Chevrolet 40 60 Series, Overhaul Manual

Page 1: ...40 60 SERIES TRUCK SUPPLEMENT ST 334 72...

Page 2: ...red section A t the beginning of each section 6Y DELCOTRON 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 plac...

Page 3: ...ear yoke and split the rear universal joint NOTE The bearings can be left on the trunnion and held in place with tape 3 Swing propeller shaft to one side and tie to the frame side rail 4 Remove bolts...

Page 4: ...ifferential Spider 16 Differential Bearing 3 Oil Seal 11 Differential Pinion Adjusting Nut 4 Oil Seal Gasket Spider Gear 17 Adjusting Nut Lock 5 Front Pinion Bearing 12 Differential Side Gear 18 Diffe...

Page 5: ...erential Bearing Retainer 8 Ring Gear Thrust Pad 12 Differential Side Gear Adjusting Nut 3 Oil Seal and Screw 13 Differential Case 17 Adjusting Nut Lock 4 Shims 9 Ring Gear Left Half 18 Differential C...

Page 6: ...oval 1 1 000 Lb Axle Fig 5G Pinion Rear Bearing Inner Race Removal 13 500 15 000 and 17 000 Lb Axles Fig 6G Drive Pinion Front Bearing Removal 1 1 000 Lb Axle 6 On the 13 500 15 000 and 17 000 lb axle...

Page 7: ...uble row Fig 8G Pinion Oil Seal Installation Typical Fig 10G Pinion Rear Bearing Lock Ring Installation 11 000 Lb Axle ball bearing on pinion shaft so that extended por tion of inner race is toward pi...

Page 8: ...d 7 Check differential side bearings and cups for broken races discoloration or roughness 8 Inspect differential case for cracks or distortion Ring Gear Replacement 1 Remove ring gear from case by tap...

Page 9: ...ce outer races over them 5 Install differential assembly in carrier and install ad justing nuts Fig 15G Ring Gear and Pinion Adjustment CAUTION Carefully slide adjusting nuts alongside the bearings so...

Page 10: ...it will be necessary to remove the pinion assembly and increase the shim thickness between the pinion bearing and the carrier 4 If the pattern is above the pitch line on the ring gear teeth the pinio...

Page 11: ...15 000 AND 17 000 LB CAPACITY TWO SPEED INDEX Differential Carrier Assembly 4 9 Removal 4 9 Disassembly 4 4 2 Repairs 4 4 3 Drive Pinion and Bearing Retainer 4 4 3 Disassembly 4 1 3 Inspection 4 14 Re...

Page 12: ...ion Adjusting Right 20 Axle Housing Cover 28 Shift Yoke Shim 13 Axle Shaft Welded 29 Shift Sleeve 6 Pinion Bearing 14 Axle Housing 21 Differential Pinion 30 Anchor Bolt Lock Preload Spacer 15 Differen...

Page 13: ...ring 12 Shift Unit M ounting 18 Ring Gear 23 Thrust W asher 28 Differential Side Gear 34 5 Pinion and Bearing Bracket 19 D ifferential Bearing 24 Differential and 2 Retainer 13 Shifter Yoke Lever Cap...

Page 14: ...ft yoke anchor then remove anchor from carrier 8 Drive out shifter yoke shaft using drift and hammer as shown in Figure 4J 9 Slide the shifter yoke and sleeve to the left removing the sleeve and shift...

Page 15: ...d in tool Press pinion from bearing fig 12J 5 Remove the pinion rear bearing from the carrier by tapping on the outer race with a brass drift to unseat the bearing fig 13J Inspection 1 Wash all metal...

Page 16: ...ll pinion intermediate bearing inner race on pinion with thick end of race toward pinion head using a suitable length of 2 inch I D pipe to press against inner race fig 15J 4 Place pinion bearing spac...

Page 17: ...17J Installing Pinion Oil Seal Differential and Planet Disassembly 1 Mark the ring gear and differential and planet support case and case cover for alignment by scribing or making lines on case cover...

Page 18: ...se and case cover by inserting a suita ble size drift through the cast holes in the case and cover Tap alternately through the holes from side to side of bearing to prevent race from binding on hub Fi...

