for overall flatness.
(Fig. 7A-74C). 10. Check for scores or chips in pressure regulator bore.
3. Check face of pump body for scores or nicks. 11. Check that all passages are open and not
4. Check oil passages (Fig. 7A-75C). interconnected (Fig. 7A-76C).
5. Check for damaged cover bolt attaching threads.
6. Check for overall flatness of pump body face.
DRIVE MODULATOR OR
INTERMEDIATE
REVERSE

EXHAUST

TO
COOLER

INTAKE
COOLER
RETURN

BREATHER
HOLE

LUBE

PRESSURE REGULATOR
FEED HOLE VENT COVER-PUMP

Fig. 7 A - 74 C ~ C h e c kin g Pump Body Face to Gear Face

Clearance Fig. 7 A - 7 6 C - P u m p Cover Oil Passages
(4 0 0 )7 A-24 A U T O M A T IC TR A N SM IS S IO N S

RETAINING PIN
BORE PLUG

PRESSURE REGULATOR VALVE-

PRESSURE REGULATOR SPACER

SPRING RETAINER W ASHER-i

PRESSURE REGULATOR SPRING PUMP COVER

PRESSURE BOOST VALVE THRUST WASHER

PRESSURE BOOST BUSHING PUMP OIL SEAL RINGS

SNAP RING

Fig. 7A-77C--Pump C over-Exploded V iew

12. Check for scoring or damage at pump gear face. 14. Inspect oil ring grooves for damage or wear.
13. Inspect stator shaft for damaged splines, or scored 15. Inspect selective washer thrust face for wear or
bushings. If replacement of bushing is necessary proceed as damage.
follows: 16. Inspect pressure regulator and boost valve for free
Front operation in their respective bores.
a. With pump cover and stator shaft properly 17. Inspect pump cover for open 1/8" breather hole
supported, using Tool J-21465-15, with slide hammer tool (Fig. 7A-76C).
J-2619, and adapter Tool J-2619-4 remove bushing. Assembly
b. Using Tool J-21465-3 with Driver Handle J-8092 1. Install drive and driven pump gears with alignment
press or drive replacement bushing into place until tool marks up into pump body (Fig. 7A-72C) drive gear tangs
bottoms. up.
Rear 2. Protect stator shaft and install pump cover in vise.
c. With pump and stator shaft properly supported, 3. Install spacer(s) if used, retainer and spring, into
using Tool J-21465-15, with slide hammer Tool J-2619 and pressure regulator bore (Fig. 7A-77C).
adapter tool J-2619-4, remove bushing. 4. Install pressure regulator valve from opposite end
d. Using Tool J-21465-2 with Driver Handle J-8092, of bore, stem end first.
pressor drive replacement bushing into place until tool 5. Install boost valve into bushing, stem end out, and
bottoms. install both parts into pump cover by compressing bushing
 A U T O M A T IC T R A N S M IS S IO N S (4 0 0)7 A-25

against spring.
6. Install retaining snap ring.
7. Install pressure regulator valve bore plug and
retaining pin into opposite end of 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).
NOTE: 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.
FO RW ARD CLUTCH DISASSEMBLY,
INSPECTION AND ASSEMBLY

NOTE: See Clutch Chart, Fig. 7A-79C, for details of

clutch components by specific model designations.
Fig. 7A-7 8C ~ A lign in g and Installin g Pump Cover to Pump
Body
(400)7A-26 A U T O M A T IC TR A N SM IS S IO N S

1978 CLUTCH APPLICATION CHART

400, 475 AND 425
Forward Clutch Direct Clutch Intermediate Clutch

Flat Steel No. of No. of No. of No. of No. of No. of No. of No. of No. of
Model plates waved dished composi­ flat waved composi­ flat waved composi­
steel steel tion steel steel tion steel steel tion
No. Thickness plates plates plates plates plates plates plates plates plates

BB, OB, OD,

AA, AB, AC, 3 .0775 1 0 4 4 0 4 2 1 3
AE, AH, AT

CM, CT, CJ,

CP, CG, CF. 4 .0775 1 0 5 5 0 5 2 1 3
CK

BC 3 .0775 1 0 4 5 0 5 2 1 3

AD, AL 4 .0915 1 0 5 4 1 5 2 1 3

AM 4 .0915 1 0 5 6 0 6 2 1 3

CC 4 .0775 1 0 5 3 1 4 2 1 3

CB 4 .0775 1 0 5 6 0 6 3 0 3*

CL, CD 5 .0915 0 0 5 6 0 6 3 0 3*

AJ, OJ 5 .0915 0 1 5 5 0 5 3 -0 3

AK 5 .0915 0 1 5 4 1 5 3 0 3

GM 5 .0915 0 1 5 5 1 6 3 0 3

JM, JR 3 .0775 1 0 4 4 1 5 2 1 3

JC, JS, JK 3 .0775 1 0 4 3 1 4 2 1 3

NOTE: For Service use only the 1978 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. 7 A-79C~Clutc h Chart, Component Details

 A U T O M A T IC TR A N S M IS S IO N S (400)7A-27

BOLT

TURBINE SHAFT

Fig. 7A-82C--Rem oving T urbine Shaft from Forward Clutch

Housing

Fig. 7 A-80C~Removing Forward Clutch Housing to Direct

Clutch Hub Snap Ring 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
Disassembly
1. Place forward clutch assembly with turbine shaft with Adapter J-21664, compress spring retainer and remove
through hole in bench or Holding Fixture J-6116, and snap ring (Fig. 7A-83C).
remove forward clutch housing to direct clutch hub snap 7. Remove spring retainer and sixteen (16) clutch
ring (Fig. 7A-80C). release springs.
2. Remove direct clutch hub.
3. Remove forward clutch hub and thrust washers (Fig. NOTE: Keep springs separate from direct clutch
7A-81C). release springs.
4. Remove composition, steel clutch plates, and waved 8. Remove forward clutch piston.
steel plate.
NOTE: Models CL and CS do not use a waved steel
plate.
FORWARD
CLUTCH HUB

THRUST
J- 46 70
WASHERS

FORWARD CLUTCH
H O U S IN G

Fig. 7 A-8 1 C--Removing Forward Clutch Hub and Thrust Fig. 7A-83C--Removing Forward Clutch Spring Retaining
Washers Snap Ring
(4 0 0)7 A-28 A U T O M A T IC TR A N SM IS S IO N S

5. Inspect clutch housing for wear, scoring, open oil

F O R W A R D C LU TC H P IS T O N
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.
NOTE: Turbine shaft and clutch housing are serviced
separately. Shaft may be removed from housing by
C LU TC H O U T E R SEAL using a suitable size socket in an arbor press (Fig. 7A-
82C).
Fig. 7 A -84C -R em oving Forward Clutch Piston O uter Seal
Assembly (Fig. 7A-86C)

NOTE: The Turbo Hydra-Matic forward and direct

9. Remove inner and outer clutch piston seals (Fig. clutch pistons have identical inside and outside
diameters. It is possible to reverse the pistons during
7A-84C). reassembly, therefore, care should be exercised to make
10. Remove center piston seal from forward clutch certain the proper piston be installed in the clutch
housing (Fig. 7A-85C). assemblies, as shown in Figure 7A-102C.
1. Place new inner and outer oil seals on clutch piston,
Inspection lips face away from spring pockets (Fig. 7A-84C).
1. Inspect composition-faced and steel clutch plates for 2. Place a new center seal on clutch housing, as shown
signs of burning, scoring or wear. in Fig. 7A-85C.
2. Inspect sixteen (16) springs for collapsed coils or
signs of distortion. NOTE: Apply automatic transmission oil to all seals
3. Inspect clutch hubs for worn splines, proper and clutch plates.
lubrication holes or scored thrust faces. 3. Place seal protector Tool J-21362, over clutch hub
4. Inspect piston for cracks. and install outer clutch piston seal Protector J-21409, into
clutch drum and 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
FORW ARD CLUTCH H O U S IN G 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 five (5) composition, and four (4) flat
steel and one (1) 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.
NOTE: Models CD and CL do not use a waved steel
clutch plate.
CLUTCH CENTER SEAL

Fig. 7A-85C--Removing Forward Clutch Center Seal

 A U T O M A T IC TR A N S M IS S IO N S (400)7A-29

FORW ARD CLUTCH

ASSEMBLY

FLAT STEEL FORW ARD DIRECT SNAP

PLATES (4) CLUTCH HUB CLUTCH HUB RING

W AVED
STEEL
PLATE

CO M PO SITIO N
PLATES (5) THRUST
W ASHERS

Fig. 7A-86C ~Forw ard Clutch A ssem bly-E xploded V ie w

CAUTION: Do not confuse the flat steel clutch

plate (plate with "V" notch) with the waved steel
clutch plate (plate with "U" notch).
NOTE: Radially grooved composition clutch plates are
installed at the factory only. All service composition CO M PO SITIO N
plates have the smooth surface configuration. PLATES

J-21362 STEEL PLATES

FORW ARD
CLUTCH
H O U SIN G

FO R W A R D
CLU TC H P IS T O N J -2 1 4 0 9

Fig. 7A-88C--lnstalling Forward Clutch Composition and Steel

Fig. 7A-87C--lnstalling Forward Clutch Piston Plates
(4 00)7A-30 A U T O M A T IC TRA N SM IS S IO N S

FORWARD CLUTCH ASSEMBLY

PUMP ASSEMBLY

Fig. 7A -89C --lnstalling Forw ard Clutch Housing to D irect Fig. 7 A -9 0 C -A ir C hecking Forw ard Clutch Assem bly
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-9 1 C -D ire c t Clutch and Intermediate Roller Assembly

 A U T O M A T IC TR A N S M IS S IO N S (400)7A-31

Fig. 7A-94C--Rem oving or Installin g Direct Clutch Snap Ring

4. Remove direct clutch backing plate, composition

Fig. 7 A-92C--Removing Interm ediate Clutch Retainer Snap
Ring plates, and steel clutch plates.
5. Using clutch compressor Tool J-4670 and J-21664,
11. Install direct clutch hub and retaining snap ring compress spring retainer in arbor press and remove snap
(Fig. 7A-89C). ring (Fig. 7A-94C).
12. Place forward clutch housing on pump delivery 6. Remove retainer and fourteen (14) piston release
sleeve and air check clutch operation (7A-90C). springs.
DIRECT CLUTCH AND INTERM EDIATE NOTE: Keep springs separate from forward clutch
ROLLER DISASSEM BLY, INSPECTION AND release springs.
ASSEMBLY 7. Remove direct clutch piston (Fig. 7A-95C).
8. Remove outer seal from piston.
NOTE: Refer to Fig. 7A-79C. 9. Remove inner seal from piston.
Disassembly (Fig. 7A-91C) 10. Remove center piston seal from direct clutch
1. Remove intermediate roller assembly retainer snap housing.
ring and retainer (Fig. 7A-92C). Inspection
2. Remove roller outer race and roller assembly. 1. Inspect roller assembly for popped or loose rollers.
3. Turn unit over and remove backing plate to direct 2. Inspect inner cam and outer race for scratches or
clutch housing snap ring (Fig. 7A-93C). wear.
DIRECT CLUTCH B A C K IN G PLATE
DIRECT CLUTCH
PISTON ASSEMBLY

DIRECT CLUTCH
X DIRECT
CLUTCH
H O U S IN G HOUSING
Fig. 7 A - 9 3 C - R e m o v in g Direct Clutch Backing Plate Snap Fig. 7A-95C--Removing Direct Clutch Piston Assembly
Ring
(4 0 0)7 A-32 A U T O M A T IC TR A N SM IS S IO N S

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.
NOTE: The 14 direct clutch release springs are not
serviced. If one or more of these springs require
replacement, discard all of them and install the 16
service direct clutch release springs.
8. Inspect housing for free operation of check ball.

Assembly

NOTE: The Turbo Hydra-Matic 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. 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). CLUTCH OUTER SEAL
3. Install a new center seal on clutch housing with lip
of seal facing up (Fig. 7A-98C). Fig. 7 A -9 7C ~ lnstalling D irect Clutch Outer Seal

NOTE: Apply automatic transmission oil to all seals CAUTION: The direct clutch housing for models
and clutch plates before installation. CB, CD and CL use the 6 plate clutch assembly.
This housing can be identified by the elimination
o f the inside diameter chamfer on the clutch plate
end and/or a groove in the face at the base o f the
CLUTCH INNER SEAL

CLUTCH
CENTER SEAL

Fig. 7A-96C--lnstalling Direct Clutch Inner Seal Fig. 7A-98C--lnstalling Direct Clutch Center Seal
 A U T O M A T IC T R A N S M IS S IO N S (400)7A-33

CHAMFER FOR
IDENTIFICATION

J- 2 1 3 62

DIRECT CLUTCH HOUSING DIRECT CLUTCH HOUSING J-21409

FOR 4 OR 5 PLATE PACK FOR 6 PLATE CLUTCH PACK

Fig. 7 A -9 9 C -D ire ct Clutch Housing Ide n tifica tio n

Fig. 7 A -1 0 1 C -ln s ta llin g Direct Clutch Piston

tower (Fig. 7A-99C). Should replacement o f the

direct 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). I f 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
AN D /O R THE PISTON M UST CONTAIN A BLIND HOLES

CHECK BALL(S). DIRECT CLUTCH FORWARD CLUTCH

4. Place seal protectors, Tools J-21362 Inner, J-21409
Outer, over hub and clutch housing and install clutch Fig. 7A -102C --Forw ard and D irect Clutch Piston Id e n tific a tio n

piston, with a rotating motion (Fig. 7A-101C).

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 CC, start with one (1) waved steel plate,

CHECK BALL

DIRECT
CLUTCH
HOUSING
DIRECT CLUTCH
HOUSING

(5) COMPOSITION PLATES

(4) FLAT STEEL PLATES
DIRECT CLUTCH BACKING PLATE
SNAP RING

Fig. 7A-1 OO C-Direct Clutch Housing with Check Ball Fig. 7 A - 10 3 C - D i r e c t Clutch Assembly Exploded
(4 0 0 )7 A-34 A U T O M A T IC TR A N SM IS S IO N S

INTERMEDIATE CLUTCH
ROLLER ASSEMBLY

DIRECT CLUTCH
BACKING PLATE

FLAT STEEL PLATES

C O M PO SITIO N PLATES
W AVED STEEL PLATE

DIRECT CLUTCH H O U SIN G

Fig. 7A -1 04 C —Install D irect Clutch Backing Plate,
A N D C AM ASSEMBLY
C om position Plates, and Steel Plates

Fig. 7 A -1 0 6 C -!n s ta llin g Interm ediate Clutch Roller Assem bly

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) NOTE: Install rollers that may have come out of the
composition and six (6) flat steel plates, starting with a flat roller cage by compressing the energizing spring with
steel plate and alternating composition and flat steel clutch forefinger and inserting the roller from the outer side.
plates.
11. Turn unit over and install the intermediate clutch
NOTE: Do not use radial grooved composition plates roller assembly onto the intermediate clutch inner cam (fig.
here. 7A-106C).
9. Install clutch backing plate. 12. Install the intermediate clutch outer race with a
10. Install backing plate retaining snap ring (Fig. 7A- clockwise turning motion (fig. 7A-107C).
105C). NOTE: Intermediate roller clutch is not released for
the CB, CD and CL models. The sprag assembly is
released for these models.
Outer race should not turn counter-clockwise
after installation. (See Figure 7A-108C).

INTERMEDIATE CLUTCH
OUTER RACE

ROLLER
ASSEMBLY
INTERMEDIATE
CLUTCH

DIRECT CLUTCH
HOUSING

Fig. 7 A - 1 0 5 C - ln s t a llin g Direct Clutch Housing to Backing Fig. 7 A - 1 0 7 C - l n s t a l li n g Interm ediate Clutch Outer Race to
Plate Snap Ring Direct Clutch
 A U T O M A T IC TR A N S M IS S IO N S (4 0 0)7 A-35

Fig. 7A-1 10C —Installin g Interm ediate Clutch Retainer Snap

Ring

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).
NOTE: If air is applied through reverse passage, (right
oil feed hole) it will escape from direct clutch passage
(left oil feed hole). This is considered normal. Apply
air through left oil feed hole to actuate piston and move
direct clutch plates.
DISASSEMBLY, INSPECTION AND RE­
ASSEM BLY OF CENTER SUPPORT
Fig. 7A-1 1 1 C -A ir Checking Direct Clutch A ssem bly
Disassembly
1. Remove four (4) oil seal rings from the center
support (Fig. 7A-112C). TEFLON OIL SEAL R IN G S

CENTER SUPPORT

Fig. 7 A - 109C--lnstalling Interm ediate Clutch Retainer Fig. 7A-1 1 2 C -C e n t e r Su pport and Oil Seal Rings
(400)7A-36 A U T O M A T IC TRA N SM IS S IO N S

IN T E R M E D IA T E CLU TC H
RELEASE S P R IN G (3 )

Fig. 7 A -1 13C -R em oving Interm ediate Clutch Piston Snap Fig. 7A-1 15C -R em oving C lutch Release Springs
Ring

2. Compress spring retainer and remove snap ring (7A- 5. Remove intermediate clutch piston (Fig. 7A-117C).
113C). 6. Remove inner and outer piston seal.
3. Remove spring retainer (Fig. 7A-114C) and three (3)
clutch release springs (Fig. 7A-115C). CAUTION: Do not remove three (3) screws
4. Remove intermediate clutch spring guide (Fig. 7A- retaining roller clutch inner race to center support.
116C).

SP R IN G
RETAINER- INTERMEDIATE CLUTCH
SPRING GUIDE

Fig. 7 A - 1 1 4 C -R e m o vin g Spring Retainer Fig. 7A-1 1 6 C-R em ov in g Interm ediate Clutch Spring Guide
 A U T O M A T IC T R A N S M IS S IO N S (400)7A-37

INTERMEDIATE
PIS T O N

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.
7A-47C).
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.
NOTE: All service center support oil seal rings are
hook type cast iron.
4. Air check oil passages to be sure they are not inter­
CENTER SUPPORT
& RACE ASSEMBLY connected.
5. Inspect piston sealing surfaces for scratches.
Fig. 7A-1 17C~Removing Interm ediate Clutch Piston
6. Inspect piston seal grooves for nicks or other
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
I
INTERMEDIATE CLUTCH
INNER SEAL

INTERMEDIATE CLUTCH
RELEASE SPRINGS
THRUST WASHER

SUPPORT TO
TEFLON OIL CASE SPACER
SEAL RINGS X
INTERMEDIATE CLUTCH
OUTER SEAL
INTERMEDIATE
CLUTCH PISTON
\
INTERMEDIATE CLUTCH INTERMEDIATE CLUTCH
SPRING RETAINER SPRING GUIDE

Fig. 7A-1 18C--Center Support Assembly-E xploded V ie w

(4 0 0)7 A-38 A U T O M A T IC TRA N SM IS S IO N S

CLUTCH J -2 1 3 6 3
PISTON

CENTER
PPORT

Fig. 7A-1 2 1C—Installin g Interm ediate Clutch Piston

Fig. 7A-1 19C—Installing Interm ediate Clutch Inner Seal

2. Install inner seal protector, Tool J-21363, on center

Assembly support hub, install piston, indexing spring pockets of piston
1. Lubricate and install new inner and outer seals on into cored areas of the center support (Fig. 7A-121C).
piston with lip of seal facing away from spring pocket (Fig. 3. Install intermediate clutch spring guide (Fig. 7A-
7A-119C and 7A-120C). 122C).

INTERMEDIATE CLUTCH
SPRINQ GUIDE

CLUTCH OUTER SEAL

Fig. 7A-1 20C--lnstalling Interm ediate Clutch Outer Seal Fig. 7A-1 22C--lnstalling Interm ediate Clutch Spring Guide
 A U T O M A T IC T R A N S M IS S IO N S (4 0 0)7 A-39

IN T E R M E D IA T E CLUTCH
RELEASE S P R IN G (3 )

Fig. 7A-1 2 5 C -T e flo n Rings

Fig. 7 A - 123 C —Installing Interm ediate Clutch Release Springs

6. Compress springs and install snap ring (Fig. 7A-
124C).
7. Install four (4) oil seal rings on the center support.
4. Install three (3) release springs into holes of spring
guide. Space equally during assembly (Fig. 7A-123C). NOTE: When installing teflon oil seal rings, make sure
5. Place spring retainer and snap ring over springs. 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. 7 A - 1 2 4 C -ln s ta llin g Interm ediate Clutch Piston Snap Ring Fig. 7 A - 1 2 6 C ~ A i r Checking Interm ediate Clutch Piston
(4 0 0 )7 A-40 A U T O M A T IC TR A N SM IS S IO N S

NOTE: The reaction carrier with the undercut and

SPACER
REACTION
CARRIER
spacer ring is used optionally and interchangeably with
RING
the reaction carrier 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
or 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.
Fig. 7A -1 27 C ~ lnsp ectin g Spacer Ring 10. Inspect front internal gear (output carrier) for
damaged teeth.
11. Inspect output carrier pinions for damage, rough
Inspection of Reaction Carrier, Roller Clutch,
bearings or excessive tilt.
and Output Carrier Assembly 12. Check pinion end play. Pinion end play should be
1. If the reaction carrier has a spacer ring in an .009 "-.024" (Fig. 7A-129C).
undercut at the bottom of the roller cam ramps, inspect it 13. Inspect parking pawl lugs for cracks or damage.
for damage (Fig. 7A-127C). 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 a 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, thrust washers and roller needle
bearing.
Fig. 7A-1 28C--Checking Pinions End Play 5. Inspect pinion pocket thrust faces for burrs and
remove if present.
6. Install eighteen (18) needle bearings into each pinion

Fig. 7A-1 29C--Checking Output Carrier Pinion End Play Fig. 7A-130C--Rem oving Planet Pinion Pin
 A U T O M A T IC TR A N S M IS S IO N S (4 0 0)7 A-41

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.

O UTPUT SHAFT, REAR INTERNAL GEAR, SUN Replace

Using Tool J-21465-5 with Driver Handle J-8092 press
GEAR AND SHAFT
or drive replacement bushing into place until tool bottoms.
Output Shaft INSPECTION OF M A IN SHAFT
1. Inspect bushing for wear or galling. If replacement 1. Inspect shaft for cracks or distortion.
is necessary, proceed as follows: 2. Inspect splines for damage.
a. Thread Tool J-21465-16 into bushing and using Slide 3. Inspect ground bushing journals for damage.
Hammer J-2619, remove bushing. 4. Inspect snap ring groove for damage.
b. Using Tool J-21465-1 with drive handle J-8092, 5. Make sure that lubrication holes are open.
install bushing into place until tool bottoms.
2. Inspect bearing and thrust washer surfaces for NOTE: If replacement of mainshaft is required, make
damage. sure that the orifice cup plug in the service mainshaft
3. Inspect governor drive gear for rough or damaged is removed.
teeth. INSPECTION OF FRONT AND REAR BANDS,
4. Inspect splines for damage. SUPPORT TO CASE SPACER
5. Inspect drive lugs for damage. 1. Inspect lining for cracks, flaking, burning, or
6. Inspect speedometer drive gear. looseness.
2. Inspect bands for cracks or distortion.
Inspection of Rear Internal Gear 3. Inspect end for damage at anchor lugs or apply lugs.
1. Inspect gear teeth for damage or wear. 4. Inspect support to case spacer for burrs or raised
2. Inspect splines for damage. edges, if present remove with stone or fine abrasive.
3. Inspect gear for cracks. INSPECTION OF CASE EXTENSION - ALL
EXCEPT CL MODEL
Inspection of Sun Gear 1. Inspect bushing for excessive wear or damage. If
1. Inspect gear teeth for damage or wear. replacement is necessary, remove rear seal and with
2. Inspect splines for damage.
3. Be sure oil lubrication hole is open.
Inspection of Sun Gear Shaft PLANET PINION PIN
HEAD END UP
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.
Fig. 7A-132C--ln sta lling Planet Pinion Pin
(4 0 0)7 A-42 A U T O M A T IC TRAN SM IS S IO NS

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
BALL B EARINGS
REAR OIL
seal, and install oil seal into case extension using tool (J-
SEAL
24057) (see Fig. 7A-171C).
I 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.
0
c. Remove ball bearings and bearing spacer, using a
brass rod on the outside race of bearing. An arbor press can
I be used if tool to press bearing out is located on outer race
SNAP
R IN G
BEARING
SPACER CASE E X T E N S IO N
of bearing.
CAUTION: DO NO T locate against inner race or
balls.
d. Install ball bearing assembly and spacer, bearing
first.
e. Install ball bearing assembly and snap ring.
Fig. 7A-1 33C~M odel CL Case Extension

f. Install new rear oil seal.

extension housing properly supported, remove bushing as
follows: INSPECTION OF M O DULATO R AND VALVE
1. Inspect modulator assembly for any sign ; of bending
a. With rear seal removed, position case extension on or distortion (Fig. 7A-134C).
bench, with seal end up. Assemble remover J-21465-17 on 2. Inspect "O" ring seal seat for damage.
handle J-8092, and drive out bushing with lead or brass 3. Apply suction to vacuum tube and check for
hammer. diaphragm leaks.
b. Using tool J-21465-17, with Driver Handle J-8092, 4. Check modulator bellows as outlined i n Section 7
drive or press replacement bushing into place, flush to .010 of Service Manual (modulator plunger is unde r pressure -
below oil seal counter bore area. Stake bushing, using tool 16 lbs.). If bellows is damaged plunger will ha\ e very little
J-21465-10. Stake marks to be in bushing lubrication pressure.
grooves.
2. Inspect gasket mounting face for damage. 5. Inspect modulator valve for nicks or d mage.
3. Inspect housing for cracks or porosity. 6. Check freeness of valve operation in cs >e bore.
4. Be sure rear seal drain back port is not obstructed. INSPECTION OF M A N U A L AND PARKING
INSPECTION OF CASE EXTENSIO N- LINKAGE
1. Inspect parking actuator rod for crack:, or broken
CL MODEL (FIG. 7A -133C )
spring retainer lugs (Fig. 7A-135C).
1. Inspect seal (case extension to case) groove for 2. Inspect actuator spring for damage.
damage. 3. Inspect actuator for free fit on actuatoi rod.
2. Inspect for cracks, or porosity. 4. Inspect parking pawl for cracks or wea r.
3. Inspect dowel pin in rear face for damage. 5. Inspect manual shaft for damaged threat s, rough oil
surface or loose lever.
6. Inspect inside detent lever for cracks or a loose pin.
7. Inspect parking pawl 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.
MODULATOR VALVE
10. Inspect detent roller and spring assembly.
INSPECTION OF CASE ASSEM BLY (FIGS. 7A-
136C AND 7A-137C)
MODULATOR ASSEMBLY
OIL RING CAUTION: I f the case assembly requires
replacement, make sure the center support-to-case
spacer is removed from the old case and reinstalled
Fig. 7A-1 3 4 C ~ M o d u la to r Assembly and Valve
in the new case.
 A U T O M A T IC TR A N S M IS S IO N S (400)7A-43

RETAINING
PIN INSIDE DETENT
LEVER ASSEMBLY

LOCK NU
PARKING LOCK
BRACKET

PARKING LOCK
ACTUATOR ASSEMBLY
PARKING
LOCK MANUAL
PAWL SHAFT

PARKING LOCK SPRING RETAINER

PARKING LOCK PAWL

RETURN SPRING

Fig. 7A-135C --M anual and Parking Linkage-E xploded V ie w

DRIVE lETENT
EXHAUST
REVERSE INTERMEDIATE
LINE N DRIVE MODULATOR
REVERSE, OR INTERMEDIATE

TO COOLER IMODULATOR
■■O R ■ C *
INTERMEDIATE •ggf

INTERMEDIATE
lODULATOR jCLUTCH
PUMP
INTAKE
-OVERNOR
COOLER "ACCUMULATOR
RETURN
(INTERMEDIATE
CLUTCH
INTERMEDIATE CLUTCH VENT
CUP PLUG

SERVO DIRECT
CLUTCH

Fig. 7A-1 3 7 C -ln s p e c t T ransm ission Case

Fig. 7A-136C--Case-Front V i e w Passage Identification

(4 0 0 )7 A-44 A U T O M A T IC TR A N SM IS S IO N S

NOTE: 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
facing front of transmission case, drive replacement bushing
Fig. 7A -138C --A ir Checking Converter
into case until .040 to .055 above selective washer face. Stake
1. Inspect case assembly for cracks, porosity or inter­ bushing with tool J-21465-10. Stake marks to be in bushing
connected passages. lubrication grooves.
2. Check for good retention of band anchor pins. INSPECTION OF CONVERTER
3. Inspect all threaded holes for thread damage. 1. Check converter for leaks as follows (Fig. 7A-138C):
4. On model CL inspect studs for thread damage, and a. Install Tool J-21369 and tighten.
make sure they are tight. b. Apply 80 psi air pressure to tool.
c. Submerge in water and check for leaks.
NOTE: The two (2) studs at 9 o’clock and 11 o’clock 2. Check converter hub surfaces for signs of scoring or
(when viewed from the rear of case and transmission wear.
in vehicle) are approximately 1/4" longer than the
other four (4) studs. These two longer studs are Converter End Clearance Check (Figs. 7A-139C
required to accommodate the parking brake actuating and 7A-140C)
cable bracket. 1. Fully release collet end of Tool J-21371 -8.
5. Inspect intermediate clutch driven plate lugs for 2. Install collet end of Tool J-21371-8 into converter
damage or brinneling.

J - 2 1 3 71 -3

Fig. 7 A - 1 3 9 C - L o o s e n i n g Collet on Tool J - 2 1 5 7 1 - 8 Fig. 7 A -140C--Checking Converter End Clearance

 A U T O M A T IC T R A N S M IS S IO N S (400)7A-45

SNAP
RING
SPEEDOMETER
DRIVE GEAR
FLANGED
THRUST
WASHER
I.D. FLANGE O.D. FLANGE (METAL)
RACE RACE
REAR BEARING
INTERNAL
GEAR O-RING

O.D. FLANGE
RACE
I.D. FLANGE
RACE
SNAP RING

MAIN SHAFT

OUT PUT
BEARING CARRIER
I.D. FLANGE ASSEMBLY
RACE
BEARING THRUST WASHER
(N O N -M E T A L )

FRONT INTERNAL
__ ON GEAR RING
ROLLER CARRIER
SUN GEAR ASSEMBLY ASSEMBLY

SUN GEAR
I.D. FLANGE SHAFT
RACE

Fig. 7A -141C ~G ear U nit A ssem bly-E xploded V iew

hub until it bottoms; then tighten cap nut to 5 lb. ft. (Fig. INTERNAL GEAR
7A-139C).
3. Install Tool J-21371-3 and tighten hex nut to 3 lb.
ft. (Fig. 7A-HOC).
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.
ASSEM BLY OF REAR UNIT (FIG 7A-141C)
1. Install rear internal gear on end of main shaft. SNAP RING
2. Install rear internal gear retaining snap ring (Fig. M AIN SHAFT
7A-142C).
3. Install sun gear to internal gear thrust races and
bearings against inner face of rear internal gear as follows,
and retain with petrolatum.
Fig. 7A-1 4 2 C -ln s ta llin g Rear Internal Gear Snap Ring
(4 0 0 )7 A-46 A U T O M A T IC TR A N SM IS S IO N S

O .D . FLA N G E D RACE

I.D . FLA N G E D RACE

THRUST BEARING

Fig. 7A-1 4 3 C ~ ln sta lling 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. Fig. 7 A -1 4 5 C -ln s ta llin g O utput Shaft

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 a. Place small diameter race against internal gear with
and bearings as follows and retain with petrolatum (Fig. center flange facing up.
7A-144C). 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
FLANGED RAC E
(Fig. 7A-145C).
8. Install output shaft to output carrier snap ring.
9. Install "O" ring on output shaft of models that use
an "O" ring.
TH R U S T
B E A R IN G
NOTE: Models CA, CB, CD, CF and CG do not use
an output shaft "O" ring.
I.D . F L A N G E D
RACE 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.
NOTE: 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.

Fig. 7A-1 4 4C--Installing Rear Internal Gear to Output Shaft

Bearing and Races
 A U T O M A T IC T R A N S M IS S IO N S (400)7A-47

G E A R R IN G

SUN GEAR
S H A FT

I.D . F L A N G E D
RACE
THRUST B E A R IN G

I.D . F L A N G E D
RACE

OUTPUT
CARRIER

Fig. 7A-1 46C --lnstalling Front Internal Gear Ring to O utput

Carrier

13. Install front internal gear ring over output carrier Fig. 7 A -14 8 C -ln s ta llin g Center Support to Sun Gear T hrust

(Fig. 7A-146C).
Bearing and Races

14. Install sun gear shaft with long splined end down. NOTE: When a new output carrier and/or reaction
15. Install reaction carrier (Fig. 7A-147C). 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-1 47 C -ln s ta llin g Reaction Carrier Fig. 7A-1 49C--lnstalling Roller into Roller Clutch Cage
(4 0 0 )7 A-48 A U T O M A T IC TR A N SM IS S IO N S

ROLLER CLUTCH
ASSEMBLY

Fig. 7A-1 50C --lnstalling Roller Clutch to Reaction C arrier

21. Install J-21795 on gear unit assembly to hold units Fig. 7A-1 52C--Checking Roller Clutch Rotation
in place.
22. Install output shaft to case thrust washer tabs in
pockets (Fig. 7A-152C), and retain with petrolatum.
NOTE: This must be a metal washer.
ASSEM BLY OF UNITS TO TR A N SM IS S IO N
CASE
NOTE: The first three steps can be omitted if the parts
involved were not removed on disassembly.
1. Install parking pawl tooth toward inside of case, and
parking pawl shaft (Fig. 7A-154C).
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 THRUST WASHER
(Fig. 7A-47C). (METAL)
20. Install center support into roller clutch in reaction
carrier (Fig. 7A-151C). Fig. 7A-1 5 3 C -ln s ta llin g Case to O utpu t Shaft T hrust W asher

NOTE: With reaction carrier held, center support

should only turn counter-clockwise after installation.
See Fig. 7A-152C for check of roller clutch.

Fig. 7A-1 5 1C—Installing Center Su pport to Reaction Carrier Fig. 7A-1 5 4 C -ln s ta llin g Parking Pawl Sh aft Cup Plug
 A U T O M A T IC T R A N S M IS S IO N S (4 0 0)7 A-49

CENTER SUPPORT i
TO CASE SPACER I
R E T A IN IN G
SPRING
# LOCATE SPACER G A P
| A D JA CEN T TO
1 B A N D A N C H O R PIN

SHAFT

Fig. 7A-1 55 C —Installing Parking S haft Retaining Spring

Fig. 7 A -15 7 C—InstaKing Center Support to Case Spacer

2. Install parking pawl shaft retainer clip (Fig. 7A-

155C).
3. Install parking pawl shaft cup plug and drive into 8. Install proper rear selective washer (proper washer
the case, using a 3/8 dia. rod, until the parking pawl shaft determined by previous end play check) into slots provided
bottoms on the case rib (Fig. 7A-154C). inside rear of transmission case.
4. Install parking pawl return spring, square end 9. Install complete gear unit assembly into case, using
hooked on pawl and other end on case. Tool J-21795 (Fig. 7A-158C).
5. Install parking bracket with guides over parking 10. Install center support to case retaining snap ring
pawl using two attaching bolts, torque to 18 ft. lbs. with bevel side up (flat surface against the center support)
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).
CAUTION: Do not confuse this spacer (.040"
thick and both sides flat) 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). J -9 5 3 9

-J -2 1 7 9 5

REAR
BAND

Fig. 7 A - 156C--lnstalling Rear Band Fig. 7A-1 58C--lnstalling Center Support and Gear Unit
(4 00)7A-50 A U T O M A T IC TRA N SM IS S IO N S

Fig. 7 A - 159C --lnstalling Center S up po rt 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 Fig. 7 A -1 6 1C—Installin g Interm ediate Backing Plate and

center support locating tool into the case direct clutch

Clutch Plates

passage, with the handle of the tool pointing to the right as

viewed from the front of the transmission and parallel to composition-faced intermediate clutch plates and install,
the bell housing mounting face. Apply pressure downward starting with flat steel and alternating composition-faced
on the tool handle which will tend to rotate the center and flat steel plates (Fig. 7A-161C).
support counterclockwise as viewed from the front of the
transmission. While holding the center support firmly, NOTE: The models CB, CD and CL intermediate
counterclockwise against the case splines, torque the case composition-faced plates are different from the other
to center support bolt to 20-25 ft. lbs., using a 3/8" 12-point models. Refer to parts catalog for correct usage.
thin wall deep socket (Fig. 7A-160C). 13. Install intermediate clutch backing plate, ridge up
(Fig. 7A-161C).
CAUTION: When using the locating tool, care 14. Install intermediate clutch backing plate to case
should be taken not to raise burrs on the case valve snap ring, locating gap opposite band anchor pin.
body mounting face.
12. Install intermediate clutch plates. NOTE: Both sides of this snap ring are flat, and it is
a. (All models except CB, CD and CL) Lubricate with .093" thick.
transmission oil two (2) flat steel and one (1) waved steel 15. Check rear end play as follows:
plates and three (3) composition-faced intermediate clutch a. Install a 3/8"-16 bolt or J-9539, into an extension
plates and install, starting with waved steel plate and housing attaching bolt hole (Fig. 7A-37C).
alternating composition-faced and flat steel plates (Fig. 7A- b. Mount a dial indicator on a rod and index with end
161C). of output shaft.
b. (Models CB, CD and CL) Lubricate with c. Move output shaft in and out to read end play. End
transmission oil three (3) flat steel and three (3) 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.
CENTER SUPPORT If a different washer thickness is required to bring end
LOCATING TOOL
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 .......................... 1
.082 - .086 1 Tab S id e ................... 2
.090 - .094 2 Tab S id e ................... 3
.098-.102 1 Tab O.D......................4
.106-.110 2 Tabs O.D.................... 5
.114-.118 3 Tabs O.D.................... 6

Fig. 7A-1 60C--lnstalling Center Support Bolt Fig. 7A-1 62C--Rear End W a s h e r Selection Chart
 A U T O M A T IC T R A N S M IS S IO N S (4 0 0)7 A-51

Fig. 7A -163C --lnstalling Front Band Fig. 7 A -16 5 C ~ ln sta llin g Detent Lever and Jam Nut to M anual
Shaft

16. Install front band with anchor hole placed over shaft. Rotate transmission to vertical position and remove
band anchor pin and apply lug facing servo hole (Fig. 7A- J-21795.
163C). 17. With converter end of transmission up, carefully
install direct clutch and intermediate roller assembly. It will
Install Manual Linkage
a. Install a new manual shaft seal into transmission case be necessary to shake and slightly twist housing to allow
using a 3/4 diameter rod to seat seal. roller outer race to index with composition plates. Housing
hub will bottom on sun gear shaft (Fig. 7A-166C).
b. If removed, insert actuator rod into manual detent
lever from side opposite pin. NOTE: First visually line up the intermediate clutch
c. Install actuator rod plunger under parking bracket drive lugs, one above the other to help engagement of
over parking pawl. housing hub splines. It also may be helpful to remove
d. Install manual shaft through case and detent lever the direct clutch plates while installing housing.
(Fig. 7A-164C). 18. Install forward clutch hub to direct clutch housing
e. Install detent jam nut on manual shaft, and tighten thrust washer on forward clutch hub, if not already
to 18 ft. lbs. (Fig. 7A-165C). installed. Retain with petrolatum.
f. Install retaining pin indexing with groove in manual 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-1 64C--lnstalling M anual Shaft to Case Fig. 7A-1 66C--lnstalling Direct Clutch Assembly
(4 0 0)7 A-52 A U TO M A TIC TRA N SM IS S IO N S

D IA L
IN D IC A T O R
J -8 0 0 1

Fig. 7A-1 67 C —Installing Forw ard Clutch Assem bly and Fig. 7 A - 16 9 C -C h e ckin g Front U nit End Play
Turbine S haft

seated it will be approximately 1-1/4" from pump face in a. Install a 3/8"-16 threaded bolt or a Slide Hammer
case (Fig. 7A-167C). Bolt J-9539 into bolt hole in pump.
NOTE: If turbine shaft cannot be rotated as pump is
b. Mount a dial indicator on rod and index indicator
being pulled into place, forward or direct clutch to register with end of turbine shaft.
housing have not been properly installed to index with c. Push turbine shaft rearward.
all clutch plates. This condition must be corrected d. Push output shaft forward.
before pump is pulled fully into place. e. Set dial indicator to zero.
21. Install all but one pump attaching bolts and seals. f. Pull turbine shaft forward.
Torque to 18 ft. lbs. (See Figure 7A-169C for location of Read resulting travel or end play which should be
omitted bolt.) .003 "-.024". Selective washer controlling this end play is
22. If necessary to install a new front seal, use a non­ located between pump cover and forward clutch housing.
hardening sealer on outside of seal body; and using Tool If more or less washer thickness is required to bring end play
J-21359, drive seal in place (Fig. 7A-168C). within specifications, select proper washer from the chart
23. Check front unit end play as follows (Fig. 7A- in Fig. 7A-170C.
169C).
NOTE: 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 ASSEM BLY
1. Install new case extension housing to case gasket on
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 - Brown
.104 - .108 - 4 - Green
.115 - .119 - 5 - Black
.126 - .130 - 6 - Purple

Fig. 7 A - 1 68C--lnstalling Pump Seal Fig. 7 A - 1 7 0 C - F r o n t End W a s h e r Selection Chart

 A U T O M A T IC TR A N S M IS S IO N S (4 0 0)7 A-53

SPACER PLATE

Fig. 7A-1 7 3 C -L o ca tio n of Check B a I Is—In V ehicle Installatio n

Fig. 7 A - 17 1C—Installing Extension Oil Seal (Typical)

Installation of Check Balls, Control Valve

2. Attach extension housing to case using attaching Spacer Plate and Gasket
bolts and/or studs. Torque bolts to 20-25 ft. lbs.
Detent Solenoid, Front Servo Assembly, and
NOTE: Models CA, CG and CR use two (2) studs at Electrical Connector
5 o’clock and 7 o’clock positions (when viewed from
the rear of case and transmission in vehicle). These 1. Install two control valve assembly attaching bolts
studs are for the installation of the catalytic converter. with heads cut off as guide pins as shown in figure 7A-183C.
Torque the studs to 20-25 ft. lbs. 2. Install six (6) check balls into ball seat pockets in
3. If necessary, install a new seal as follows: transmission case. Figure 7A-172C.
a. (All except CL Models) use a non-hardening sealer NOTE: If transmission is in the vehicle, install check
on outside of seal body; and using Tool J-21359, drive seal balls into ball seat pockets on spacer plate (Fig. 7A-
in place (Fig. 7A-171C). 173C).
b. (Model CL) use a non-hardening sealer on outside 3. Install control valve spacer plate-to-case gasket
of seal body; and using Tool J-24057 drive seal in place (Fig. (gasket with extension for detent solenoid and a "C" near
7A-171C). front servo location) (Fig. 7A-174C).

SPACER PLATE

GASKET

Fig. 7A-1 7 2 C -L o c a t io n of Check Balls Fig. 7A-1 7 4 C -ln s ta llin g C ontrol Valve Assem bly Spacer Plate
and Gasket
(400)7A-54 A U T O M A T IC TRAN SM IS S IO NS

Locate feeler stock

on edge of front servo , r 9
piston so front accumulator
oiston can enter bore
GASKET FRONT
SERVO
PISTON

SPACER
PLATE

FEELER
STOCK

Fig. 7A-1 77C--Front Servo G ro u p -ln Vehicle Installation

Fig. 7A-1 7 5 C -ln s ta llin g Detent Solenoid and Gasket

in the bore is a normal characteristic and does not

4. Install control valve spacer plate and control valve indicate leakage during operation. The teflon ring
to spacer plate gasket (gasket identified with a a "VB" near should only be replaced if it shows damage or if
front servo). evidence of leakage during operation exists.
5. Install detent solenoid gasket. If transmission is in the vehicle, assemble front
6. Install detent solenoid assembly with connector servo group as shown in figure 61T and install this
group of parts into front servo bore in case and hold.
facing outer edge of case (Fig. 7A-175C). Do not tighten Slip a length of straight, clean feeler gage or shim stock
bolts at this time. (about .020") between spacer plate and front servo
7. Install front servo spring and spring retainer into piston to temporarily retain front servo group. Figure
transmission case. 7A-177C.
8. Install retainer pins in front servo pin groove and 10. Install "O" ring seal on electrical connector.
install pin into case so that tapered end contacts band. Make 11. Lubricate and install electrical connector with lock
certain retainer ring is installed in servo pin groove. tabs facing into case, positioning locator tab in notch on side
9. Install seal ring on servo piston, if removed, and of case (Fig. 7A-178C).
install on servo pin with flat side of piston positioned toward 12. Install detent wire to electrical connector (Fig. 7A-
bottom pan. (Figure 7A-176C). 12C).
NOTE: The teflon ring allows the front servo piston
to slide very freely in the case. The free fit of the ring

SERVO PISTON

RETAINER R IN G

CASE CONNECTOR SLEEVE

k '''S E R V O PIN

SERVO S P R IN G SERVO PIS TO N

RETAINER SPRING

Fig. 7A-1 7 8 C —Installing Electrical Connector and "0" Ring

Fig. 7A-1 7 6 C —Installing Front Servo Piston, Washer, and Pin Seal
 A U T O M A T IC T R A N S M IS S IO N S (400)7A-55

REAR SERVO
TORQUE ASSEMBLY X
WRENCH

Fig. 7A-1 7 9 C -C h e ckin g Rear Band Pin Fig. 7A-1 8 1C—Installin g Rear Servo Assem bly

Installation of Rear Servo Assembly There are three selective pins identified as follows:
1. Check rear servo band apply pin. (Fig. 7A-179C). 1. If both steps are below the gage surface, the long pin,
a. Attach band apply pin selection Gage J-21370-6 and identified by 3 rings, should be used.
J-21370-5 to transmission case (lever pivot pin to rear) with 2. If the gage surface is between the steps, the medium
attaching screws. pin, identified by 2 rings, should be used.
Attach tool attaching screws finger tight and check 3. If both steps are above the gage surface, the short
freeness of selective pin. Torque attaching screws to 15 ft. pin, identified by 1 ring, should be used.
lbs. and recheck pin to make certain it does not bind. 2. Install rear accumulator spring into case (Fig. 7A-
b. Apply 25 ft. lb. torque and select proper servo pin 180C).
to be used from scale on tool. 3. Lubricate and install rear servo assembly into case
Selecting proper length pin is equivalent to adjusting (Fig. 7A-181C).
band. The band lug end of each selective apply pin bears 4. Install rear servo gasket and cover (Fig. 7A-182C).
identification in the form of one, two, or three rings. 5. Install attaching screws. Torque bolts to 15-20 ft. lbs.

REAR SERVO COVER

ACCUMULATOR
REAR
SERVO
GASKET

Fig. 7 A - 1 8 2 C -ln s ta llin g Rear Servo Cover and Gasket

(4 0 0 )7 A-56 A U T O M A T IC T R A N SM IS S IO N S

I DETENT ROLLER AND

G O V E R N O R SCREEN
ASSY.

G O V E R N O R FEED
PIPE HOLE

Fig. 7 A -183C --lnstalling G overnor Screen A ssem bly Fig. 7A-1 8 5 C -ln s ta llin g Detent Roller and Spring Assem bly

INSTALLATIO N OF CONTROL VALVE ihe center of the transmission). See Figure 7A-183C).
ASSEM BLY, GOVERNOR PIPES AND 3. Install control valve assembly and governor pipes on
GOVERNOR SCREEN ASSEM BLY transmission, while carefully aligning the governor feed pipe
1. Install governor pipes on control valve assembly. over the governor screen (Fig. 7A-184C). Make certain
Governor pipes are interchangeable. gasket and spacer do not become mispositioned.
2. Install governor screen assembly, open end first, into
governor feed pipe hole in case (hole nearest the center of NOTE: Check manual valve to make sure it is indexed
the transmission) (Fig. 7A-183C). properly with pin on detent lever and check governor
pipes to make certain they are properly seated in case
NOTE: If transmission is in vehicle, before installing holes.
the control valve assembly and governor pipes as 4. Start control valve assembly attaching bolts.
outlined in Step 3 below, insert the governor screen,
closed end first, into governor feed pipe. (This pipe NOTE: If transmission is in the vehicle, remove feeler
locates in the governor feed pipe hole in the case nearest 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 A N D INTAKE PIPE
1. Install case to intake pipe "O" ring seal on intake
pipe and assemble into filter assembly.
2. Install filter and intake pipe assembly (Fig. 7A-8C).
NOTE: It is recommended 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. lbs.

Fig. 7A-1 84C~ln sta lling Control Valve Assembly and

Governor Pipes
 A U T O M A T IC TR A N S M IS S IO N S (4 0 0)7 A-57

MODULATOR VALVE
NOTE: Models CB, CC and CK 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. lbs.
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. lbs.
INSTALLATIO N OF SPEEDOMETER DRIVEN
GEAR ASSEM BLY
1. Install speedometer driven gear assembly (Fig. 7A-
188C).
2. Install speedometer driven gear retainer and
VACUUM MODULATOR attaching bolt.
Fig. 7A-1 86C --lnstalling Vacuum M o d u la to r and Valve INSTALL CONVERTER ASSEMBLY
With the transmission in cradle or portable jack, install
the converter assembly into the pump assembly making
INSTALLATIO N OF M O DULATO R VALVE AND
certain that the converter hub drive slots are fully engaged
V A C U U M MODULATOR with the pump drive gear tangs and the converter installed
1. Install modulator valve into case, stem end out (Fig. fully towards the rear of the transmission.
7A-186C).
2. Install "O" ring seal on vacuum modulator. NOTE: The converter used in the CB, CD, CF, CL,
3. Install vacuum modulator into case. CM and CT models has six (6) mounting lugs.

SPEEDOMETER DRIVEN
GEAR ASSEMBLY

O" RING SEAL

Fig. 7A-1 8 7 C —Installing Governor Assembly

Fig. 7 A - 1 8 8 C -ln s ta llin g Sp eedometer Driven Gear and Sleeve

(400)7A-58 A U T O M A T IC TRAN SM IS S IO NS

SPECIFICATIONS
TURBO HYDRA-MATIC—375/400

TORQUE SPECIFICATIONS

Pump Cover Bolts............................................18 ft. lbs.

Parking Pawl Bracket B olts............................. 18 ft. lbs.
Center Support Bolt..........................................23 ft. lbs.
Pump to Case Attaching B olts.........................18 ft. lbs.
Extension Housing to Case Attaching Bolts . . 23 ft. lbs.
Rear Servo Cover Bolts.....................................18 ft. lbs.
Detent Solenoid Bolts....................................... 7 ft. lbs.
Control Valve Body Bolts................................ 8 ft. lbs.
Bottom Pan Attaching Screws.........................12 ft. lbs.
Modulator Retainer Bolt.................................. 18 ft. lbs.
Governor Cover Bolts .....................................18 ft. lbs.
Manual Lever to Manual Shaft N u t................. 8 ft. lbs.
Manual Shaft to Inside Detent Lever...............18 ft. lbs.
Linkage Swivel Clamp Nut................................43 ft. lbs.
Converter Dust Shield Screws...........................93 ft. lbs.
Transmission to Engine Mounting Bolts..........35 ft. lbs.
Converter to Flywheel B olts...........................32 ft. lbs.
Rear Mount to Transmission B o lts................. 40 ft. lbs.
Rear Mount to Crossmember B olt................. 40 ft. lbs.
Crossmember Mounting B olts.........................25 ft. lbs.
Line Pressure Take-Off Plug ...........................13 ft. lbs.
Strainer Retainer Bolt .....................................10 ft. lbs.
Oil Cooler Pipe Connectors to Transmission
Case............................................................ . 28 ft. lbs.
Oil Cooler Pipe to Connector.........................10 ft. lbs.
Gearshift Bracket to Frame............................. 15 ft. lbs.
Gearshift Shaft to Swivel.................................. 20 ft. lbs.
Manual Shaft to Bracket ................................20 ft. lbs.
Downshift Switch to Bracket........................ 30 in. lbs.
 A U T O M A T IC TR A N S M IS S IO N S (400)7A-59

SP EC IA L TOOLS

1. J-61 16-01 Rear Unit H olding Fixture 14. J - 2 1 7 9 5 -2 Part of Above Holding Tool
2. J -8 0 9 2 Driver Handle 15. J -5 3 8 4 Converter H olding Strap
3. J -2 1359 Pump Oil Seal Installer 16. J -2 1 4 6 5 -0 1 Bushing Tool Set
4. J -2 1364 Holding Fixture A d ap ter (Used 17. J - 2 1 4 6 5 -5 Part of Bushing Tool Set
w ith J-61 16-01 Fixture) 18. J - 2 1 4 6 5 -3 Part of Bushing Tool Set
5. J -2 6 1 9 Slide H am m er (Used w ith 19. J - 2 1 4 6 5 -2 Part of Bushing Tool Set
2 6 1 9 -4 A d ap ter 20. J - 2 1 4 6 5 -1 Part of Bushing Tool Set
and Remover Tools J -2 1 4 6 5 -0 1 ) 21. J - 2 1 4 6 5 -1 7 Part of Bushing Tool Set
6. J -5 1 5 4 Extension Oil Seal Installer 22. J - 2 1 4 6 5 -8 Part of Bushing Tool Set
7. J -6 5 8 5 Slide H am m er W eigh ts 23. J - 2 1 4 6 5 -1 3 Part of Bushing Tool Set
8. J -9 5 3 9 Slide Ham m er Bolts ( 3 / 8 " - 16 24. J - 2 1 4 6 5 -6 Part of Pushing Tool Set
Threads) 25. J - 2 1 4 6 5 -1 5 Part of Bushing Tool Set
9. J -5 5 9 0 Speedo Gear Installer 26. J-2 1 4 6 5 -1 6 Part of Bushing Tool Set
10. J -2 1867 Pressure G auge and Hose 27. J - 2 1 4 6 5 -9 Part of Bushing Tool Set
11. J - 2 1 3 7 0 -6 Rear Band A p ply Fixture 28. J -2 1 4 6 5 -1 0 Part of Bushing Tool Set
12. J - 2 1 3 7 0 -5 Rear Band A pply Pin 29. J -2 2 1 8 2 Ext. Bushing Rem. and Inst.
13. J-2 1 7 9 5 -1 Gear Unit Assem bly Holding (Not Illustrated)
Tool

Fig. 7 A - 1 S T - T H M 4 0 0 Special Tools

(4 0 0)7 A-60 A U T O M A T IC TRA N SM IS S IO N S

1. J-8763 Transmission Holding Fixture 11. J-21664 Clutch Spring Compressor

2. J-3289-14 Holding Fixture Base Adapter Ring
3. J-21427-1 Speedo Gear Remover 12. J-4670 Clutch Spring Compressor
4. J-9539 Side Hammer Bolts (3 /8 " - 16 13. J-8059 Snap Ring Pliers
Threads) 14. J-5586 Snap Ring Pliers
5. J-8105 Speedo Gear Remover Puller 15. J-5403 Snap Ring Pliers
6. J-22269-01 Accumulator Piston Remover and Installer 16. J-1313 Torque Wrench 0-140 Ft. Lbs.
7. J-21369 Converter Pressure Check Fixture Not 11lustrated
8. J-21362 Seal Protector - Forward and J-24684 Pressure Regulator
Direct Clutch - Inner Valve Compressor
9. J-21363 Seal Protector - Intermediate J-24675 Accumulator Piston Adapter
Clutch - Inner (Used with J-22269-01)
10. J-21409 Seal Protector - Forward Clutch - Outer

Fig. 7A-2S T--TH M 4 0 0 Special Tools

 M A N U A L TR A N S M IS S IO N 7B-1

SECTION 7B

M A N U A L T R A N S M IS S IO N
CONTENTS
3-Speed 76mm Transmission.........................................7B-1
3-Speed 77mm Transmission.........................................7B-9
4-Speed 76mm Transmission.........................................7B-17
4-Speed 83mm Transmission.........................................7B-25
4-Speed 117mm Transmission.......................................7B-34
Specifications................................................................. ..7B-46
Special Tools................................................................. ..7B-47

3-SPEED 76MM TRANSM ISSION

INDEX
Disassembly of Transmission........................................7B-1 Repairs..............................................................................7B-4
Disassembly of Mainshaft........................................... ..7B-1 Clutch Keys and Spring.......................................... ..7B-4
Cleaning and Inspection.............................................. ..7B-4 Extension Oil Seal or Bushing..................................7B-5
Transmission Case......................................................7B-4 Clutch Bearing Retainer Oil Seal..............................7B-5
Front and Rear Bearings...........................................7B-4 Assembly of Mainshaft...................................................7B-5
Bearing Rollers............................................................7B-4 Assembly of Transmission........................................... ..7B-6
Gears.............................................................................7B-4
Reverse Idler Gear Bushing......................................7B-4

DISASSEM BLY OF TR A N S M IS S IO N (FIG. 7B-1A) position within the countergear bore. Remove the gear,
bearings and thrust washers.
1. Remove side cover attaching bolts and side cover 10. Use a long drift or punch through the front bearing
assembly. case bore and drive the reverse idler shaft and woodruff key
2. Remove drive gear bearing retainer and gasket. through the rear of the case (Fig. 7B-6A).
3. Remove drive gear bearing-to-gear stem snap ring,
then remove clutch gear bearing by pulling outward on DISASSEM BLY OF M A IN S H A FT
clutch gear until a screwdriver or other suitable tool can be 1. Using snap ring pliers, remove the 2nd and 3rd speed
inserted between bearing large snap ring and case to sliding clutch hub snap ring from mainshaft and remove
complete removal (Fig. 7B-2A). The clutch gear bearing is clutch assembly, second speed blocker ring and second
a slip fit on the gear and into the case bore. (This provides speed gear from front of mainshaft. See Fig. 7B-7A.
clearance for removal of clutch gear and mainshaft 2. Depress speedometer retaining clip and slide or tap
assembly.) gear from mainshaft.
4. Remove speedometer driven gear from extension. 3. Remove rear bearing snap ring from mainshaft
5. Remove extension to case attaching bolts. groove. See Fig. 7B-8A.
6. Remove the reverse idler shaft "E" ring (Fig. 7B- 4. Support reverse gear with press plates and press on
3A). rear of mainshaft to remove reverse gear, thrust washer,
7. Remove drive gear, mainsahft and extension spring washer, rear bearing, and snap ring from rear of
assembly together through the rear case opening. Remove mainshaft. See Fig. 7B-9A.
drive gear, needle bearings and synchronizer ring from 5. Remove the 1st and Reverse sliding clutch hub snap
mainshaft assembly. ring from the mainshaft and remove the clutch assembly,
8. Using snap ring pliers, expand the snap ring in the 1st speed blocker ring and first speed gear from rear of the
extension which retains the mainshaft rear bearing (Fig. 7B- mainshaft.
4A) and remove the extension.
9. Using J-22246 at the front of the countershaft, drive NOTE: Under certain tolerance conditions, it may be
the shaft and its woodruff key out the rear of the case (Fig. necessary to press the synchronizer hub and gear from
7B-5A). Tool J-22246 will now hold the roller bearings in the mainshaft.
 7B-2
MANUAL TR A N SM IS S IO N
1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 18 19 20 21
Fig. 7B-1 A--3-Speed
76mm
Transmission Cross-Section

30 31 32 33 34 35 36 37 38 39

1. Clutch Gear 10. 1st Speed Gear 16. Snap Ring-Bearing 24 Clutch Gear Bearing 31. Magnet
2 Bearing Retainer 11. 1st Speed Blocker to Mainshaft 25 Snap Ring-Bearing 32 2-3 Synch. Sleeve
3 Pilot Bearings Ring 17. Extension to Case 33. Countergear
4 Case 12 1st Speed Synch. 18 Vent 26 Thrust W asher-Front 34 Counter Shaft
5. 3rd Speed Blocker Hub 19 Speedometer Drive 27. Thrust W asher-R ear 35 Reverse Idler Shaft
Ring 13. 1st Speed Synch. Gear and Clip 28 Snap Ring-Bearing 36 1st Speed Synch.
6. 2-3 Synch. Snap Ring Snap Ring 20 Mainshaft to Extension Sleeve
7. 2-3 Synch. Hub 14. Reverse Gear 21 Rear Oil Seal 29 Rear Bearing 37. ”E" Ring
8. 2nd Speed Blocker 15. Reverse Gear Thrust 22 Retainer Oil Seal 30 Countergear Roller 38. Reverse Idler Gear
Ring and Spring Washers 23 Snap Ring-Bearing Bearings 39 W oodruff Keys
9 2nd Speed Gear to Gear
 M A N U A L T R A N SM IS S IO N 7B-3

Fig. 7B-4A--Removing Rear Extension From Main Shaft Fig. 7 B -7 A -R e m o v in g 2nd-3rd Clutch Hub Retaining Ring
7B-4 M A N U A L TR A N SM IS S IO N

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
All clutch gear and counter gear bearing rollers should
be inspected closely and replaced if they show wear. Inspect
counter shaft and reverse idler shaft at the same time,
replace if necessary. Replace all worn washers.
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.
NOTE: Reverse gear bushing is not serviced
separately.
3. Check both clutch sleeves to see that they slide freely
on their hubs.
Fig. 7B-8A~Removing Rear Bearing Retaining Ring 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
CLEANING AND INSPECTION alignment of the bushing and shaft as well as proper
Transmission Case meshing of the gears. Because of the high degree of accuracy
1. Wash the transmission thoroughly inside and outside to which these parts are machined, the bushing is not
with cleaning solvent, then inspect the case for cracks. serviced separately.
2. Check the front and rear faces for burrs, and if REPAIRS
present, dress them off with a fine mill file. Clutch Keys and Springs
3. Check bearing bores in case and, if damaged, replace
case. Replacement
NOTE: The clutch hubs and sliding sleeves are a
Front and Rear Bearings selected assembly and should be kept together as
1. Wash the front and rear ball bearings thoroughly in originally assembled, but the keys and two springs may
a cleaning solvent. be replaced if worn or broken.
2. Blow out bearings with compressed air. 1. Mark hub and sleeve so that they can be matched
CAUTION: Do not allow the bearings to spin, upon reassembly.
turn them slowly by hand. Spinning bearings may 2. Push the hub from the sliding sleeve, the keys and
damage the race and balls. 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 synchronizer

S P R IN G
SLEEVE

Fig. 7B-9A--Removing Rear Bearing From Mainshaft Fig. 7B-1 OA--Synchronizer Assembly
 M A N U A L T R A N SM IS S IO N 7B-5

J-5778

Fig. 7B-1 1A-R em oving or Installin g Rear Extension Bushing Fig. 7B-1 3A -R em o ving Drive Gear Bearing Retainer Seal

spring should be installed into different key cavities on old seal out (Fig. 7B-13A) and replace with a new seal using
either side. Slide the sleeve onto the hub aligning the marks Installer Tool J-23096, or similar tool, until seal seats in its
made before disassembly. bore (Fig. 7B-14A).
NOTE: A groove around the outside of the
synchronizer hub identifies the end that must be ASSEM BLY OF M A IN S H A FT (FIG. 7B-15A)
opposite the fork slot in the sleeve when assembled. Turn the front of the mainshaft upward. Install the
This groove indicates the end of the hub with a greater following components of the mainshaft:
recess depth. 1. Install the second speed gear with clutching teeth
Extension Oil Seal or Bushing upward; the rear face of the gear will ubtt against the flange
If bushing in rear of extension requires replacement, on the mainshaft.
remove seal and use Tool J-5778 to drive bushing into 2. Install a blocking ring with clutching teeth
extension housing (Fig. 7B-11A). Using the same tool, drive downward over the synchronizing surface of the second
new bushing in from the rear. Coat I.D. of bushing and seal speed gear. All three blocker rings used in this transmission
with transmission lubricant, then install new oil seal using are identical.
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

J-21426

Fig. 7B-1 2A -ln s ta llin g Rear Extension Seal Fig. 7B-1 4 A—Installing Clutch Gear Bearing Retainer Seal
7B-6 M A N U A L TRAN SM IS S IO N

Drive Gear 2-3 Synchronizer 1st Speed Blocker Reverse Gear Thrust
Drive Gear Bearing Assembly Ring Washer
3rd Speed Blocker 2nd Speed blocker 1st Speed Spring W asher
Ring Ring Synchronizer Rear Bearing
M ainshaft Pilot 2nd Speed Gear Assembly Snap Ring
Bearings (14) Shoulder (Part of Snap Ring Speedo Drive Gear
Snap Ring Main Shaft) Reverse Gear and Clip
1st Speed Gear Mainshaft

Fig. 7 B -1 5A~Clutch Gear and M ainshaft Assem bly

3. Install the second and third synchronizer assembly 12. Install rear ball bearing with snap ring slot
with the fork slot downward; press it onto splines on the downward; press onto mainshaft.
mainshaft until it bottoms out. Both synchronizer 13. Install rear bearing to mainshaft snap ring.
assemblies used in this transmission are identical. (If sleeve 14. Install speedometer drive gear and retaining clip.
becomes removed from 2-3 hub; notches on hub O.D. face
forward end of mainshaft.) ASSEMBLY OF T R A N S M IS S IO N (FIG. 7B-18A)
1. Using Tool J-22246 load a row of roller bearings (27)
CAUTION: Be sure the notches o f the blocker ring and a bearing thrust washer at each end of the countergear.
align with the keys o f the synchronizer assembly. Use heavy grease to hold them in place (Fig. 7B-16A).
4. Install snap ring retaining synchronizer hub to 2. Place countergear assembly through case rear
mainshaft. Both synchronizer snap rings are identical. Turn opening along with a tanged thrust washer (tang away from
the rear of the mainshaft upward. Install the following gear) at each end and install countergear shaft and woodruff
components on the mainshaft: key from rear of case.
5. Install the first speed gear with clutching teeth CAUTION: Be sure countershaft picks up both
upward; the front face of the gear will butt against the flange thrust washers and that the tangs are aligned with
on the mainshaft. their notches in the case.
6. Install a blocker ring with clutching teeth downward 3. Install reverse idler gear and shaft with its woodruff
over synchronizing surface of the first speed gear. key from the rear of case. Do not install idler shaft "E" ring
7. Install the first and reverse synchronizer assembly yet.
with fork slot downward; push it onto splines on the 4. Using snap ring pliers, expand the snap ring in the
mainshaft. extension and assemble extension over rear of mainshaft and
8. Install synchronizer hub to mainshaft snap ring. onto rear bearing. Seat snap ring in rear bearing groove (Fig.
CAUTION: Be sure the notches o f the blocker ring 7B-4A).
align with the keys o f the synchronizer assembly. 5. Load the mainshaft pilot bearings (14) into the
9. Install reverse gear with clutching teeth downward. clutch gear cavity and assemble the 3rd speed blocker ring
10. Install reverse gear thrust washer (steel). onto the clutch gear clutching surface with its teeth toward
11. Install reverse gear spring washer. the gear.
 M A N U A L T R A N SM IS S IO N 7B-7

MAIN DRIVE GEAR

Fig. 7 B -1 7A--Loading Pilot Bearings

Fig. 7B-1 6A--Loading C ountergear

6. Pilot the clutch gear, pilot bearings and 3rd speed 10. Install snap ring to clutch gear stem, and clutch
blocker ring assembly over the front of the mainshaft gear bearing retainer and gasket to case.
assembly. Do not assemble bearing to gear yet. NOTE: The retainer oil return hole should be at the
CAUTION: Be sure the notches in the blocker ring bottom.
align with the keys in the 2-3 synchronizer 11. Install reverse idler gear retainer "E" ring to shaft.
assembly. 12. Shift synchronizer sleeves to neutral positions and
7. Place extension to case gasket at rear of case holding install cover, gasket and fork assembly to case. Be sure forks
in place with grease and, from the rear of case, assemble the align with their synchronizer sleeve grooves.
clutch gear, mainshaft and extension to case as an assembly. 13. Install speedometer driven gear in extension.
8. Install extension to caSe retaining bolts. 14. Tighten all bolts to specified torque.
9. Install front bearing outer snap ring to bearing and 15. Rotate clutch gear shaft and shift transmission to
position bearing over stem of clutch gear and into front case free rotation in all gears.
bore.
7B-8 M A N U A L TR A N SM IS S IO N

1. Snap R ing 24. Bearing Retainer Bolts and Washers (4) 46. Thrust Washer
2. Synchronizer Ring 25. Front Bearing Retainer 47. Countergear Shaft
3. 2 -3 Synchronizer Sleeve 26. Bearing Retainer Gasket 48. Countergear Shaft Key
4. Synchronizer Key Spring 27. Bearing Retainer Oil Seal 49. Idler Shaft Key
5. Synchronizer Hub and Keys 28. Snap Ring 50. Reverse Idler Shaft
6. Synchronizer Key Spring 29. Bearing Snap Ring 51. Snap Ring
7. Synchronizer Ring 30. Front Bearing 52. Reverse Idler Gear
8. Second Gear 31. Drive Gear 53. Side Cover Gasket
9. Main Shaft 32. P ilo t Bearings 54. 2 -3 S h ift Fork
10. First Gear 33. Case 55. 1 -R ev S h ift Fork
11. Synchronizer Ring 34. Extension to Case Gasket 56. 2 -3 S h ifte r Shaft
12. Synchronizer Key Spring 35. Rear Bearing to Extension Retaining Ring 57. Retaining " E " Ring
13. Synchronizer Hub and Keys 36. Rear Extension 58. 1-Rev S h ifte r Shaft w ith “ O " Ring
14. Synchronizer Key Spring 37. Extension to Case Retaining Bolts and Washers 59. 2 -3 Detent Cam
15. 1-2 Synchronizer Sleeve 38. Rear Extension Bushing 60. Detent Cam Spring
16. Snap Ring 39. Rear Seal 61. 1-Rev Detent Cam
17. Reverse Gear 40. Thrust Washer 62. S h ift Cover
18. Thrust Washer 41. Spacer 63. TCS Sw itch and Gasket
19. Waved Washer 42. Countergear Shaft Bearings 64. S hifter Shaft Seal
20. Rear Bearing 43. Countergear 65. S h ifter Shaft Seal
21. Snap Ring 44. Countergear Shaft Bearings 66. S h ift Cover Bolts and Washers
22. Speedometer Gear Clip 45. Spacer 67. Damper Assembly
23. Speedometer Drive Gear

Fig. 7 B-18A--3-S peed, 7 6 m m , Transmission Exploded V ie w

 M A N U A L T R A N SM IS S IO N 7B-9

3 SPEED 77MM TRANSM ISSION

INDEX
Overhaul Operations.....................................................7B-9 Repairs........................................................................ 7B-13
Transmission Disassembly.........................................7B-9 Synchronizer Keys and Spring............................. 7B-13
Mainshaft Disassembly............................................ ..7B-13 Extension Oil Seal or Bushing.............................. 7B-14
Cleaning and Inspection.......................................... ..7B-13 Clutch Bearing Retainer Oil Seal......................... 7B-14
Transmission Case................................................. ..7B-13 Mainshaft Assembly................................................... 7B-14
Front and Rear Bearings.........................................7B-13 Transmission Assembly.............................................. 7B-15
Roller Bearings..........................................................7B-13
Gears...........................................................................7B-13

T R A N S M IS S IO N DISASSEM BLY NOTE: With countershaft removed, allow countergear

1. Remove lower extension housing bolt and drain to lie at bottom of case.
transmission (Fig. 7B-3B). 8. Punch alignment mark in front bearing retainer and
2. Remove top cover and gasket from case. transmission case to ensure correct assembly and remove
3. Remove long spring that retains the detent plug in front bearing retainer and gasket (Fig. 7B-6B).
the case (Fig. 7B-4B). Remove the detent plug with a small 9. Remove large locating snap ring from front bearing
magnet. and smaller snap ring from clutch gear shaft.
4. Remove extension housing and gasket. 10. Remove clutch shaft front bearing using tool J-
5. Press down on speedometer gear retainer and remove 6654-01 and tool J-8433-1 (Fig. 7B-7B).
speedometer drive gear and retainer from output shaft. NOTE: It may be necessary to alternate the tightening
6. Remove fill plug from right side of case (Fig. 7B-3B). of the bolts between tools J-6654-01 and J-8433-1 to
Working through the plug opening drive out countergear remove the front bearing.
roll pin with a 3/16 inch pin punch that has been chamfered 11. Remove large locating snap ring from rear bearing
slightly. and smaller retaining snap ring from output shaft.
NOTE: It may be necessary to place a screwdriver or
NOTE: Do not attempt to retrieve pin at this time. Pin
can easily be retrieved after output shaft assembly is a piece of bar stock between the case and the first-
removed. reverse sleeve and gear assembly. This will hold the
7. Insert dummy shaft tool J-25232 into bore at front output shaft assembly in place while removing the rear
of case, tap lightly on tool to push countershaft out rear of bearing.
case (Fig. 7B-5B). 12. Remove rear bearing from output shaft using tool
J-8157-01 (Fig. 7B-8B).

Fig. 7B-1 B -3 -S p e e d 7 7 m m Transmission

7B-10 M A N U A L TR A N SM IS S IO N

1. M AINSHAFT ROLLER BEARINGS 35. EXTENSION HOUSING TO CASE GASKET

2. 2ND & 3RD SYNCHRONIZER RETA IN IN G RING 36. SPEEDOMETER D R IVER GEAR RETA ININ G CLIP
3. SYNCHRONIZER BLOCKER RINGS 37. TRANSMISSION REAR BEARING LOCK RING
4. 2ND & 3RD SYNCHRONIZER SPRING 38. M AINSHAFT BEARING ASSEMBLY
5. 2ND & 3RD SYNCHRONIZER SLEEVE 39. SPEEDOMETER D R IVE GEAR
6. 2ND & 3RD SYNCHRONIZER KEYS 40. EXTENSION TO CASE WASHER
7. 2ND & 3RD SYNCHRONIZER HUB 41. EXTENSION TO CASE BOLT
8. SECOND SPEED GEAR 42. TRANSMISSION EXTENSION V ENTILATO R ASSEMBLY
9. 1ST SPEED GEAR RETA INING RING 43. EXTENSION HOUSING ASSEMBLY
10. 1ST SPEED GEAR TABBED WASHER 44. EXTENSION HOUSING BUSHING
11. 1ST SPEED GEAR 45. EXTENSION HOUSING O IL SEAL ASSEMBLY
12. REVERSE SYNCHRONIZER SPRING 46. COUNTERGEAR THRUST WASHER
13. 1ST & REVERSE SYNCHRONIZER SLEEVE & GEAR 47. COUNTERGEAR SPACER
14. REVERSE SYNCHRONIZER KEYS 48. COUNTERGEAR ROLLET BEARINGS
15. 1ST & REVERSE SYNCHRONIZER HUB 49. COUNTERGEAR SHAFT
16. 1ST & REVERSE SYNCHRONIZER RETAIN ING RING 50. COUNTERGEAR SPRING PIN
17. REAR BEARING R ETAINING RING 51. COUNTERGEAR
18. TRANSMISSION MAINSHAFT 52. 2ND 8i 3RD SHIFTER FORK
19. REVERSE-SYNCHRONIZER ASSEMBLY 53. SHIFT FORK LOCKING SCREW
20. ACCESS COVER BOLTS 54. 1ST 8t 2ND SHIFTER INTERLOCK SPRING
21. ACCESS COVER 55. SHIFTER INTERLOCK PIN
22. ACCESS COVER GASKET 56. 1ST & REVERSE SHIFT R AIL
23. BEARING RETAINER TO CASE BOLTS 57. 1ST & REVERSE SHIFT FORK
24. BEARING RETAINER - CLUTCH GEAR 58. 2ND 8> 3RD SHIFTER INTERLOCK SPRING
25. GASKET - CLUTCH GEAR BEARING RETAINER 59. 2ND Si 3RD SH IFT R AIL
26. SEAL ASSEMBLY CLUTCH GEAR BEARING RETAINER 60. REVERSE ID LER GEAR THRUST WASHER
27. CLUTCH GEAR BEARING R ETA INING RING 61. REVERSE ID LER GEAR SHAFT
28. CLUTCH GEAR BEARING LOCK RING 62. SPRING PIN ID LER GEAR SHAFT
29. CLUTCH GEAR BEARING ASSEMBLY 63. REVERSE IDLER GEAR BUSHING
30. CLUTCH GEAR 64. REVERSE ID LER GEAR
3V EXPANSION PLUG 65. REVERSE IDLER GEAR ASSEMBLY
32. FILLER PLUG 66. SEAL TRANSMISSION SHIFTER
33. TRANSMISSION CASE MAGNET 67. TRANSMISSION SHIFTER SHAFT 4 LEVER ASSEMBLY
34. CASE

Fig. 7B-2B--Exploded V ie w - 3 Speed 7 7 m m Transmission

 M A N U A L T R A N S M IS S IO N 7B-11

ALIGNMENT
MARKS

Fig. 7 B -3 B -D ra in Transm ission

Fig. 7B -6B-R em oving Front Bearing Retainer

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).
16. Using a long thin punch (1/4 inch diameter or less)
insert through access hole in rear case to drive out shift rail
UPPER DETENT
SPRING (LONG)
and expansion plug located in shift rail bore at front of case.

Fig. 7B-4B--Location of U pper Detent Spring

NOTE: ALIGN ROLL
PIN HOLE WHEN

DUMMY SHAFT
I TOOL J-25232
COUNTERSHAFT

Fig. 7 B -5B -R e m ov ing Countershaft Fig. 7 B -7B -R e m o v in g Front Bearing

7B-12 M A N U A L TR A N SM IS S IO N

FIRST-REVERSE
SLEEVE AND GEAR IN
FORWARD POSITION
TO CLEAR CASE

Fig. 7B-10B~Rem oving O utpu t S haft Assem bly

17. Rotate second-third shifter fork upward and out of NOTE: First and reverse sleeve and gear must pass
case. through notch at right rear end of case.
18. Remove the bottom detent plug and short detent
spring from case. 20. Remove clutch gear through top of case.
19. Separate clutch gear from output shaft and remove 21. Remove both shifter fork shafts (Fig. 7B-11B).
output shaft assembly (Fig. 7B-10B); tilt spline end of shaft 22. Remove countergear (with tool in place), thrust
downward and lift gear end upward and out of case. washers and roll pin.

O - RING
LOCATION

Fig. 7B-9B~Rotating Shift Rail Fig. 7B-1 1B--Shift Fork Shafts

 M A N U A L T R A N SM IS S IO N 7B-13

SPRING “
UNDER LIP OF FIRST-REVERSE
KEYS SLEEVE AND GEAR

HUB
ALIGN ROLL PIN
WITH COUNTERBORE
WHEN INSTALLING

7 RETAINING
SNAP RING
COUNTERBORE
REVERSE IDLER
GEAR SHAFT
FIRST-REVERSE
SYNCHRONIZER

Fig. 7B-1 2B--Removing Reverse Idler Gear Shaft Fig. 7B-13B--First-Reverse Synchronizer Hub

23. Remove reverse idler gear and thrust washers by 3. Make sure bearings are clean, then lubricate with
tapping shaft with hammer until end of idler gear shaft (end light engine oil and check them for roughness by slowly
with roll pin) clears counterbore in rear of case and remove turning the race by hand.
shaft (Fig. 7B-12B).
24. From the bottom of the case retrieve, clutch shaft Bearing Rollers
roller bearing or countergear needle bearing that may have All clutch gear and countergear bearing rollers should
fallen into case during disassembly. be inspected closely and replaced if they show wear. Inspect
M A IN S H A FT DISASSEM BLY countershaft and reverse idler shaft at the same time, replace
1. Remove snap ring from front of output shaft and if necessary. Replace all worn washers.
remove Second-Third synchronizer assembly and second
gear. Mark hub and sleeve for correct assembly. Gears
1. Inspect all gears for excessive wear, chips, or cracks
2. Remove snap ring and tabbed thrust washer from and replace any that are worn or damaged.
shaft and remove first gear and blocking ring. 2. Check both clutch sleeves to see that they slide freely
3. Remove First-Reverse hub retaining snap ring. on their hubs.
NOTE: Observe position of spring and keys before
removal, also, mark hub and sleeve for correct
assembly. REPAIRS
4. Remove sleeve and gear, spring and three keys from Synchronizer Keys and Spring
hub (Fig. 7B-13B). Replacement
1. Mark hub and sleeve so they can be matched upon
5. Using an arbor press, remove hub from output shaft. reassembly.
CLEANING A N D INSPECTION 2. Push the hub from the sliding sleeve, the keys and
the springs may be easily removed.
Transmission Case 3. Install one spring into second-third hub. Be sure
1. Wash the transmission thoroughly inside and outside spring covers all three key slots in hub. Align second-third
with cleaning solvent, then inspect the case for cracks. sleeve to hub using marks made during disassembly, and
start sleeve onto hub.
2. Check the front and rear faces for burrs, and if
present, dress them off with a fine mill file. 4. Place the three keys into hub slots and on top of
spring, then push sleeve fully onto hub to engage keys in
Front and Rear Bearings sleeve (Fig. 7B-14B).
1. Wash the front and rear ball bearings thoroughly in 5. Install remaining spring in exact same position as
a cleaning solvent. first spring. Ends of both spring must cover same slots in
2. Blow out bearings with compressed air. hub and not be staggered.
CAUTION: Do not allow the bearings to spin, NOTE: Keys have small lip on each end. When
turn them slowly by hand. Spinning bearings may correctly installed, this lip will fit over spring (Fig. 7B-
damage the race and balls. 14B).
7B-14 M A N U A L TR A N SM IS S IO N

ALIGNMENT K E Y S (3)
MARKS

SPRING
(UNDER
LIP OF
KEYS )

Fig. 7B-1 4B~Second-Third S ynchronizer Assem bly Fig. 7B-1 6 B—Installing Extension Housing Seal

Extension Oil Seal or Bushing ASSEMBLY OF MAINSHAFT

If bushing in rear of extension requires replacement, 1. Install First-Reverse synchronizer hub on output
remove seal and use Tool J-5778 to drive bushing into shaft splines by hand. Slotted end of hub should face front
extension housing (Fig. 7B-15B). Using the same tool, drive of shaft. Use an arbor press to complete hub installation on
new bushing in from the rear. Coat I.D. of bushing and seal shaft and install retaining snap ring (in most rearward
with transmission lubricant, then install new oil seal using groove).
Tool J-5154 (Fig. 7B-16B). CAUTION: DO NO T attempt to drive hub onto
shaft with hammer. Hammer blows will damage
Clutch Bearing Retainer Oil Seal
If the lip seal in the retainer needs replacement; pry the hub and splines.
old seal out and replace with a new seal using Installer Tool 2. Install First-Reverse sleeve and gear half-way onto
J-25233, or similar tool, until seal seats in its bore (Fig. hub with gear end of sleeve facing rear of shaft. Index sleeve
7B-17B). to hub with marks made during disassembly.

OIL RETURN TOOL

SLOT J-25233

FRONT
/
BEARING
CAP

Fig. 7B-1 5 B —Installing Extension Housing Bushing Fig. 7B-1 7 B —Installing Clutch Bearing Retainer Seal
 M A N U A L T R A N SM IS S IO N 7B-1 5

Fig. 7B-1 8B —Installin g Tabbed T hrust W asher Fig. 7 B -2 0 B -M e a su rin g O utput S haft End Play

3. Install spring in First-Reverse hub. (Make sure 7. Install Second-Third synchronizer assembly with flat
spring is bottomed in hub and covers all three key slots.) portion of synchronizer hub facing rearward on output
Position three synchronizer keys in hub, with small ends in shaft. Rotate Second gear until notches in blocking ring
hub slots and large ends inside hub. Push keys fully into hub engages keys in Second-Third synchronizer assembly.
so they seat on spring. Then slide First-Reverse sleeve and NOTE: It may be necessary to tap synchronizer with
gear over keys until the keys engage in the synchronizer a plastic hammer to ease assembly.
sleeve (Fig. 7B-13B).
4. Place first gear blocking ring on tapered surface of 8. Install retaining snap ring on output shaft and
gear. Install First gear on output shaft. Rotate gear until measure end play between snap ring and Second-Third
notches in blocking ring engages keys in First-Reverse hub. synchronizer hub with feeler gauge (Fig. 7B-20B). End play
5. Install tabbed thrust washer (sharp edge facing out) should be 0.004 to 0.0014 inch. If end play exceeds 0.014
and retaining snap ring on output shaft (Fig. 7B-18B). inch, replace thrust washer and all snap rings on output
shaft assembly.
6. Place second gear blocking ring on tapered surface
of gear and install second gear on output shaft with tapered ASSEMBLY OF TRANSMISSION
surface of gear facing front of output shaft (Fig. 7B-19B). 1. Coat transmission case reverse idler gear thrust
washer surfaces with Vaseline (or equivalent) and position
thrust washer in case.
NOTE: Be sure to engage locating tabs on thrust
washers in locating slots in case.
SECOND
2. Install reverse idler gear with helical cut gear
towards front of case. Align gear bore, thrust washers, case
GEAR

bores, and install reverse idler gear shaft from rear of case.
NOTE: 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.
NOTE: Be sure to engage locating tabs on thrust
washer in locating slots in case.
BLOCKING
RING 6. Insert countershaft into bore at rear of case just far
enough to hold rear thrust washer from being displaced
Fig. 7 B -1 9 B -ln s ta llin g Second Gear when the countergear is installed.
7B-16 M A N U A L TRAN SM IS S IO N

J-24433

Fig. 7 B -2 1 B -ln s ta lla tio n Sequence - Detent Plugs and Fig. 7 B -2 2 B -ln s ta llin g Front Bearing
S prings

7. Align bore in countergear with countershaft and NOTE: Tapered end of rail faces front of case.
front thrust washer, then start countershaft into 18. Turn shift rail until detent notches in rail face
countergear. Before countershaft is completely installed bottom of case. Insert a phillips screwdriver in detent bore
make sure that roll pin hole in countershaft is aligned with to depress lower detent plug and push shift rail into rear
hole in case. When holes are aligned, tap countershaft into bore. Move rail inward until detent plug engages forward
place, remove tool J-25232 (Fig. 7B-5B). notch in shift rail (second gear position).
8. Measure countershaft end play by inserting feeler 19. Secure fork to rail with setscrew and move second-
gauge between thrust washer and countergear. End play third synchronizer to Neutral (centered) position.
should be 0.004 to 0.018 inch. If end play exceeds 0.018 20. Install interlock plug in detent bore. With Second-
inch, remove gear and replace thrust washers. Third synchronizer in Neutral position, top of plug will be
9. After correct end play has been obtained, install roll slightly below surface of First-Reverse shift rail bore.
pin in case. 21. Move first reverse synchronizer forward to first
10. Lower shorter detent spring in detent bore in case gear position. Place First-Reverse shifter fork in groove of
(Fig. 7B-21B). Allow spring to drop into place at bottom sleeve. Be sure setscrew hole in fork is facing up. Rotate fork
of Second-Third shift rail bore. Insert lower detent plug in into position in case, engage fork in shifter fork shaft, and
detent bore on top of spring. insert First-Reverse shift rail through rear case bore and
11. Install shifter fork shafts in their case bores with shifter fork.
the pivot lug facing up. 22. Turn shift rail until detent notches in rail face
NOTE: Shifter fork shafts are interchangeable.
12. Install (15) roller bearings in clutch shaft bore. Use
vaseline (or equivalent) to hold bearings in place.
CAUTION: Do not use chassis grease or a similar
"heavy" grease in clutch shaft bore. Heavy grease
will plug the lubricant holes in the shaft and
prevent proper lubrication o f 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
of sleeve. Be sure setscrew hold in shifter fork is facing up.
NOTE: 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. Fig. 7B-23B--lnstalling Rear Bearing
 M A N U A L T R A N SM IS S IO N 7B-17

25. Install smaller snap ring on clutch gear shaft.

26. Position bearing retainer gasket on case. Be sure
cut-out in gasket is aligned with oil return hole in case.
27. Install front bearing retainer and tighten attaching
bolts to 30 to 36 foot-pounds of torque. 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
Fig. 7 B -2 4 B ~ ln sta llin g S peedom eter Retainer and Gear

upward. Move rail inward until setscrew hole in fork and bore in front of case. Be sure plug is fully seated in bore and
setscrew bore in shift rail are aligned. Secure fork to rail with is approximately 1/16 inch below front face of case.
setscrew and place First Reverse sleeve and gear into 34. Install upper detent plug in detent bore, then install
Neutral (centered) position (Fig. 7B-20B). long detent spring on top of plug. Install transmission fill
23. Install large snap ring on front bearing. plug and tighten 10 to 20 foot pounds torque.
24. Install front bearing on clutch gear shaft by hand 35. Install top cover and gasket on case and secure with
drive bearing on clutch gear shaft using tool J-24433 (Fig. attaching bolts. Tighten bolts 20 to 25 foot pounds torque.
7B-22B).

4-SPEED 76MM TRANSM ISSION

INDEX
Disassembly of Transmission......................................7B-17 Repairs.......................................................................... 7B-20
Disassembly of Mainshaft...........................................7B-17 Clutch Keys and Springs Replacement............... 7B-20
Cleaning and Inspection............................................ ..7B-20 Extension Oil Seal or Bushing............................. ..7B-21
Transmission Case................................................. ..7B-20 Clutch Bearing Retainer Oil Seal......................... ..7B-21
Bearings................................................................... ..7B-20 Assembly of Mainshaft.............................................. ..7B-22
Gears and Bushings............................................... ..7B-20 Assembly of Transmission...........................................7B-23
DISASSEM B LY OF TR A N S M IS S IO N (Fig. 7B-1 J) 7. Using J-22246 at the front of the countershaft, drive
1. Remove side cover attaching bolts and remove side the shaft and its woodruff key out the rear of the case. Tool
cover assembly. J-22246 will now hold the roller bearings in position within
2. Remove clutch gear bearing retainer bolts, retainer the counter gear bore. Remove the gear and bearings (Fig.
and gasket. 7B-5J).
3. Remove clutch gear bearing to gear stem snap ring, 8. Remove reverse idler gear stop ring. Use a long drift
then remove clutch gear bearing by pulling outward on or punch through the front bearing case bore and drive the
clutch gear until a screwdriver or other suitable tool can be reverse idler shaft and woodruff key through the rear of the
inserted between bearing, large snap ring and case to case (Fig. 7B-6J).
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 DISASSEM BLY OF M A IN S H A FT
assembly. 1. Using snap ring pliers, remove the 3rd and 4th speed
4. Remove extension to case attaching bolts. sliding clutch hub snap ring from mainshaft and remove
5. Remove clutch gear, mainshaft and extension clutch assembly, third gear blocker ring and third speed gear
assembly together through the rear case opening (Fig. 7B- from front of mainshaft (Fig. 7B-7J).
3J). 2. Depress speedometer retaining clip and slide gear
6. Using snap ring pliers, expand the snap ring in the from mainshaft.
extension which retains the mainshaft rear bearing (Fig. 7B- 3. Remove rear bearing snap ring from mainshaft
4J) and remove the extension. groove (Fig. 7B-8J).
7B-18 MANUAL TR A N SM IS S IO N
Fig. 7B-1 J--4-Speed 76mm Transmission Cross Section
 M A N U A L TR A N S M IS S IO N 7B-19

PULL MAIN J -2 2 2 4 6 COUNTER

DRIVE GEAR SHAFT

FORWARD Fig. 7B-5J--Removing C o untershaft

Fig. 7B-2J--Rem oving Clutch Gear Bearing

Fig. 7B-6J--Rem oving Reverse Idler Gear S haft

Fig. 7B-3J--Rem oving C lutch Gear and M ainshaft

Fig. 7B-4J--Removing Extension to Rear Bearing Snap Ring Fig. 7B-7J--Removing 3rd and 4th Synchronizer Snap Ring
7B-20 M A N U A L TRAN SM IS S IO N

Fig. 7 B -10J--Rem oving 1st and 2nd Synchronizer Snap Ring

Front and Rear Bearings

Fig. 7B-8J--Rear Bearing to M ainsh aft Snap Ring
1. Wash the front and rear ball bearings thoroughly in
4. Support first gear with press plates and press on rear a cleaning solvent.
of mainshaft to remove first gear, thrust washer, spring 2. Blow out bearings with compressed air.
washer and rear bearing from rear of mainshaft (Fig. 7B-9J).
5. Remove the 1st and 2nd sliding clutch hub snap ring CAUTION: Do not allow the bearings to spin,
from the mainshaft and remove the clutch assembly, 2nd turn them slowly by hand. Spinning bearings may
speed blocker ring and 2nd speed gear from the rear of the damage the race and balls.
mainshaft (Fig. 7B-10J).
CLEANING AND INSPECTION 3. Make sure bearings are clean, then lubricate with
light engine oil and check them for roughness by slowly
Transmission Case turning the race by hand.
1. Wash the transmission thoroughly inside and outside
with cleaning solvent, then inspect the case for cracks. Bearing Rollers
2. Check the front and rear faces for burrs, and if
present, dress them off with a fine mill file. All clutch gear and countergear bearing rollers should
be inspected closely and replaced if they show wear. Inspect
counter shaft and reverse idler shaft at the same time,
replace if necessary. Replace all worn washers.

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
NOTE: 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
Fig. 7B-9J--Removing Rear Bearing and 1st Speed Gear be replaced if worn or broken.
 M A N U A L T R A N SM IS S IO N 7B-21

SPR IN G
SLEEVE

J-5778

Fig. 7B-1 2J-E xte n sio n Bushing Replacement

Fig. 7B-1 1J--3-4 Synchronizer Assem bly

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 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.
NOTE: 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, for the 1-2
synchronizer, the groove is at the same end as the fork Fig. 7B-13 J —Installin g Extension Oil Seal
slot. This groove indicates the end of the hub with a
greater recess depth.
SCREWDRIVER
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).
NOTE: Lip of seal must face rear of bearing retainer. Fig. 7B-14J~R em oving Bearing Retainer Oil Seal
7B-22 M A N U A L TRAN SM IS S IO N

3. Install the 3rd and 4th synchronizer assembly with

the fork slot downward on the mainshaft until it bottoms
out against flange.
CAUTION: Be sure the notches o f the blocker ring
align with the keys at the synchronizer assembly.
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.
8. Install synchronizer hub to mainshaft snap ring (Fig.
7B-10J).
9. Install a blocker ring with notches downward so they
align with the keys of the 1-2 synchronizer assembly.
Fig. 7B-1 5J—Installing Bearing Retainer Oil Seal 10. Install first gear with clutching teeth downward.
11. Install first gear thrust washer (steel).
ASSEMBLY OF M A IN S H A FT (Fig. 7B-16J) CAUTION: Be sure the notches o f the blocker ring
Turn the front of the mainshaft upward. Install the align with the keys o f the synchronizer assembly.
following components on the mainshaft: 12. Install first gear spring washer.
1. Install the third speed gear with clutching teeth 13. Install rear ball bearing with snap ring slot
upward; the rear face of the gear will butt against the flange downward; press onto mainshaft (Fig. 7B-17J).
on the mainshaft. 14. Install rear bearing to mainshaft snap ring (Fig.
2. Install a blocking ring with clutching teeth 7B-8J).
downward over the synchronizing surface of the third speed 15. Install speedometer drive gear and clip.
gear. All four blocker rings used in this transmission are This completes the assembly of the mainshaft.
identical.

1. Drive Gear Bearing 8. First Speed Gear

2. Drive Gear 9. T hrust Washer
3. M ainshaft P ilot 10. Spring Washer
Bearings 11. Rear Bearing
4. 3-4 S ynchronizer 12. Speedo Drive Gear
A sse n b ly 13. Mainshaft
5. T h ird Speed Gear 14. Snap Ring
6. Second Speed Gear 15. S ynchronizing
7. 1 2 Synchronizer and "B lo c k e r" Ring
Reverse Gear Assem bly

Fig. 7B-1 6 J -C lu tc h Gear and Mainshaft Details

 M A N U A L T R A N SM IS S IO N 7B-23

CAUTION: Be sure countershaft picks up both

thrust washersandthat the tangsarealigned 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 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: Besurethenotchesin theblockerring
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
Fig. 7B-1 7J--InstaMing Rear Bearing
bore.
10. Install snap ring to drive gear stem, and drive gear
ASSEMBLY OF TR A N SM IS S IO N (Fig. 7B-18J) bearing retainer and gasket to case.
1. Using Tool J-22246 load a row of roller bearings (27) NOTE: The retainer oil return hole should be at the
and a bearing thrust washer at each end of the countergear. bottom.
Use heavy grease to hold them in place (Fig. 7B-19J).
2. Place countergear assembly through case rear 11. Shift synchronizer sleeves to neutral positions and
opening along with a tanged thrust washer (tang away from install cover, gasket and fork assembly to case. Be sure forks
gear) at each end and install countergear shaft and woodruff align with their synchronizer sleeve grooves.
key from rear of case. 12. Tighten all bolts to specified torque.
 7B-24
9 rt V*.

MANUAL TR A N SM IS S IO N
Fig. 7B-1 8J-4-Speed
76mm
Transmission-Exploded

1. Bearing Retainer 15. T hrust W asher-Front 29. 3rd Speed B locker 42. G asket-Extension to 55 D etent Spring
2 G asket-Retainer to Gear Ring Case 56. 3-4 D etent Cam
Case 16. Needle Retainer 30. 3rd Speed Gear 43. Snap Ring-Extension 57. 1-2 D etent Cam
3. Oil Seal W asher 31. Needle Bearings to Rear Bearing 58. 3-4 S h ifte r S haft
V iew

4. Snap Ring: Bearing to 17. Needle Bearings 32 Second Speed Gear 44. Extension 59. Gasket-Cover to Case
Shaft 18. C ountergear 33. 2nd Speed B locker 45 Vent 60. Cover
5. Snap R ing-Bearing to 19. Needle Retainer Ring 46. Bushing 61. TCS S w itch and
Case W asher 34. M a in sh a ft 47. Oil Seal Gasket
6 D rive Gear Bearing 20 T hrust W asher-Rear 35. 1st Speed B locker 48. 1-2 S ynchronizer 62 Lipseal
7. D rive Gear Gear Ring Sleeve and Reverse 63 Detent Cam Retainer
8. M a in sh a ft P ilot 21. C ountershaft 36. First Speed Gear Gear 64 1-2 S h ift Fork
B earings 22. W o o d ru ff Key 37. T hrust W asher 49. Key Retainer 65. " 0 " Ring
9. 4th Speed B locker 23. Synchronizer Sleeve 38. W ave W asher 50. 1-2 S ynchronizer Hub 66. 1-2 S h ift S haft
Ring 24. Snap Ring-Hub to 39. Rear Bearing 51 Clutch Keys 67. Spring
10 Case Shaft 40. Snap R ing-Bearing to 52 Key Retainer 68 Ball
11. F iller Plug 25. Key Retainer S haft 53 Snap Ring-Hub to 69. " 0 " Ring
12. Reverse Idler Gear 26. 3-4 Synchronizer Hub 41. Speedo Drive Gear Shaft 70. Reverse S hifte r S haft
13. Reverse Idler S haft 27. Clutch Keys and Clip 54. 3-4 S h ift Fork and Fork
14. W o o d ru ff Key 28. Key Retainer
 M A N U A L T R A N S M IS S IO N 7B-25

MAIN DRIVE GEAR

Fig. 7B -19J--Loading C ountergear Bearing Fig. 7B -2 0J~ Lo ad ing M ainshaft Bearings

4-SPEED 83MM TRANSM ISSION

INDEX
Disassembly of Transmission......................................7B-25 Extension Oil Seal and/or Bushing Replacement. 7B-31
Disassembly of Mainshaft...........................................7B-28 Drive Gear Bearing Retainer Oil..............................7B-31
Cleaning and Inspection............................................ ..7B-28 Reverse Shifter Shaft and/or Seal Replacement... 7B-31
Transmission Case................................................... ..7B-28 Reverse Idler Shaft Replacement........................... ..7B-32
Bearing Rollers and Spacers......................................7B-28 Transmission Side Cover...........................................7B-32
Gears............................................................................7B-28 Assembly of Countergear.......................................... ..7B-32
Front and Rear Bearings...........................................7B-28 Checking Countergear End Play.................................7B-32
Repairs............................................................................7B-30 Assembly of Mainshaft.............................................. ..7B-32
Clutch Keys and Springs Replacement...................7B-30 Assembly of Transmission...........................................7B-33

D ISASSEM B LY OF TR A N S M IS S IO N 7. Remove speedometer gear outer snap ring (Fig. 7B-

NOTE: Sectional and exploded view of the 4K). Tap or slide speedometer gear from mainshaft, then
transmission are provided in Figures 7B-1K and 7B-2K remove second snap ring.
to assist in the disassembly of the transmission. 8. Slide the reverse gear from the mainshaft (Fig. 7B-
1. Thoroughly clean the exterior of the transmission 5K), and slide the rear portion of the reverse idler gear from
assembly. the transmission case.
2. Shift transmission into second gear, remove drain 9. Remove four (4) front bearing retainer bolts, gasket,
plug from lower right of case and drain lubricant from and front bearing retainer from case.
transmission. 10. Remove front bearing snap ring selective fit snap
3. Remove nine (9) shift cover attaching bolts, cover ring and spacer washer.
assembly and gasket. Remove both shift forks. 11. Using Tool J-6654-01, remove front main drive gear
4. Remove four (4) drive gear bearing retainer bolts, bearing from transmission case (Fig. 7B-6K).
retainer and gasket from front of transmission. 12. Remove the rear retainer lock bolt.
5. Remove lock pin from reverse shifter lever boss (Fig. 13. Shift first-second and third-fourth clutch sliding
7B-3K) and pull shifter shaft partially out to disengage the sleeves forward to permit adequate clearance for mainshaft
reverse shifter fork from the reverse gear. removal. Remove mainshaft and rear bearing retainer
6. Remove five (5) rear extension attaching bolts, tap assembly from the transmission case.
extension rearward with a soft hammer to start removal. 14. Remove front reverse idler gear and thrust washer
Slide extension rearward until reverse idler shaft is clear of from case.
reverse idler gears. Then rotate extension to the left to free NOTE: Gear teeth face toward front of transmission.
shift fork from collar of reverse gear and remove the case 15. Using a dummy shaft J-24658 drive countergear
extension. Remove and discard gasket. shaft out of countergear (Fig. 7B-7K) and remove
 7B-26
5 6 7 8 9 10 11 12 14 15 16

MANUAL TR A N SM IS S IO N
Fig. 7B-1 K--Sectional View
of 4-Speed
83mm
T ransm ission

29 28 27 26
1 Clutch G e a r Bearing R etainer 12 1st & 2nd S p eed Clutch Assy. 23 Thrust W a s h e r
2 R etain er Lip Seal 13 1st S p e e d S y n o c h ro n ize r Ring 24 Thrust W a s h e r
3 S n a p Ring an d W a s h e r 14 1 st S p e e d G e a r 25 Idler S h a ft Roll Pin
4 Clutch G e a r Bearing 15 1 st S p e e d G e a r Bushing 26 Rear Id le r G e a r
5 Clutch G e a r 16 S p a c er 27 S p a c er
6 4 th S p e e d Syn chron izer Ring 17 R ear M a in B earing 28 Front Id le r G e a r
7 3 rd & 4 th S p e e d Clutch Assy. 18 S n a p Ring an d W a s h e r 29 Reverse Id le r S h a ft
8 3 rd S p e e d Syn chron izer Ring 19 Reverse G e a r 30 C o u n te rg e a r
9 3 rd S p eed G e a r 20 S n a p Rings 31 C o u n te rg e a r S leeve
10 2 n d S p eed G e a r 21 S p e e d o m e te r G e a r 32 C o u n te rg e a r B earin g Rollers
11 2n d S p e e d S yn chron izer Ring 22 M a in s h a ft 33 Thrust W a s h e rs
 M A N U A L TR A N S M IS S IO N 7B-27

1. Bearing Retainer 23. First and Second Speed 44. Rear Bearing Retainer To 63. Countershaft
2. Gasket Clutch Sliding Sleeve Case Extension Gasket 64. Countershaft Woodruff Key
3. Selective Fit Snap Ring 24. First and Second Speed 45. Reverse Shifter Shaft 65. Gasket
4. Spacer Washer Clutch Assembly Detent Ball 66. Forward Speed Shift Forks
5. Bearing Snap Ring 25. First Speed Gear 46. Reverse Shifter Shaft 67. First and Second Speed
6. Main Drive Gear Bearing Synchronizing Ring Ball Detent Spring Gear Shifter Shaft and
7. Transmission Case 26. First Speed Gear 47. Case Extension Detent Plate
8. Rear Bearing Retainer Gasket 27. First Speed Gear Sleeve 48. Extension Bushing 68. Third and Fourth Speed
9. Main Drive Gear 28. Rear Bearing Snap Ring 49. Rear Oil Seal Gear Shifter Shaft and
10. Bearing Rollers (16) 29. Thrust Washer 50. Reverse Shifter Shaft Detent Plate
11. Washer 30. Rear Bearing Lock Pin 69. Poppet Spring
12. Snap Ring 31. Rear Bearing Retainer 51. Reverse Shifter Shaft 70. Interlock Pin
13. Third and Fourth Speed 32. Washer "O " Ring Seal 71. Interlock Sleeve
Clutch Sliding Sleeve 33. Selective Fit Snap Ring 52. Reverse Shift Fork 72. Detent Balls
14. Fourth Speed Gear 34. Reverse Gear 53. Reverse Shifter Shaft 73. Transmission Side Cover
Synchronizing Ring 35. Snap Ring and Detent Plate 74. Lip Seals
15. Clutch Key Spring 36. Speedometer Drive Gear 54. Reverse Shifter Lever 75. Third and Fourth Speed
16. Clutch Hub 37. Reverse Idler Front 55. Speedometer Driven Gear Shifter Lever
17. Third Speed Gear Thrust Washer (Flat) and Fitting 76. First and Second Speed
Synchronizing Ring 38. Reverse Idler Gear (Front) 56. Retainer and Bolt Shifter Lever
18. Third Speed Gear 39. Snap Ring 57. “ O ” Ring Seal 77. T.C.S. Switch and Gasket
19. Mainshaft 40. Reverse Idler Gear (Rear) 58. Washer (Tanged) 78. Lever Attaching Nuts
20. Clutch Keys (3) 41. Thrust Washer (Tanged) 59. Spacer (.050")
21. Second Speed Gear 42. Reverse Idler Shaft 60. Bearing Rollers (28)
22. Second Speed Gear 43. Reverse Idler Shaft Lock 61. Countergear
Synchronizing Ring Pin and Welch Plug 62. Countergear Roller Spacer

Fig. 7B-2K--Exploded V ie w of 4-Speed 8 3 m m Transmission

7B-28 M A N U A L TR A N SM IS S IO N

Fig. 7 B-3K-R em oving Reverse S hifte r Shaft Lock Pin

Fig. 7B-6K--Removing M ain Drive Gear Bearing

countergear and tanged thrust washers from case. Check

bottom of case for pilot bearings or other loose components.
DISASSEM BLY OF M A IN S H A FT (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, 1st gear and sleeve, 1-2 clutch
and synchronizer assembly, and the second gear (Fig. 7B-
12K).
CLEANING AND INSPECTION
Transmission Case
Fig. 7B-4K--Speedom eter Gear and Retaining Rings 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.

Fig. 7 B -5K -R e m o v in g Reverse Gear Fig. 7B-7K--Removing Co untergear Shaft

 M A N U A L T R A N SM IS S IO N 7B-29

17
1 Washer 7 2nd Speed Gear 13 Washer
2 Snap Ring 8 2nd Speed Synchronizer Ring 14 Rear Bearing
3 4th Speed Synchronizer Ring 9 1st & 2nd Speed Clutch Assy. 15 Washer
4 3rd & 4th Speed Clutch Assy. 10 1st Gear Bushing 16 Snap Ring
5 3rd Speed Synchronizer Ring 11 1st Speed Synchronizer Ring 17 Mainshaft
6 3rd Speed Gear 12 First Gear

Fig. 7B-8K--M ainshaft Assem bly C om ponents

3. Make sure bearings are clean, then lubricate with 2. Inspect reverse gear bushing and if worn or damaged
light' engine oil and check them for roughness by slowly replace the entire gear (reverse gear bushing is not serviced
turning the race by hand. separately).
Roller Bearings and Spacers 3. Check both clutch sleeves to see that they slide freely
All main drive gear and countergear bearing rollers on their hubs.
should be inspected closely and replaced if they show wear. Front and Rear Bearings
Inspect countershaft and reverse idler shaft at the same
time, replace if necessary. Replace all worn spacers. 1. Wash the front and rear ball bearings thoroughly in
Gears
a cleaning solvent.
1. Inspect all gears for excessive wear, chips or cracks 2. Blow out bearings with compressed air.
and replace any that are worn or damaged.

BEARING
RETAINER

SNAP RING
PLIERS

Fig. 7B-9K--Removing 3-4 Clutch Assembly Retainer Fig. 7B-1 OK-Re moving Rear Bearing Retainer
7B-30 M A N U A L TRAN SM IS S IO N

SPRING

SLEEVE

Fig. 7B-1 1K~Removing Rear Bearing Snap Ring Fig. 7B-1 3 K -S yn ch ro n ize r Assem bly

CAUTION: Do not allow the bearings to spin. 1. If relation of hub and sleeve are not already marked,
Turn them slowly by hand. Spinning bearings may mark for assembly purposes.
damage the race and balls. 2. Push the hub from the sliding sleeve; the keys will
REPAIRS fall free and the springs may be easily removed.
Synchronizer Keys and Springs 3. Place the two springs in position (one on each side
Replacement of hub), so all three keys are engaged by both springs (Fig.
The synchronizer hubs and sliding sleeves are a selected 7B-13K).
assembly and should be kept together as originally Place the keys in position and while holding them in
assembled, but the keys and two springs may be replaced place, slide the sleeve onto the hub, aligning the marks made
if worn or broken. before disassembly.

J - 2 1465-1 7
W /H AN D LE
J -8 0 9 2

Fig. 7 B -12 K -P re s sin g Rear Bearing From Mainshaft Fig. 7B-1 4K--Removing Rear Extension Bushing
 M A N U A L T R A N S M IS S IO N 7B-31

J-23096

J—21359

Fig. 7 B -1 6 K ~ ln sta llin g Drive Gear Bearing Retainer Seal

Fig. 7B-1 5K—Installin g Rear Extension Seal

Extension Oil Seal and/or 4. Place ball detent spring into detent spring hole and
start reverse shifter shaft into hole in boss.
Bushing Replacement 5. Place detent ball on spring and while holding ball
1. Pry seal from rear of extension. down, push the shifter shaft into place and turn until the
2. Remove bushing using Tool J-21465-17 with Handle ball drops into place in detent on the shaft detent plate.
J-8092. Drive bushing from rear of extension housing (Fig. 6. Install "O" ring seal on shaft.
7B-14K). 7. Install shift fork.
3. Using a new bushing and Tool J-21465-17 with NOTE: Do not drive the shifter shaft lock pin into
Handle J-8092, press bushing into extension from rear of place until the extension has been installed on the
extension. transmission case.
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 I.D. of seal with transmission lubricant.
Reverse S hifter S haft 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 "O" ring seal from shaft.

Fig. 7B-1 7K -R e m o vin g Reverse Idler Shaft Roll Pin

7B-32 M A N U A L TRAN SM IS S IO N

Reverse Idler S haft

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.
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.
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 lst/2nd cross shaft
and 3rd/4th linkage and remove the attaching bolts.
1. Remove the outer shifter lever nuts and lockwasher Fig. 7B-1 8 K—S hift Cover Assem bly
and pull levers from shafts.
2. Carefully push the shifter shafts into cover, allowing
the detent balls to fall free, then remove both shifter shafts.
3. Remove interlock sleeve, interlock pin and poppet
spring. ROLLERS

4. Replace necessary parts (Fig. 7B-18K) and assembly SPACER

by reversing Steps 1-3.

ASSEM BLY 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.
SPACERS
CHECKING COUNTERGEAR END PLAY
1. Rest the transmission case on its side with the side
cover opening toward the assembler. Put countergear Fig. 7B-1 9K ~C ountergear Cross Section
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.
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
.025", a new thrust washers must be installed.
ASSEMBLY OF M A IN S H A FT
1. From rear of mainshaft, assemble the 2nd speed gear
(with hub of gear toward rear of shaft).
2. Install lst-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. Fig. 7B-20K--Checking Co untergear End Play
 M A N U A L T R A N SM IS S IO N 7B-33

9. Install the rear bearing retainer over end of

mainshaft. Spread the snap ring to drop around the rear
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 TR A N S M IS S IO N
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.
NOTE: 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
Fig. 7B-2 1 K--lnstalling 1st Gear Sleeve case and install the countergear shaft from the rear of the
case. Install the woodruff key and tap shaft into gear until
3. Position the 1st gear sleeve on the shaft and press shaft is flush with rear face of transmission case.
the sleeve onto the mainshaft until the 2nd gear, clutch 3. Install front reverse idler gear (teeth forward) and
assembly and sleeve bottom against the shoulder of the thrust washer in case. Use a heavy grease to hold thrust
mainshaft (Fig. 7B-21K). washer in position.
4. Install 1st speed gear (with hub toward front) and 4. Using a heavy grease install sixteen (16) roller
supporting inner race, press the rear bearing onto the bearings and washer into main drive gear. Mate main drive
mainshaft with the snap ring groove toward front of the gear with mainshaft assembly. Position 3rd-4th clutch
transmission (Fig. 7B-22K). sliding sleeve forward. This will provide clearance for
5. Install spacer and new correct selective fit (thickest installation as well as hold the assembly together.
that will assemble) snap ring in mainshaft behind rear 5. Position new rear bearing retainer to case extension
bearing. gasket on rear of case. Install mainshaft and drive gear
assembly into case.
6. Install the 3rd speed gear (hub to front of 6. Align rear bearing retainer with transmission case.
transmission) and the 3rd speed gear synchronizing ring Install retainer to case locating pin and retainer locking bolt.
(notches to front of transmission). Torque to recommended specifications.
7. Install the 3rd and 4th speed gear clutch assembly 7. Place bearing snap ring on front main bearing.
(hub and sliding sleeve) with taper toward the front making Position front main bearing to case opening and with a
sure that the keys in the hub correspond to the notches in hollow shaft, or tool J-5590, tap bearing into case (Fig. 7B-
the 3rd speed gear synchronizing ring. 23K). Install spacer washer and selective fit snap ring to
8. Install new selective fit snap ring (thickest that will secure main drive bearing.
install) in the groove in mainshaft in front of the 3rd and 8. Install front bearing retainer and gasket. Apply
4th speed clutch assembly. sealer to bolts and torque to recommended specification.
9. Install rear reverse idler gear engaging the splines
with the portion of the gear within the case.

1ST G EA R

REAR BEA RIN G

J-5 5 9 0

Fig. 7B-22K--lnstalling Rear Bearing Fig. 7B-23K--lnstalling Front Main Bearing

7B-34 M A N U A L T R A N SM IS S IO N

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 USE SEALER
selective fit snap rings. ON THIS BOLT

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.
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.
NOTE: 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 lst-2nd speed and 3rd-4th speed clutch
sliding sleeve in neutral position. Pull reverse shift shaft Fig. 7 B-24K--Extension B olt

partially out of extension and reverse shift fork as far

forward in as possible. Start the extension onto the NOTE: It is essential that sealer be used on the
mainshaft while pushing in on the shifter shaft to engage extension bolt as indicated in Fig. 7B-24K.
the shift fork with the reverse gear shift collar. When the 17. Position lst-2nd speed clutch sliding sleeve into 2nd
fork engages, rotate the shifter shaft to move the reverse
gear rearward permitting the extension to mate against the gear and 3rd-4th speed clutch sliding sleeve into neutral.
transmission case. Position forward shift forks in sliding sleeves.
15. Install reverse shifter shaft lock pin. 18. Position lst-2nd speed gear shifter shaft and detent
16. Install rear extension housing-to-case bolts. Install plate into 2nd gear position and using a sealer, install cover
rear extension to rear bearing retainer bolts (short bolts). gasket and side cover assembly to transmission.
Torque all bolts to recommended specification. 19. Check operation of transmission.

4-SPEED 117MM TRANSM ISSION

INDEX
Disassembly of Transmission.......................................7B-34 Drive Gear Bearing Retainer Oil Seal.......................7B-40
Subassembly Operations.............................................. .7B-37 Mainshaft..................................................................... ..7B-41
Transmission Cover................................................... .7B-37 Disassembly.................................................................7B-41
Disassembly................................................................7B-37 Inspection.................................................................. ..7B-42
Assembly................................................................... .7B-38 Assembly.....................................................................7B-42
Drive Gear.................................................................. .7B-39 Countershaft..................................................................7B-43
Disassembly................................................................7B-39 Disassembly.................................................................7B-43
Inspection.................................................................. .7B-39 Assembly................................................................... ..7B-44
Assembly................................................................... .7B-39 Assembly of Transmission.............................................7B-44

DISASSEMBLY OF TRANSMISSION 2. Place transmission in two gears at once to lock gears.

Remove the universal joint flange nut, universal joint front
Refer to Figures 7B-1L and 7B-2L flange and brake drum assembly.
1. Mount transmission in suitable holding fixture and NOTE: On models equipped with 4-wheel drive
remove cap screws attaching transmission cover assembly transmfer case, use Tool J-23070 to remove mainshaft
to transmission case. If required, insert two 5/16x18 screws rear lock nut (Fig. 7B-26L).
in cover flange threaded holes and turn evenly to raise cover 3. Remove parking brake and brake flange plate
dowel pins from case. assembly on models equipped with propeller shaft parking
NOTE: Move reverse shifter fork so that reverse idler brake. Refer to Section 5, Truck Service Manual.
gear is partially engaged before attempting to remove 4. Remove rear bearing retainer and gasket.
cover. Forks must be positioned so rear edge of the slot 5. Slide speedometer drive gear off mainsahft.
in the reverse fork is in line with the front edge of the
slot in the forward forks as viewed through tower 6. Remove drive gear bearing retainers and gasket.
opening. 7. Remove countergear front bearing cap and gasket.
 M A N U A L T R A N S M IS S IO N 7B-35

36 35 34 33 32 31 30

1. Main Drive Gear 11 Reverse Driven Gear 24. Mainshaft Rear 37. Thrust W asher
2 Drive Gear Bearing 12 Poppet Spring Bearing 38. Snap Ring
Retainer 13. Poppet Ball 25. Rear Bearing Snap 39 Front Countershaft
3. Snap Ring-Outer 14. Shift Rail Ring Bearing
4. 3rd and 4th 15. 1st and 2nd Shift 26. Snap Ring 40. Countergear Front
Synchronizer Ring Fork 27. Countershaft Cover
5. 3rd and 4th 16. 1st Speed Gear 28. Countershaft Rear 41. Pilot Bearing Rollers
Synchronizer Collar 17. Thrust Washer Bearing 42. Clutch Gear Oil
6. 3rd and 4th Shift 18. Bearing Snap Ring 29. Bearing Snap Ring Slinger
Fork 19. Speedometer Drive 30. Reverse Idler Gear 43. Snap Ring
7. 3rd and 4th Speed Gear 31. Reverse Idler Shaft 44. 3rd Speed Gear
Synchronizer Ring 20. Output Yoke 32 Case Magnet Bushing
8. 3rd Speed Gear 21. Flange Nut 33 Snap Ring 45. Thrust W asher
9. 2nd Speed Gear 22 Rear Bearing 34. Snap Ring 46. 2nd Speed Gear
10. 1st and 2nd Retainer Oil Seal 35. Spacer Bushing
Synchronizer 23 Rear Bearing 36 Countergear 47. 1st Speed Gear
Assembly Retainer Bushing

Fig. 7B-1 L--4-Speed 1 17mm Transmission Assembly-Cross Section

 7B-36
MANUAL TR A N SM IS S IO N
Fig. 7B-2L--4-Speed
117mm
Transmission
Exploded
V iew

1. Drive Gear Bearing 13. 1st-2nd Speed 26. 2nd Speed Gear 37. Snap Ring 48. Rear Retainer Gasket
Retainer Synchronizer Hub 27. 3rd Gear Bushing 38. Snap Ring 49. Rear Retainer
2. Retainer Gasket 14. Synchronizer Keys 28. Thrust Washer 39. Thrust Washer 50. Retainer Bolts
3. Lip Seal 15. Synchronizer Spring 29. 3rd Speed Gear 40. Clutch Countergear 51. Retainer Lip Seal
4. Snap Ring 16. Reverse Driven Gear 30. 3rd Speed Blocker 40a. Spacer 52. Reverse Idler Shaft
5. Drive Gear Bearing 17. 1st Gear Bushing Ring 41. Snap Ring 53. Drain Plug
6. Oil Slinger 18. 1st Gear 31. Synchronizer Spring 42. Snap Ring 54. Reverse Idler Gear
7. Drive Gear and Pilot 19. Thrust Washer 32. Synchronizer Keys 43. 3rd Speed 55. Case
Bearings 20. Rear Main Bearing 33. 3rd-4th Synchronizer Countergear 56. Fill Plug
8. Power Take-Off Cover 21. Bearing Snap Ring Hub 44. Countergear Shaft 57. Countergear Front
Gasket 22. Speedometer Gear 34. Synchronizer Spring 45. Countergear Rear Bearing
9. Power Take-Off Cover 23. Rear Mainshaft Lock 35. 3rd-4th Speed Bearing 58. Gasket
10. Retaining Screws Nut Blocker Ring 46. Snap Ring 59. Front Cover
11. 1st-2nd Speed 24. 2nd Speed Bushing 36. 3rd-4th Speed 47. Bearing Outer Snap 60. Cover Screws
Blocker Ring (On Shaft) Synchronizer Sleeve Ring
12. Synchronizer Spring 25. Mainshaft
 M A N U A L T R A N SM IS S IO N 7B-37

11. Remove drive gear and bearing by tapping gently

on bottom side of drive gear shaft and prying directly
opposite against the case and bearing snap ring groove at
the same time. Remove 4th gear synchronizer ring.
CAUTION: 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.

Fig. 7B-3L~Removing C ountergear Rear Bearing

SUBASSEMBLY OPERATIONS
TRANSM ISSION COVER
8. Pry countergear front bearing out by inserting a two­ Disassembly (Fig. 7B-5L)
pronged puller through the cast slots in case. 1. Using a small punch drive out pins retaining lst-2nd
9. Remove countergear rear bearing retaining rings and 3rd-4th shifter forks to shifter shafts and also drive out
(snap ring) from shaft and bearing. Using Tool J-22832 and expansion plugs.
J-8433-1, remove countergear rear bearings (Fig. 7B-3L). NOTE: The pin retaining the third and fourth shifter
This will allow countergear assembly to rest on bottom of fork to the shaft must be removed, and the shifter fork
case. removed from the cover before the reverse shifter head
CAUTION: Make sure Tool J-22832 engages full pin can be removed.
circumference of groove in bearing to prevent tool 2. With shifter shafts in neutral position, drive shafts
damage. out of cover and shafter forks.
10. Remove drive gear bearing outer race to case CAUTION: Exercise care so shaft detent balls,
retaining ring. springs and innerlock pin located in the cover are
not lost as the shifter shafts are removed.
3. Drive out pin holding reverse shifter head and drive
out the shaft.

Fig. 7B-4L~Removing Mainshaft Rear Bearing Fig. 7 B - 5 L - C o v e r Assembly

7B-38 M A N U A L T R A N SM IS S IO N

CAUTION: Exercise extreme care during shaft 4. Hold 3rd and 4th fork in position and push shaft
removalsincedetent ballsareunderspringtension through yoke, but not through front support bore.
in the rear rail boss holes. 5. Place two (2) interlock balls in cross-bore in front
support boss between reverse and 3rd and 4th shifter shaft.
Assembly (Fig. 7B-6L) Install the interlock pin in the 3rd and 4th shifter shaft hole.
1. In reassembling the transmission cover, care must Apply grease to hold in place. Push 3rd and 4th shaft
be used in installing the shifter shafts. They should be through fork and cover bore, keeping both balls and pin in
installed in the order shown in Fig. 7B-7L, namely, reverse, position between shafts until retaining holes line up in fork
3rd-4th, and lst-2nd. Fig. 7B-6L illustrates the difference and shaft. Install retaining pin and move to neutral position.
in the shafts. 6. Place two (2) interlock balls between the 1st and 2nd
2. Place fork detent ball springs and balls in position shifter shaft and 3rd and 4th shifter shaft in the cross-bore
in holes in cover. of the front support boss. Hold 1st and 2nd fork in position
3. Start shifter shafts into cover; depress detent balls and push shaft through cover bore in fork until retainer hole
with small punch and push shafts on over balls. (See Fig. and fork line up with hole in shaft. Install retainer pin and
7B-7L). Hold reverse fork in position and push shaft move to neutral position.
through yoke. Install split pin in fork and shaft; then, push 7. Install new shifter shaft hole expansion plugs and
fork in neutral position. expand in place.

1. Transmission Cover 8. 3rd-4th Shifter Fork 13. Interlock Plunger

2. Interlock Balls 9. "C" Ring Lock Clip Spring
3. 3rd-4th Shifter Shaft 10. Reverse Shifter Fork 14. Reverse Interlock
4. Reverse Shifter Shaft 11. Shifter Shaft Hole Plunger
5. Fork Retaining Pin Plugs 15. 1st-2nd Shifter Shaft
6. Detent Ball 12. 1st-2nd Shifter Fork 16. Interlock Pin
7. Detent Spring 17. Cover Gasket

Fig. 7B-6L~Cover Assembly Exploded V ie w

 M A N U A L TR A N SM IS S IO N 7B-39

REVERSE

3RD/4TH

1ST/2N D

Fig. 7 B -7 L -S h ifte r Shaft Installatio n

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. Fig. 7 B -9 L -P o sitio n in g Tool J -2 2 8 7 2 to Drive Gear

O IL SLINGER

RETAINER R IN G

SNAP R IN G

Fig. 7B-8L--Drive Gear Assembly

7B-40 M A N U A L TR A N SM IS S IO N

2. Install snap ring to secure bearing on drive gear

shaft.
3. Install bearing retainer ring in groove on O.D. of
bearing.
CAUTION: 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-
12L).
NOTE: 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
Fig. 7B-1 O L-Rem oving Drive Gear Bearing 1. Remove retainer and oil seal assembly and gasket.
2. Pry oil seal out of retainer.
4. Inspect gear teeth for excessive wear. 3. Install new seal on Tool J-22833 with lip of seal
5. Inspect clutch shaft pilot for excessive wear. toward flange of tool.
6. Re-oil bearing, then rotate drive gear bearing slowly 4. Support front surface of retainer in press, start seal
by hand and check for roughness. and tool in retainer bore and drive seal into retainer until
flange of tool bottoms on retainer (Fig. 7B-13L).
Assembly 5. Install new gasket on retainer and install retainer on
1. Press bearing and new oil slinger onto drive gear transmission case (when assembling transmission).
shaft using Tool J-22872 (Fig. 7B-11L). Slinger should be
located flush with bearing shoulder on drive gear. See
Figure 7B-8L for direction of slinger installation.
CAUTION: Exercise care to prevent distortion of
the oil slinger.

Fig. 7B-1 1 L--Replacing Drive Gear Bearing Fig. 7B-12L--Pilot Roller Bearing Installed
 M A N U A L T R A N S M IS S IO N 7B-41

M AINSHAFT A SSEM BLY

Disassembly (Fig. 7B-14L)
1. Remove first speed gear 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 1st speed gear bushing
and 2nd speed synchronizer hub.
7. Split 2nd speed gear bushing with chisel and remove
bushing from shaft.
CAUTION: Exercise care not to damage
mainshaft.
Fig. 7 B -13 L--I nsta I ling Bearing Retainer Oil Seal

1. 1st Speed Gear 5. 2nd Speed B lo cker 10. 3 rd Speed B lo cke r 13. 4th Speed B lo cke r
2. Reverse Driven Gear Ring Ring Ring
3. 1st Gear Bushing 6. 2nd Speed Gear 1 1. 3 rd -4 th Speed 14. Snap Ring
4 1st-2nd Gear 7. T h ru st W ashe r S ynch ron izer Hub 15. M a in sh a ft
S ynch ron izer Hub 8. 3rd Speed B ushing A ssem bly 16. 2nd Speed Gear
A ssem bly 9 3rd Speed Gear 12. 3 rd -4 th Speed B ushing
S ynch ron izer Sleeve

Fig. 7B-1 4L--Mainshaft Assembly Exploded V ie w

7B-42 M A N U A L TRAN SM IS S IO N

scoring.
6. Inspect 2nd speed gear for excessive wear at thrust
surface. Check synchronizer springs for looseness 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.
NOTE: First and reverse sliding gear must be sliding
fit on synchronizer hub and must not have excessive
radial or circumferential play. If sliding gear is not free
on hub, inspect for burrs which may have rolled up on
front end of half-tooth internal splines and remove by
honing as necessary.
9. Inspect all gear teeth for excessive wear.
Assembly
1. Using Tool J-22873 press 2nd speed bushing onto
Fig. 7B-1 5L--Disassem bly of M ainshaft
mainshaft until it bottoms against shoulder (Fig. 7B-16L).
Inspection NOTE: Lubricate bushing with E.P. oil before
1. Wash all parts in cleaning solvent. pressing.
2. Inspect mainshaft for scoring or excessive wear at CAUTION: 1st, 2nd and 3rd speed gear bushings
thrust surfaces or splines. are sintered iron, exercise care when installing.
3. Inspect clutch hub and clutch sleeve for excessive 2. Press 1st and 2nd speed synchronizer hub onto
wear and make sure sleeve slides freely on clutch hub. Also mainshaft until it bottoms against shoulder with annulus
check fit of clutch hub on mainshaft splines. toward rear of shaft.
NOTE: 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.
NOTE: 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

Fig. 7 B - 1 6L —Installing 2nd Speed Gear Bushing Fig. 7B-1 7L —Installing 3rd Speed Gear Bushing
 M A N U A L T R A N S M IS S IO N 7B-43

9. Install reverse driven gear with fork groove toward

rear.
10. Install 1st speed gear onto mainshaft and against
1st and 2nd synchronizer hub. Install 1st speed gear thrust
washer.
COUNTERSHAFT ASSEM BLY
Disassembly
1. Remove front countergear retaining ring and thrust
washer. Discard snap ring.
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
Fig. 7B-1 8L—Installing 3rd Speed Gear Bushing
clutch countergear assembly.
3. Install 1st and 2nd synchronizer keys and springs (if
previously removed).
4. Using Tool J-22873 press 1st speed gear bushing
onto mainshaft until it bottoms against hub (Fig. 7B-17L).
NOTE: Lubricate all bushings with E.P. oil before
installation of gears.
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.
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. Fig. 7B-20L--Positioning Tool J - 2 2 8 3 2 on Countershaft
7B-44 M A N U A L TRAN SM IS S IO N

NOTE: 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.
CAUTION: Do not over stress snap ring.
4. Position clutch countergear and spacer on shaft and
press countergear onto shaft against snap ring using Tool
J-22873, (Fig. 7B-22L).
NOTE: Countergear is a slip fit and pressing may not
be required.
5. Install clutch countergear thrust washer and front
retaining ring using Tool J-22830 and J-22873 (Fig. 7B-
21L).
CAUTION: Do not over stress snap ring. Ring
Fig. 7B-2 1 L—Installing C ounter Gear Snap Ring should be tight in groove without side play.
NOTE: Countergear is a slip fit and pressing may not
be required. ASSEMBLY OF TRANSMISSION
3. Remove clutch countergear rear retaining ring. 1. Lower the countergear into the case until it rests on
Discard snap ring. bottoms of case.
4. Remove 3rd speed countergear retaining ring. 2. Place reverse idler gear in transmission case with
Discard snap ring. gear teeth toward the front. Install idler gear shaft from rear
5. Position assembly on an arbor press and press shaft to front, being careful to have slot in end of shaft in facing
from 3rd speed countergear. down. Shaft slot face must be at least flush with case.
Assembly
1. Position 3rd speed countergear and shaft in arbor
press and press the gear onto the shaft.

Fig. 7 B -2 2 L -ln s ta llin g Clutch Co untergear Fig. 7B-23L--lnstalling M ainshaft Rear Bearing
 M A N U A L T R A N SM IS S IO N 7B-45

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. lbs.
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 in. 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
Fig. 7B -24L--C ountergear Front Support Tool brake backing plate assembly on models equipped with
3. Install mainshaft assembly into case with rear of propeller shaft brake.
shaft protruding out rear bearing hole in case. Position Tool NOTE: On models equipped with 4-wheel drive, install
J-22874 in clutch gear case opening and engaging front rear lock nut and washer using Tool J-23070 (Fig. 7B-
mainshaft (Fig. 7B-23L). Rotate case onto front end. 26L). Torque lock nut to 120 ft. lbs. and bend washer
NOTE: Install 1st speed gear thrust washer on shaft, tangs to fit slots in nut.
if not previously installed. 14. Install parking brake drum and/or universal joint
4. Install snap ring on bearing O.D. and position rear flange.
mainshaft bearing on shaft. Using Tool J-22874-1 drive NOTE: Apply light coat of oil to seal surface.
bearing onto shaft and into case (Fig. 7B-23L). Rotate case 15. Lock transmission in two gears at once. Install
and remove Tool J-22874-5. universal joint flange locknut and tighten to 90-120 ft. lbs.
5. Install synchronizer cone on pilot end of mainshaft 16. Move all transmission gears to neutral except the
and slide rearward to clutch hub. reverse idler gear which should be engaged approximately
CAUTION: Make sure three cut out sections of 3/8 of an inch (leading edge of reverse idler gear teeth lines
4th speed synchronzier cone align with three up with the front edge of the 1st speed gear). Install cover
clutch keys in clutch assembly. 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 bolts and torque to 20-25 ft.
lbs.
18. Using Tool J-8109, replace gearshift lever and
check operation of transmission.

Fig. 7B- 26 L~lnsta llin g M ainshaft Rear Bearing Lock Nut (4-
Fig. 7B-25L--lnstalling Countergear Rear Bearing W h e e l Drive only)
7B-46 M A N U A L TRAN SM IS S IO N

SPECIFICATIONS
THREE SPEED 76mm THREE SPEED 77mm

Clutch Gear Retainer to Case Bolts............... 15 ft. lbs. Clutch Gear Retainer to Case B o lts................ 35 ft. lbs.
Side Cover to Case Bolts................................ 15 ft. lbs. Top Cover to Case Bolts ................................... 30 ft. lbs.
Extension to Case Bolts.................................. 45 ft. lbs. Extension to Case B olts..................................... 45 ft. lbs.
Shift Lever to Shifter Shaft Bolts................. 25 ft. lbs. Shift Lever to Shifter Shaft Bolts ................... 25 ft. lbs.
Lubrication Filler Plug.................................. 13 ft. lbs. Lubrication Filler Plug ..................................... 15 ft. lbs.
Transmission Case to Clutch Housing Bolts . . 75 ft. lbs. Transmission Case to Clutch Housing Bolts . . 75 ft. lbs.
Crossmember to Frame N uts........................ 25 ft. lbs. Crossmember to Frame N u ts............................ 25 ft. lbs.
Crossmember to Mount Bolts ...................... 40 ft. lbs. Crossmember to Mount Bolts .......................... 40 ft. lbs.
2-3 Cross Over Shaft Bracket Retaining Nut . 18 ft. lbs. 2-3 Cross Over Shaft Bracket Retaining Nut . 18 ft. lbs.
1-Rev. Swivel Attaching B olt........................ 20 ft. lbs. 1- Rev. Swivel Attaching B o lt.......................... 20 ft. lbs.
Mount to Transmission B o lt........................ 50 ft. lbs. Mount to Transmission Bolt ............................ 50 ft. lbs.

FOUR-SPEED 76mm

Clutch Gear Retainer to Case Bolts......................................................................................................................... 15 ft. lbs.

Side Cover to Case Bolts ..........................................................................................................................................15 ft. lbs.
Extension to Case Bolts .......................................................................................................................................... 45 ft. lbs.
Shift Lever to Shifter Shaft Bolts............................................................................................................................25 ft. lbs.
Lubrication Filler Plug...............................................................................................................................................18 ft. lbs.
Transmission Case to Clutch Housing Bolts...............................................................................................................75 ft. lbs.
Crossmember to Frame N uts.....................................................................................................................................25 ft. lbs.
Crossmember to Mount and Mount to Extension Bolts..........................................................................................40 ft. lbs.
Mount-To-Transmission Bolts.....................................................................................................................................32 ft. lbs.

FOUR-SPEED 83mm

Clutch Gear Retainer to Case B o lts ........................18 ft. lbs.

Side Cover to Case B o l t s ...................................... 18 ft. lbs.
Extension to Case B o l t s ...................................... 40 ft. lbs.
Shift Lever to Shifter Shaft B o l t s ........................20 ft. lbs.
Lubrication Filler P lu g ...........................................15 ft. lbs.
Transmission Case to Clutch Housing Bolts . . . 52 ft. lbs.
Crossmember to Mount and Mount to Extension
B olts...................................................................25 ft. lbs.
Rear Bearing Retainer to Case B o l t s ................... 25 ft. lbs.
Extension to Rear Bearing Retainer Bolts (Short) . 25 ft. lbs.
Retainer to Case B o l t ...........................................35 ft. lbs.
Transmission Drain P l u g ...................................... 20 ft. lbs.

FOUR-SPEED 117mm

Clutch Gear Bearing Retainer to Case Bolts ............................................................................................................. 25 ft. lbs.

Cover to Case B olts.................................................................................................................................................... 20 ft. lbs.
Extension and Retainer to Case Bolts—(Upper).........................................................................................................20 ft. lbs.
—(Lower).........................................................................................................30 ft. lbs.
Lubrication Filler Plug................................................................................................................................................30 ft. lbs.
Shift Lever to Shifter Shaft N u t.................................................................................................................................20 ft. lbs.
Mount-To-Transmission Bolts ....................................................................................................................................32 ft. lbs.
 M A N U A L T R A N S M IS S IO N 7B-47

SP E C IA L TOOLS

II

11

13

1. J -1126 Transmission Guide Pins 7. J-1453-01

2. J 8059 Retainer Snap Ring Pliers Press Plate Holder J-358-1
3. J-22246/J-22379 Countergear Loading Tool 8. J-2228 Rear Bearing Press Plates
4. J-5778 Extension Bushing Remover and Installer 9. J-933 Main Drive Gear Wrench
5. J-5154 Extension Seal Installer 10. J-5590 Clutch Gear Bearing Installer
6. J 5814-01 Speedometer Drive Gear Remover 11. J-9772 Clutch Gear Bearing Installer
and Adapter J 5814-15 12. J-23096 Clutch Gear Retainer Seal Installer
13. J-5752 Transmission Holding Fixture

M an u al Transmission Special Tools (Except 4-Speed, 1 17mm)

7B-48 M A N U A L TR A N SM IS S IO N

fid

O o 10

1. J 23432-1 Snap Ring Picks.

2. J-23432 Snap Ring Pliers.
3. J-8092 Handle.
4. J-23429 Intermediate Shaft Remover and Installer.
5. J 22836 Front Output Shaft Bearing Retainer Seal Installer.
6. J-21359 Rear Output Shaft Bearing Retainer Seal Installer.
7. J-23431 Rear Output Shaft Housing Bearing Remover and Installer.
8. J 7137 Adapter Seal Installer.
9. J 9276 2 Intermediate Gear Bearing Cup Installer.
10. J 22875 Rear Output Shaft Rear Bearing Installer.

4-Speed, 1 17mm, Transmission Special Tools

 CLUTCHES 7C-1

SECTION 7C

CLUTCHES
CONTENTS
Single Plate Diaphragm Spring Clutch........................................... ..7C-1
Single Plate Coil Spring Clutch.........................................................7C-3
Special Tools .........................................................................................7C-7
SINGLE PLATE DIAPHRAGM CLU TCH
INDEX
Disassembly........................................................................................ 7C-1
Inspection........................................................................................... 7C-1
Assembly............................................................................................. 7C-2
Pilot Bearing Replacement............................................................... 7C-3
DISASSEM BLY (FIG. 7C-3A) INSPECTION
NOTE: When disassembling, mark edge of pressure 1. Check drive straps for looseness at the clutch cover
plate and cover. These marks must be aligned in and evidence of looseness at pressure plate bolt holes,
assembly to maintain balance. 2. Wash all parts, except driven disk and throwout
1. Remove three drive-strap to pressure plate bolts and bearing, in cleaning solvent.
retracting springs and remove pressure plate from clutch NOTE: The throwout bearing is permanently packed
cover. with lubricant and should not be soaked in cleaning
2. The clutch diaphragm spring and two pivot rings are solvent as this will dissolve the lubricant.
riveted to the clutch cover. Spring, rings and cover should 3. Inspect pressure plate and flywheel for scores on the
be inspected for excessive wear or damage and if there is contact surfaces. Use a straight-edge and check for flatness
a defect, it is necessary to replace the complete cover of contact surfaces.
assembly. 4. Check throwout bearing for roughness and free fit

1. Flywheel 5. Pressure Plate 9. Fork

2. Dowel-hole 6. Diaphragm Spring 10. Retracting Spring
3. Pilot Bushing 7. Cover
4. Driven Disc 8. Release Bearing

Fig. 7C -1A ~F la t Finger Clutch Cross-Section (Typical)

7C-2 CLUTCHES

1. Flywheel 5. Pressure Plate 8. Throwout Bearing

2. Dowel-hole 6. Diaphragm Spring 9. Fork
3. Pilot Bushing 7. Cover 10. Retracting Spring
4. Driven Disc

Fig. 7C-2A--Bent Finger Clutch Cross-Section (Typical)

on the sleeve of the transmission clutch gear bearing freely on splines of transmission clutch shaft. If splines are
retainer. Replace retainer if rough. worn, the clutch disc or clutch gear should be replaced as
5. Inspect clutch disc for worn, loose or oil soaked necessary.
facings, broken springs, loose rivets, etc. Replace if 7. Inspect clutch fork ball socket and fingers for wear
necessary. and ball retaining spring for damage. Spring should hold
6. Examine splines in hub and make sure they slide fork tightly to ball stud.
NOTE: Ball spring on fork may be bent in toward fork
if necessary.
8. Inspect ball stud for wear. Replace if scored.
9. Check run out of 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.
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. lbs. torque. The clutch is now ready to be
Fig. 7 C -3 A -R e tra c tin g Spring Location (Typical) installed.
 CLUTCHES 7C-3

PILOT BEARING REPLACEMENT

The clutch pilot bearing is an oil impregnated type
bearing pressed into the crankshaft. This bearing requires
attention when the clutch is removed from the vehicle, at
which time it should be cleaned and inspected for excessive
wear or damage and should be replaced if necessary.
To remove, install Tool J-1448 and remove bearing
from crankshaft, as shown in (Fig. 7C-4A). 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 drops of machine oil.

Fig. 7C-4A--Clutch P ilot Bearing Removal (Typical)

SINGLE PLATE COIL SPRING CLU TCH

INDEX
Disassembly........................................................................................ .7C-3
Inspection........................................................................................... .7C-3
Assembly..............................................................................................7C-3
Adjusting Levers.................................................................................7C-4
DISASSEM BLY ASSEMBLY
1. Place the cover assembly on the bed of an arbor or 1. Lay the pressure plate on the block in the press and
drill press with a block under the pressure plate so arranged coat the lugs with a thin film of approved lubricant such
that the cover is left free to move down. as lubriplate. See Fig. 7C-6E.
2. Place a block or bar across the top of the cover with 2. Assemble lever, eyebolt and pin, holding eyebolt and
the spindle. Hold compressed while the adjusting nuts are lever as close together as possible and with the other hand
removed, as shown in Fig. 7C-2E. Then slowly release grasp strut as shown in Fig. 7C-7E.
pressure to prevent springs flying out. 3. Insert strut in the slots in the pressure plate lug, drop
slightly and tilt the lower edge until it touches vertical
3. Lift off cover and all parts will be available for milled surface of lug.
inspection. Note carefully the location of all parts including 4. Insert lower end of eyebolt in hole in pressure plate.
arrangement of springs. See Fig. 7C-3E. The short end of the lever will then be under the hook of
4. To remove levers grasp lever and eyebolt between the pressure plate and near the strut, as in Fig. 7C-5E.
thumb and fingers as shown in Figure 7C-4E, so that inner 5. Slide the strut upward in the slots of the lug, lifting
end of lever and upper end of eyebolt are close together, it over the ridge on the short end of the lever and drop it
keeping eyebolt pin seated in its socket in lever. into the groove in the lever, as shown in Fig. 7C-4E.
5. Lift strut over ridge on end of lever, as in Fig. 7C-5E. 6. Assemble the pressure springs, on the small bosses
6. Lift lever and eyebolt off pressure plate. of the pressure plate in accordance with Fig. 7C-8E in order
to retain original balance.
NOTE: It is important to replace all parts which show NOTE: If there are spaces for more springs than
wear. specified for the particular assembly, or if two different
colors of springs are used, Fig. 7C-8E shows the proper
INSPECTION sequence. It is very important that each group be
In addition to applicable items listed under Diaphragm arranged in like sequence.
Clutch Inspection, check the following items. 7. Assemble anti-rattle springs in cover. See Fig. 7C-
1. Check driving lugs for wear. 9E. The spring to the left is in operating position.
2. Check clutch cover for distortion or cracks. 8. Lower the cover on top of the assembled parts, as
in Fig. 7C-10E. Be sure that the anti-rattle springs are in
3. Check release levers for wear or cracks. correct position and also that the punch marks made before
7C-4 CLUTCHES

Fig. 7C-3E~Disassem bly of Clutch

them down until their tops are flush with the tops of the
eyebolts. Slowly release pressure of spindle and remove
cover assembly from press.
A DJUSTING 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.
NOTE: It is recommended that a spare flywheel be
obtained so that this operation may be performed at the
bench.
1. Release Lever 7. Drive Disc 2. Bolt cover on flywheel with gauge plate center.
NOTE: On assemblies with three levers, the three flat
2. Eyebolt 8. Pressure Plate
3. Strut 9. A nti-R attle Spring
4. Cover 10. Throwout Bearing
machined lands of the gauge plate must be located
directly under the levers.
5. Adjusting Nut 11. Flywheel
6. Coil Spring

3. Depress each lever several times with a hammer

Fig. 7C-1E--Coil Spring Clutch Cross-Section (Single Plate) handle to settle all parts into working position, as shown
in Fig. 7C-12E.
4. Position height gauge J-6456-01 on the hub of the
dismantling are matched to insure retaining the original gauge plate and the bearing surface of one lever. Refer to
balance. Fig. 7C-13E. Turn adjusting nut until lever is flush with the
9. Place a bar across the cover and slowly compress, 12" step of J-6456-01. Adjust remaining levers in same
guiding the holes in the cover over the pressure plate lugs manner.
and all springs into their spring seats in the cover.
10. Assemble adjusting nuts on the eyebolts and screw

Fig. 7C-2E--Compressing Clutch Fig. 7C-4E--Grasping Lever and Strut

 CLUTCHES 7C-5

3 S P R IN G S
U N P A IN T E D

9 SP R IN G S
P A IN T E D
350 V-8 ORANGE 4 5 4 -V 8
A DJA CEN T
T O LEVERS

Fig. 7C-8E--Spring A rran ge m ent Diagram

Fig. 7C-5E--Removing or Installin g Lever

Fig. 7C -6E-G reasing Lug

5. Stake adjusting nut, as shown in Fig. 7C-14E, to

eyebolt with a dull punch to lock adjustment.
6. Loosen the cover to flywheel bolts a turn or two at Fig. 7C -9E--lnstalling Anti-R attle S pring

a time and in rotation until spring pressure is relieved to

allow clutch and gauge plate to be removed.

EYEBOLT

RELEASE
LEVER

STRUT

Fig. 7C-7E—Installing Lever Fig. 7 C -1 0 E -A s s e m b lin g Cover and Pressure Plate

7C-6 CLUTCHES

Fig. 7C-1 2E--Depressing Lever Fig. 7C-1 4E~Staking Nut

 CLUTCHES 7C-7

SP E C IA L TOOLS

1. J-6456-01 Height Gauge

2. J-1048 Gauge Plate
3. J-1522 Pilot Bearing Driver
4. J-23720 Clutch Pilot Tool
5. J-1448 Pilot Bearing Puller

Fig. 7C-1 ST-Clutch Special Tools

 TRANSFER CASES 7D-1

SECTION 7D

TRANSFER CASES
CONTENTS
Model 205 (Part Time) Transfer Case...........................................7D-1
Model 203 (Full Time) Transfer Case...........................................7D-8
Adapter Assemblies..........................................................................7D-19
Specifications.....................................................................................7D-20
Special Tools.....................................................................................7D-21
MODEL 205 (PART TIME) TRAN SFER C A SE
INDEX
Disassembly of Transfer Case......................................7D-1 Assembly of Transfer Case......................................... 7D-5
Rear Output Shaft Assembly...................................7D-1 Idler Gear................................................................. 7D-5
Front Output Shaft Assembly............................... ..7D-3 Shift Rail and Fork Assemblies............................ 7D-6
Shift Rail and Fork Assemblies............................ ..7D-3 Front Output Shaft Assembly................................ 7D-6
Idler Gear...................................................................7D-5 Rear Output Shaft Assembly................................. 7D-7
Cleaning and Inspection............................................. ..7D-5 Miscellaneous........................................................... 7D-8
DISASSEM BLY OF TRANSFER CASE
(FIG. 7D-4R)
Rear Output Shaft and Yoke Assembly
(Fig. 7D-2R)
1. Loosen rear output shaft yoke nut.
2. Remove rear output 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.
8. Remove pilot rollers (15), retainer ring and washer. Fig. 7D-2R~Front View of Transfer Case

REAR OUTPUT
ASSEMBLY

IDLER SHAFT COVER FRONT

OUTPUT SHAFT
REAR BEARING
FRONT OUTPUT SHAFT RETAINER
REAR BEARING RETAINER
I
Fig. 7D-3R ~Removing Front Output Shaft Rear Bearing
Fig. 7D-1 R -R e a r V ie w of Transfer Case Retainer
7D-2 TRANSFER CASES

45 44 43 414241

1. Input Shaft 18 Rear Bearing 32 Idler Gear Shaft Bearing 43. Sliding Clutch
2 " 0 ” Ring 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 Seal 35 Idler Shaft Gear 50. Washer
Washer 24 Snap Ring Cover and Gasket 51 Locknut
9. Roller Bearings 25 Bearing 36 Thrust Washer 52. Output Yoke
10 Spacer 26. Speedometer Gear 37. Snap Ring 53. Bearing Retainer
11 Thrust Washpr 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. Idler 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 Drive Low Gear 59 Bearing Cone
17. Rear Output Shaft Low Gear 41. Roller Bearings 60. Bearing Cup
Housing 42. Spacer

Fig. 7 D -4 R ~ M o d e l 2 0 5 Transfer Case Cross Section

 TRANSFER CASES 7D-3

RANGE
SHIFT RAIL
J-23432-1

" 1 ---------------------
4-WHEEL
SNAP RING SHIFT RAIL

4-WHEEL
SHIFT RAIL

Fig. 7D-5R--Removing Gear Retaining Ring Fig. 7D-7R--Shift Rail Removal

9. Remove oil seal retainer, ball bearing, speedometer Position new bearing to outside face of cover and using a
gear and spacer. Discard all gaskets. Press out bearing as piece of pipe or wood to cover outside diameter of bearing,
required. press bearing into cover until flush with opening.
10. Remove oil seal from the retainer. Shift Rail and Fork Assemblies
Front Output Shaft Assembly (Fig. 7D-3R) 1. Remove the two poppet nuts on top of case, two
1. Remove lock nut, wahser and yoke. poppet springs, and using a magnet, remove the poppet
2. Remove front bearing retainer attaching bolts and bails.
retainer. 2. Drive cup plugs into case using a 1/4 inch punch.
3. Remove front output shaft rear bearing retainer 3. Position both shift rails in neutral and using a long,
attaching bolts. narrow punch, drive shift fork pins through shift rails into
4. Tap on output shaft with a soft hammer (Fig. 7D- the case (Fig. 7D-6R).
4R) and remove shaft, gear assembly, and rear bearing 4. Remove clevis pins and shift rail link.
retainer from case. 5. Remove shift rails (Fig. 7D-7R), upper (range) rail
NOTE: Remove the sliding clutch from output high first, then lower (4-wheel) rail.
gear, washer, and bearing which will have remained in 6. Remove shift forks and sliding clutch from case.
the case. 7. Remove the front output high gear, wahser, and
5. Using large snap ring picks, such as J-23432-1, bearing from the case. Remove the shift rail cup plugs and
remove the gear retaining ring from the shaft (Fig. 7D-5R) pins from the case.
and discard. Input Shaft Assembly
6. Remove thrust washer and pin from shaft. 8. Remove snap ring in front of bearing. Using a soft
7. Remove gear, needle bearings (32 per row) and hammer, tap shaft out rear of case. Tap bearing out front
spacer. of case.
8. If necessary to replace front output shaft rear 9. Tip case on P.T.O. and remove two interlock pins
bearing, support cover and press bearing from cover. from inside of case.

“ T” HANDLE W / ^ 2 EASY
OUT WELDED O N END

TOOL J-23429

Fig. 7D-6R ~Removing Shift Fork Pins Fig. 7D-8R--Removing Idler Gear Shaft
7D-4 TRANSFER CASES

1 Rear Output Shaft Locknut 26 Sliding Clutch 49 Cover Gasket

2 Washer 27 Input Shaft 50 Rear Cover
3 Yoke 28 Transfer Case 51 Front Out put Shaft Locknut
4 Bearing Retainer and Seal 29 Poppet Plug, Spring and Ball 52 Wa s h e r
Assembly 30 P T 0 Gasket and Cover 53 Yoke
5. Snap Ring 31 Input Shaft Bearing and Snap 54 Bearing Retainer and Seat
6 Bearing Ring 55 Gasket
7 Speedomet er Gear 32 Snap Ring and Rubber "O ' 56 Snap Ring
Ring 57 Front Bearing
9 Gasket 33 Shift Link Clevis Pin 58 Thrust Wa s h e r
10 Housing 34 Range Shift Rail 59 Front Whe e l High Gear
11 Gasket 35 Shift Rail Connector Link 60 Front Output Shaft
12 Bearing 36 Front Wheel Drive Shift Rail 61 Needl e Bearings
13 Snap Ring 37 Interlock Pins 62 Spacer
14 Thrust Washer 38 Rear Idler Lock Nut 63 Needl e Bearing
15 Thrust Washer Lock Pin 39 Washer 64 Sliding Clutch Gear
16 Thrust Washer (Tanged) 40 Shift Rail Seals 65 Shift Fork
17 Low Speed Gear 41 Idler Shaft Bearing 66 Roll Pin
18. Needl e Bearings 42 Bearing Cup 67 Front Out put Low Gear
19 Spacer 43 Shims 68 Thrust Wash er Lock Pm
20 Needl e Bearings 44 Idler Gear 69 Thrust Wa s h e r
21 Tanged Washer 45 Bearing Cup 70 Snap Ring
22 Rear Output Shaft 46 Spacer 71 Rear Cover Gasket
23 Needl e Bearings 47 Idler Shaft Bearing 72 Reai Cover and Bearing
24 Wash er and Retainer 48 Idler Shaft
25 Shift Fork

Fig. 7D-9R --New Process Model 2 0 5 Transfer Case Exploded V ie w

 TRANSFER CASES 7D-5

FRONT OUTPUT
BORE

J-8092

J -9 2 7 6 -2

IDLER GEAR ASSEMBLY

Fig. 7 D -10R --lnstalling New Bearing Cups Fig. 7D-1 2 R—I rista I ling Idler Gear

Idler Gear as much lubricant as possible. Remove bearings and blow

1. Remove idler gear shaft nut. out with compressed air, being careful to direct air across
2. Remove idler shaft rear cover. bearing so that bearings do not spin.
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 Shafts and Gears -Clean all shafts in cleaning
from case. solution to remove all accumulations. Dry with compressed
5. Remove bearing cups (2) as required from idler gear. air.
CLEANING AND INSPECTION Case, Cover and Bearing Cups -Transfer case,
Bearings -Place all bearings and rollers in cleaning cover, and bearing cups must be thoroughly cleaned in
solution and allow to remain long enough to loosen all solution to remove all accumulation of lubricant and dirt.
accumulated lubricant. Bearings should be sloshed up and Remove all trace of gaskets from surface where used.
down and turned slowly below surface of solution to remove
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 dlamaged, 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.
ASSEM BLY 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-
Fig. 7D-1 1R~Checking Idler Gear End Play 12R).
7D-6 TRANSFER CASES

Fig. 7D -13R --lnstalling Idler Shaft Fig. 7D-1 5 R—Installing S h ift Rail Lock Pins

4. Install idler shaft from large bore side and drive 7. Install sliding clutch onto fork, place over input shaft
throuhg using a soft hammer (Fig. 7D-13R). in case. Position to receive range rail and push rail through
5. Install washer and new locknut. Check for end play to neutral position.
and free rotation. Torque nut to 150 ft. lbs. 8. Install new lock pins through holes at top of case
6. Install idler shaft cover and gasket. Torque bolts to and drive them into the forks (Fig. 7D-15R).
20 ft. lbs. NOTE: Tip case on P.T.O. opening when installing
NOTE: Flat on cover must be located adjacent to front range rail lock pin.
output shaft rear cover (Fig. 7D-14R). Front Output Shaft and Gear Assembly
Shift Rail and Fork Assemblies 1. Install two rows of needle bearings (32 each)
1. Press the two rail seals into the case. Seals should separated by a spacer in the front low output gear and reatin
be installed with metal lip outward. with a sufficient amount of grease.
2. Place front output shaft in soft jawed vise, spline end
2. Install interlock pins through large bore or P.T.O. down. Install front low gear over shaft with clutch gear
opening. facing down and install thrust washer pin, thrust washer
3. Start front output drive shift rail into case from back, and new snap ring using Tool J-23432.
slotted end first, with poppet notches up. NOTE: Position the snap ring so that the opening is
4. Install shift fork (long end inward) into rail, push opposite the pin.
rail through to neutral position.
5. Install input shaft bearing and shaft into case.
6. Start range rail into case from front, with poppet
notches up.

COVER FLAT

J-22836

Fig. 7D-1 4R —Installing Idler Shaft Rear Cover Fig. 7D-1 6R —Installing Front Output Bearing Retainer Seal
 TRANSFER CASES 7D-7

3. Position front wheel hi-gear and washer in case. Rear Output Shaft Assembly
Install sliding clutch in the shift fork, then put fork and rail 1. Install two rows of needle bearings (32 each)
in the front wheel drive (4-Hi) position with the clutch teeth separated by a spacer into the output low gear.
in mesh with the teeth of the front wheel hi-gear. NOTE: Use sufficient grease to retain needles.
4. Line up washer, high gear, and sliding clutch with 2. Install thrust washer onto rear output shaft, tang
bearing bore. Insert front output shaft and low gear down in clutch gear groove. Install output low gear onto
assembly through the high gear assembly. shaft with clutch teeth facing down.
5. Install new seal in bearing retainer using Tool J- 3. Install thrust washer over gear with tab pointing up
22836 (Fig. 7D-16R) and install the front output bearing and away from gear. Install washer pin and also large thrust
and retiner in the case. washer over shaft and pin. Rotate washer until tab fits into
6. Clean and grease rollers in front output rear bearing slot approximately 90 degrees away from pin. Finally, install
retainer. Install onto case using one gasket. Dip bolts into snap ring using Tool J-23423 and J-23423-1 and check end
sealant. Install bolts and torque to 30 ft. lbs. play which should be within .002-.027 inch.
7. Install front output yoke, washer and lock nut. 4. Grease pilot bore or rear output shaft and install
Torque nut to 150 ft. lbs. 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
J-234 31

BEARING

REAR OUTPUT
LOW GEAR
CLUTCH GEAR

Fig. 7D-1 8R --lnstalling Rear O utpu t S haft Spacer and

Fig. 7D-1 7R ~lnstallin g Rear O utput S haft Housing Bearing Speedom eter Gear
7D-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. lbs.
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. lbs.
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. lbs.
4. Install shift rail cross link, clevis pins and lock pins.

Fig. 7D -19R --lnstalling Rear Bearing Retainer Seal

MODEL 203 (FULL TIME) TRAN SFER C A SE

INDEX
Disassembly of Transfer Case......................................7D-8 Input Gear Bearing Replacement........................... ..7D-15
Cleaning and Inspection............................................. ..7D-10 Input Gear Bearing Retainer Seal Replacement.... 7D-16
Subassembly Repairs......................................................7D-10 Rear Output Shaft Housing Assembly.....................7D-16
Differential Carrier Assembly....................................7D-10 Front Output Shaft Bearing Retainer Seal
Lockout Clutch Assembly..........................................7D-11 Replacement................................................................7D-17
Input Shaft Assembly............................................... ..7D-11 Front Output Shaft Rear Bearing Replacement.... 7D-17
Range Box Assembly................................................ ..7D-11 Assembly of Transfer Case.........................................7D-17
DISASSEM B LY OF TRANSFER CASE 6. Remove bolts retaining rear section of rear output
Refer to Figs. 7D-1 OS, 7D-11S and 7D-12S for cross housing from front section of rear output housing, and
sectional and exploded views of the transfer case. disengage. Remove shims and speedometer gear from
1. Position transfer case on work bench or suitable output shaft.
work table.
NOTE: If lubricant was not drained from unit prior
to removal from vehicle, remove front output rear INPUT GEAR
cover and P.T.O. cover lower bolts and drain lubricant
into waste container.
FRONT OUTPUT
SHAFT ASSY.
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.
NOTE: 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 bolts retaining front output shaft front CHAIN
bearing retainer (Fig. 7D-4S). Remove bearing retainer and HOUSING RANGE SELECTOR
COUNTER GEAR
gasket from transfer case. Discard gasket. HOUSING

5. Using a hoist or other suitable lifting tool, position

assembly on blocks (Fig. 7D-5S). Fig. 7 D - 1 S - F r o n t V i e w o f Transfer Case
 TRANSFER CASES 7D-9

LOCKOUT CLUTCH
REAR OUTPUT
SHIFT RAIL POPPET PLUG
H O U S IN G
RANGE SELECTOR
^ SHIFTER SHAFT

CHAIN
H O U S IN G

REAR OUTPUT
FRONT OUTPUT
SHAFT ASSY.
BEARING REAR
COVER
Fig. 7D -4S-R em oving Front O utput Shaft Front Bearing
Fig. 7D -2S-R ear V iew of Transfer Case Retainer
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.
NOTE: 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. 7D-6S).
9. Remove shift rail poppet ball plug, gasket spring and
ball from case (Fig. 7D-7S). A 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-5S-Positioning Transfer Case for Disassembly

Fig. 7 D - 3 S - R e m o v i n g Rear O u t p u t S h a ft Flange N u t Fig. 7 D - 6 S - R e m o v i n g S h ift F o r k Retaining Pin

7 D-10 TRANSFER CASES

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
Fig. 7D-7S-Rem oving or Installing Poppet Ball Plug
non-adjustable and if worn or damaged, must be replaced
NOTE: If necessary to replace rear bearing, support with new parts. Inspect shaft splines drive chain and gears.
cover and press bearing from cover. Position new If any indication of failure, such as chipped teeth or
bearing to outside face of cover and press bearing into excessive wear, is indicated, those parts should be replaced
cover with a .06 inch overhang. with new parts.
12. From lower side of case, remove (pry) output shaft
front bearing. SUBASSEMBLY REPAIRS
13. Disengage front output shaft from chain and NOTE: Refer to Figure 7D-12S for exploded view of
remove shaft from transfer case (Fig. 7D-8S). subassemblies.
14. Remove bolts attaching intermediate chain housing
to range box. Lift or using a chain hoist, remove Differential Carrier Assembly (Fig. 7D-12S)
intermediate housing from range box (Fig. 7D-9S).
15. Remove chain from intermediate housing. Disassembly
16. Remove lockout clutch, drive gear and input shaft 1. Remove bolts from carrier assembly and separte
assembly from range box. carrier sections.
NOTE: A 1 1/2" to 2" hose clamp may be installed 2. Lift the pinion gear and spider assembly from
on end of the input shaft to prevent loosing the roller carrier.
bearings (123) which may fall out of clutch assembly NOTE: Observe that undercut side of pinion gear
if it is pulled off the input shaft. spider faces toward front side gear.
17. Pull up on shift rail and disconnect rail from link. 3. Remove the pinion thrust washers, pinion roller
18. Remove (lift) input shaft assembly from range box. washers pinion gears and roller bearings from the spider
NOTE: At this point the transfer case is completely unit.
disassembled into its subassemblies. Each of these
subassemblies should then be disassembled fro cleaning 4. Clean and inspect all components. Replace all worn
and insnertinn or broken narts.

Fig. 7 D - 8 S - R e m o v i n g F ro n t O u t p u t S h a ft Fig. 7 D - 9 S - R e m o v i n g Inte rm e dia te (Chain) Housing

 TRANSFER CASES 7 D -1 1

Assembly 6. Remove "O" ring from end of shaft and discard.

1. Using a petroleum jelly, load roller bearings in pinion 7. Clean and inspect all components. Replace as
gears (132 required, 33 each pinion). required.
2. Install pinion roller washer, pinion gear, roller Assembly
1. Position bearing to retainer and tap or press into
washer and thrust washer on each leg of spider. place. Ball loading slots should be toward concave side of
3. Place the spider assembly in the carrier (front half) retainer.
with undercut surface of spider thrust surface facing 2. Install large snap ring securing bearing in retainer.
downward or toward gear teeth. NOTE: Snap ring is a select fit. Use size A, B, C or
4. Align marks on carrier sections and position carrier D as required to provide tightest fit.
halves together. Install retaining bolts and tighten to 3. Install low speed gear on shaft with clutch end
specifications. 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
Lockout Clutch Assembly (Fig. 7D-11S) snap ring, holding bearing in place on shaft.
NOTE: Snap ring is a select fit. Use size A, B, C or
Disassembly D as required to provide tightest fit.
1. Remove front side gear from input shaft assembly 6. Slide spacer and thrust washer onto shaft. Align
and remove thrust washer, roller bearings (123) and spacers spacer with locator pin.
from front side gear bore. Note position of spacers to 7. Using a heavy grease, install roller bearings (15) in
facilitate reassembly. end of shaft.
2. Using snap ring pliers, remove the snap ring 8. Install new rubber "O" ring on end of shaft.
retaining drive sprocket to clutch assembly. Slide the drive
sprocket from the front side gear. Range Selector Housing (Range Box)
3. Using snap ring pliers, remove lower snap ring. Disassembly (Fig. 7 D -1 1S)
4. Remove sliding gear, spring and spring cup washer
from front side gear. Removing Shifter Assembly
1. Remove poppet plate spring, plug and gasket.
5. Clean and inspect all components. Replace all worn Discard gasket.
or defective parts. 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
Assembly shift lever from shifter shaft.
1. Install spring cup washer, spring and sliding clutch 4. Remove shift lever snap ring and lower lever.
gear on front side gear. 5. Push shifter shaft assembly downward and remove
2. Install snap ring retaining sliding clutch to front side lockout clutch connector link.
gear. NOTE: Long end of connector link engages poppet
3. Using a petroleum jelly, load roller bearings (123) plate.
and spacers in the front side gear. 6. Remove shifter shaft assembly from case and
4. Install thrust washer in gear end of front side gear. separate the inner and outer shifter shafts. Remove and
5. Slide drive sprocket on to clutch splines and install discard "O" rings.
retaining ring. 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
Input Shaft Assembly (Fig. 7D-11S) 8. Remove input gear bearing retainer and seal
assembly. Discard gasket.
Disassembly
1. Slide thrust washer and spacer from shaft. 9. Remove large snap ring from bearing outer diameter.
2. Using snap ring pliers, remove snap ring retaining 10. Tap input gear and bearing from case.
input bearing retainer assembly to shaft (Fig. 7D-13S) and 11. Remove snap ring retaining input shaft bearing to
remove bearing retainer assembly from shaft. shaft and remove bearing from input gear.
NOTE: This is a select fit snap ring. Snap rings, size
3. Support low speed gear (large gear) and tap shaft A, B, C, and D are released for service. Select tightest
from gear and thrust washer. fit.
NOTE: Observe thrust washer pin(s) located in shaft
(Fig. 7D-11S). Removing Cluster Gear Assembly (Fig. 7D-15S)
4. Using a screw driver, pry behind open end of large 12. From intermediate case side, remove counter shaft
snap ring retaining input bearing in bearing retainer (Fig. from cluster gear and case using Tool J-24745. Remove
7D-14S) and remove ring from retainer. Tap bearing from cluster gear assembly from case.
retainer. NOTE: Recover roller bearings (72 required) from
5. Remove pilot roller bearings (15) from end of input gear case and shaft.
shaft. 13. Remove cluster gear thrust washers from case.
7D-12 TRANSFER CASES

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 O u tp ut Rear Brg. 47. Brg. O uter Ring
5. Low Speed Gear Bushing 26. Rear O u tp ut Shaft 48. F ront O u tp u t F ront Brg.
6. Low Speed Gear 27. Washer 49. F ro n t O u tp ut Shaft Seal
7. Thrust Washer & Locating Pin 28. Locknut 50. F ro n t O u tp u t Brg. Retainer
8. Gasket 29. Rubber Spline Seal 51. Rubber Spline Seal
9. Input Brg. Retainer 30. Rear O u tp u t Yoke 52. L o ckn ut
10. Input Brg. 31. Rear O u tp u t Seal 53. F ro n t O u tp u t Yoke
11. Brg. Outer Ring 32. Shims 54. Countergear
12. Brg. Retaining Ring 33. Input Shaft " 0 ” Ring 55. Countergear Spacers and Brgs.
13. Thrust Washer, Locating Pin, 34. Input Shaft Pilot Bearings 56. Countergear Shaft
Lubricating Washer & Spacer 35. D ifferential Carrier Assembly 57. Countergear Thrust Washer
14. Intermediate (Chain Housing) 36. Spring Washer Cup 58. Gasket
15. Drive Shaft Sprocket 37. Lo cko ut Clutch Spring 59. Brg. Retainer Gasket
16. Gasket 38. Snap Ring 60. Brg. O uter Ring
17. Sliding Lock Clutch 39. Snap Ring 61. In p ut Gear Brg.
18. Rear Output Housing 40. Front O utput Rear Brg. Cover 62. In p ut Gear Seals (2)
19. Rear Output Front Brg. 41. F ront O u tp ut Rear Brg. 63. Brg. Snap Ring
20. Vent 42. F ront O u tp ut Drive Sprocket 64. In p u t Gear
21. Oil Seal 43. Gasket 65. In p u t Gear Brg. Retainer

Fig. 7D-10S-Model 203 Transfer Case, Cross Sectional View

 TRANSFER CASES 7D-13

Fig. 7D-1 1S~Model 2 0 3 Transfer Case Exploded V ie w

7D-14 TRANSFER CASES

1. A d a pter 48. T h ru s t Washer

2. In p u t Gear Bearing Retainer 49. L u b ric a tin g T h ru s t Washer
3. In p u t Gear Bearing R etainer Gasket 50. Retaining Ring
4. In p u t Gear Seals 51. Flange Lock N ut
5. Bearing O uter Ring 52. Seal
6. Bearing to S haft Retaining Ring 53. F ro n t O u tp u t Y oke
7. In p u t Gear Bearing 54. D ust Shield
8. A d a p te r to S elector Housing Gasket 55. F ro n t O u tp u t S haft Seal
9. Range Selector Housing (Range Box) 56. F ro n t O u tp u t S haft Bearing R etainer
10. P.T.O. Cover Gasket 57. F ro n t O u tp u t S haft Bearing
11. P.T.O. Cover 58. Bearing O uter Ring
12. Selector Housing to Chain Housing Gasket 59. Bearing Retainer Gasket
13. Main Drive In p u t Gear 60. F ro n t O u tp u t S haft
14. Range Selector Sliding C lutch 61. F ro n t O u tp u t S h a ft Rear Bearing
15. S h ift Lever Lock N ut 62. F ro n t O u tp u t Rear Bearing Retainer Cover Gasket
16. Range Selector S h ift Lever 63. F ro n t O u tp u t Rear Bearing Retainer
17. S h ift Lever Retaining Ring 64. Drive S haft S procket
18. L o c k o u t S h ift Lever 65. Drive Chain
19. D eten t Plate Spring Plug 66. Retaining Ring
20. D etent Plate Spring Plug Gasket 67. S liding Lock C lutch
21. D etent Plate Spring 68. L o c k o u t S h ift Rail
22. D etent Plate 69. S h ift F o rk R etaining Pin
23. L o c k o u t S h ifte r Shaft 70. L o c k o u t S h ift Fork
24. " O " Ring Seal 71. L o c k o u t C lutch Spring
25. L o c k o u t S haft C onnector L in k 72. Spring Washer Cup
26. " 0 " Ring Seal 73. F ro n t Side Gear
27. Range Selector S h ifte r Shaft 74. F ro n t Side Gear Bearing and Spaces (123 Bearings Req'd.)
28. Range Selector S h ift F ork 75. D iffe re n tia l Carrier Assem bly (132 Bearings R eq'd.)
29. D etent Plate Pivot Pin 76. Rear O u tp u t Shaft R oller Bearings (15 R eq'd.)
30. T h ru st Washer 77. Rear O u tp u t Shaft
31. Spacer (short) 78. Speedom eter D rive Gear
32. Range Selector C ounter Gear 79. Rear O u tp u t S haft F ro n t R oller Bearing
33. Countergear R oller Bearings and Spacers (72 Bearings Req'd.) 80. Oil Pump “ 0 " Ring Seal
34. Countergear Shaft 81. Rear O u tp u t Housing Gasket
35. T h ru st Washer 82. Rear O u tp u t Housing (F ro n t)
36. In p u t S haft R oller Bearings (15 R eq'd.) 83. " 0 " Ring Seal
37. T h ru s t Washer Pins (2 R eq'd.) 84. Rear O u tp u t Housing (Rear)
38. In p u t Shaft 85. Shim Pack
39. " 0 " Ring Seal 86. Bearing Retainer
40. Low Speed Gear and Bushing 87. Rear O u tp u t Rear Bearing
41. T h ru s t Washer 88. Rear O u tp u t S haft Seal
42. In p u t Shaft Bearing R etainer 89. .Rear O u tp u t Flange
43. In p u t Shaft Bearing 90. Rear O u tp u t S haft R ubber Seal
44. In p u t Shaft Bearing R etaining Ring (Large) 91. Washer
45. In p u t Shaft Bearing R etaining Ring 92. Flange N ut
46. Chain D rive Housing
47. L o c k o u t S h ift Rail Poppet Plug, Gasket, Spring and Ball.

Fig. 7D-1 2S--Model 2 0 3 Transfer Case Exploded V i e w Continued

 TRANSFER CASES 7D-15

Fig. 7D-1 3S--Removing in p u t S haft-to-Bearing Snap Ring Fig. 7D-1 5S--Removing Cluster Gear Shaft

14. Clean and inspect all components. Replace worn 5. Install snap ring in outside diameter of bearing.
and defective parts. 6. Align oil slot in retainer with drain hold in case and
Assembly (Fig. 7D-11S) install input gear bearing retainer, gasket and retaining
bolts. Tighten bolts to specifications.
Installing Countergear Assembly
1. Using Tool J-24745 and a heavy grease, install roller Installing Shifter Shaft Assembly
bearings (72 required) and spacers in clustergear bore. 7. If removed, install poppet plate and pivot pin
2. Using a heavy grease, position countershaft thrust assembly in housing. Use sealant on pin.
washers in case. Engage tab on washers with a slot in case 8. Install new "O" rings on the inner and outer shifter
thrust surface. shiafts. Lubricate "O" rings and assemble inner shaft in the
3. Position cluster gear assembly in case and install outer shaft.
countershaft through front face of range box into gear 9. Push the shifter shafts into the housing, engaging the
assembly. Countershaft face with flat should face forward long end of the lockout clutch connector link to the outer
and must be aligned with case gasket. shifter shaft before the shaft assembly bottoms out.
Installing Input Gear Assembly 10. Install lower shift lever and retaining ring.
4. Install bearing (without large snap ring) on input 11. Install upper shift lever and shifter shaft retaining
gear shaft positioning snap ring groove outward and install nut.
new retaining ring on shaft. Position input gear and bearing 12. Install shift fork and sliding clutch gear. Push fork
in housing. up into shifter shaft assembly to engage poppet plate, sliding
NOTE: The retaining ring is a select fit. Use service clutch gear forward onto the input shaft gear.
ring size A, B, C or D as required to provide tightest 13. Install poppet spring, gasket and plug in top of
fit. 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.
NOTE: 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 into place with a soft
hammer.
NOTE: 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.
Fig. 7D-1 4S--Removing Input Shaft Bearing-to-Retainer Snap 6. Position new gasket and the bearing retainer to
Ring housing. Install retaining bolts, tightening to specifications.
7D-16 TRANSFER CASES

Fig. 7D-1 7S--Removing Rear O utput Bearing Retaining Ring

REAR O UTPUT SHAFT HOUSING (FRONT)

Fig. 7D-1 6S—Installing Inp ut S haft Bearing Retainer Seal Disassembly

1. Remove "O" ring from rear output shaft housing
(front) and discard.
Input Gear Bearing Retainer Seal Replacement
1. Remove bearing retainer attaching bolts, retainer 2. To remove roller bearings from housing, insert a long
and gasket from housing. Discard gasket. drift through rear opening and drive bearing from housing
2. Pry seal out of reatiner and discard. (Fig. 7D-18S). Remove and discard rubber seal.
3. Position new seal to retainer and install using tool
J-21359 (Fig. 7D-16S). Assembly
4. Position bearing retainer and gasket to housing. 1. Position rubber seal in bearing bore. Use grease to
Install attaching bolts and tighten to specifications. hold in place. Position roller bearing in bore and press into
REAR O UTPUT SHAFT HOUSING (REAR)
place until bearing bottoms out in housing.
Disassembly
2. Position new "O" ring on housing.
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). Rmeove and discard rubber seal.
Assembly
1. Position rear bearing in housing and tap into place.
2. Install snap ring retaining bearing to case.
NOTE: Retaining ring is a select fit. Use service ring
size A, 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 the old seal in place. Fig. 7D-1 8S--Removing Rear Output Shaft Front Bearing
 TRANSFER CASES 7D-17

Fig. 7 D -2 1 S--Positioning Range Box fo r Assem bly

Fig. 7 D -19S—Installin g Rear O utput Shaft Seal Front Output Shaft Rear Bearing Replacement
1. Remove rear cover from transfer case. Remove
gasket and discard.
Front Output Shaft Bearing Retainer Seal 2. Support rear cover and press bearing from cover.
Replacement (Fig. 7D-20S) 3. Position new bearing to outside face of cover and
using a piece of wood to cover bearing, press bearing into
1. Pry or drive out existing seal from retainer bore. cover until flush with opening.
4. Position gasket and cover to transfer case and tap
2. Clean and inspect retainer. into place.
5. Install cover retaining bolts and torque to
3. Apply sealer to outer diameter of new seal. specifications.
4. Position seal to retainer bore and using Tool J-22836 ASSEM BLY OF TRANSFER CASE (FIGS. 7D-10S
or equivalent, install seal in retainer. and 7D-11S)
1. Place range box on blocks, with input gear side
toward bench (Fig. 7D-21S).
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.
NOTE: A 2" band clamp may be installed on end of
shaft to prevent loosing bearings from clutch assembly.
4. Install input shaft, lockout clutch and drive sprocket
P R E S S S E A L IN R E T A IN E R B O R E
T O T H IS D IM E N S IO N

assembly in the range box, aligning tab on bearing retainer

J -2 2 8 3 6 with notch in gasket.
W O R D " O U T S ID E ' 5. Connect lockout clutch shift rail to the connector
M O L D E D IN R U B I
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.
FRO N T
SH A FT FRO N T
B E A R I N G R E T A IN E R
SEAL 6. Install drive chain in chain housing, positioning the
SEAL
chain around the outer wall of the housing.
V/////// 7. Install the cahin housing on the range box (Fig. 7D-
FR O N T O U TPU T S H A F T -— -J) j 23S), engaging the shift rail channel of the housing to the
F R O N T B E A R IN G R E T A IN E R '...1
shift rail. Position chain on the input drive sprocket.
8. Install the front output sprocket in the case, 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
Fig. 7D-20S--lnstalling Front Output Bearing Retainer Seal sprocket. Install roll pin retaining shift fork to shift rail.
7 D-18 TRANSFER CASES

Fig. 7D-22S--Drive Gear and Lockout Clutch Assem lby Fig. 7 D -24 S -C he cking Rear O utpu t S haft End Play
Installed

10. Install front output shaft bearing. NOTE: If rear bearing was removed, position new
11. Install front output shaft bearing retainer, gasket bearing to outside face of cover and press into cover
and retaining bolts. until bearing is flush with opening.
12. Install the front output shaft flange, gasket, seal, 14. Install differential carrier assembly on the input
washer and retaining nut. Tap dust shield back in place after shaft. Carrier bolt heads should face rear of shaft.
installing bolts in flange. 15. Position rear output shaft to differential carrier
13. Install front output shaft rear bearing retainer, assembly (load bearings in pinion shaft).
gasket and retaining bolts. a. 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 to rear
output housing (front). Be sure "O" ring is in proper
position on front section of output housing.
NOTE: 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.
Fig. 7D-23S--lnstalling Interm ediate Housing to Range Box 23. Install and tighten filler plug to specifications.
 TRANSFER CASES 7D-19

ADAPTER A SSEM B LIES

ADAPTERS USED W ITH M A N U A L ADAPTERS USED W IT H A U TO M A TIC
T R A N S M IS S IO N S TR A N S M IS S IO N S
Adapters used with automatic transmissions do not
Disassembly of Adapter require service since there are no internal components such
as seals, sleeves or bearings.
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 broken. J-8092
J-7137
Assembly of Adapter

1. Position sleeve to adapter bore and tap into place

using a suitable piece of pipe.

NOTE: Assemble drive sleeve with oil groove facing

transmission side. Lubricate sleeve spline with
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. Fig. 7 D -2 T -ln s ta llin g A da pter Seal

Fig. 7D -1T~A dapter Assem blies Used W ith M anual

T ransm issions
7D-20 TRANSFER CASES

SPECIFICA TIO N S

N-m

Model 203 Model 205

Nut, Shift Lever-to-Shifter Asm 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 4 8 -60 26-34

Bolt, Adapter-to-Transfer Case 46-54 27-41
Filler Plug 41-48 4 1 -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 No. 205 (Part-Time) 203 (F u ll Tim e)

Availability K 10-30 (Manual Trans) K 10-30 (A u tom atic Trans)

Ratios: Hi Range 1.00 to 1 1.00 to 1

Lo Range 1.96 to 1 2.0 0 to 1

Lever Positions 4-Lo (All wheel underdrive) 4-Lo (Lock-all wheels

N (Neutral) locked - underdrive)
2-Hi (Rear wheel drive) 4-Lo (All wheels underdrive)
4-Hi (All wheel direct drive) N (Neutral)
4-Hi (All wheels direct drive)
4-Hi (Lock - all wheels
locked - direct drive)

Lever Location Rear o f trans. shift lever Floor, right of center

Power Take-O ff Data:

Opening & Location SAE 6-bolt; Left side

Lubricants:
Oil capacity 5.2 pints 8.2 pints

Type, grade See Owner's Manual

 TRANSFER CASES 7D-21

SP E C IA L TOOLS

1. J-22836 - Front Output Shaft Bearing Retainer Seal

Installer
2. J-22388 - Rear Output Shaft Seal Installer
3. J-21359 - Input gear Bearing Retainer Seal Installer
4. J-24745 - Cluster Gear Loading Tool
5. J-8614-1 - Companion Flange Remover

Fig. 7D-1 ST--Model 2 0 5 (Part Time) Transfer Case Sp ecial Tools

 7D-22
TRANSFER
CASES
Fig. 7D-2ST--Mode! 203
(Full Time) Transfer Case Special Tools

1. J-22836 — Front Output Shaft Bearing Retainer Seal

Installer
2. J-22388 — Rear Output Shaft Seal Installer
3. J-21359 — Input gear Bearing Retainer Seal Installer
4. J-24745 — Cluster Gear Loading Tool
5. J-8614-1 — Companion Flange Remover