Page 19: ...ng gear fig 23J 6 Support the differential and planet support cover and ring gear with ring gear teeth on two blocks of wood then the assembled palnet and differential assembly into cover Make sure th...

Page 20: ...flange bearings and spacer are all Fig 27J Tightening Differential Right Adjusting Nut Using J 0972 firmly seated then measure torque required to rotate pinion 11 Continue tightening in small increme...

Page 21: ...ts to specifications and recheck ring gear to pinion backlash Install adjusting nut locks and torque to specifications 9 Install oil trough to differential carrier adjust trough to ring gear so that c...

Page 22: ...jaws Key numbers in text refer to Figure IK unless otherwise noted 2 Center punch side of differential carrier leg and bearing cap for identification when reassembling 3 Remove bearing cap attaching...

Page 23: ...LH Inner 40 Strip Sealer Seal 6 Differential Bearing 19 Side Gear Thrust 30 Pinion Bearing Retainer Adjuster RH W asher LH Spacer 41 Oil Seal 7 Differential Bearing 20 Bolt and Nut 31 Pinion Bearing...

Page 24: ...inion is being installed an estimate of the shim pack thickness required can be obtained by increasing or decreasing thickness of shim pack removed by the amount that the old and new pinions differ in...

Page 25: ...t wash ers 15 Install remaining side gear and new thrust washer 4 Install other half of case over assembly Align mating marks on differential case halves fig 4K Install four bolts holding two halves o...

Page 26: ...t it could affect the performance of vital components and systems and or could result in major repair expense It must be replaced with one of the same part number or with an equivalent part if replace...

Page 27: ...er Gear Support Case LH Half 52 Pinion Bearing Cup Inner Locknut 53 Pinion Bearing Cage Shims Differential Bearing Cone LH 54 Pinion Bearing Cage Differential Bearing Cup LH 55 Lock Washer Differentia...

Page 28: ...rk seal 44 and spring 45 Note that seal has words BOTTOM HOLE also 1 8 hole to indicate correct positioning at reassembly 2 At underside of carrier remove expansion plug cover ing shift fork shaft Use...

Page 29: ...remove pinions and pins 5 Remove differential assembly from right hand support case 10 Remove support case thrust washer 11 View A fig 4L Differential Disassembly 1 Mark both halves of differential c...

Page 30: ...be used for this purpose 4 Install pinion and bearing assembly in pinion cage In stall same bearing adjusting spacer 50 and spacer washer if required 51 as removed at disassembly Press outer bearing...

Page 31: ...on after final adjustment of left hand bearing adjusting nut must be such that lock can be properly installed over notches of nut 5 After gear lash and tooth contact adjustments have been made and wit...

Page 32: ...le operation TANDEM REAR AXLES AND POWER DIVIDER INDEX Differential Carrier and or Carrier Cover Removal 4 30 Differential Carrier Cover 4 32 Disassembly 4 32 Input Shaft 4 32 Vacuum Operated Differen...

Page 33: ...REAR AXLE DIFFERENTIAL CARRIER 4 31 LOCKOUTS AIR OPERATED VACUUM OPERATED Fig lM Forward Rear Axle Assembly Exploded View See legend on next page CHEVROLET OVERHAUL M ANUAL SUPPLEMENT...

Page 34: ...g Cover 61 Pinion Bearing Cup Shims Outer 89 Bearing Cover 62 Pinion Bearing Cone 90 Lock Washer Outer 91 Cap Screw 63 Pinion Helical Gear 92 Input Companion 64 Pinion Nut Flange 65 Cotter Pin 93 Flat...

Page 35: ...aft assembly and shims fig 6 M 4 If lockout shift components have not been removed slip the sliding clutch out of shift fork and remove clutch from cover Vacuum Operated Differential Lockout 1 Remove...

Page 36: ...ARRIER Fig 5M Removing Helical and Differential Side Gear and Fig 6M Removing Input Shaft Assembly Fig 7M Removing Inter Axle Lock Out Shift Lever Fig 8M Removing Shift Spring Fork and Clutch CHEVROLE...

Page 37: ...k washers and cover from shift cylin der body Discard cover grommets Remove nut flat washer and grommet from push rod fig 11M 2 Remove cap screws lock washers shift cylinder body assembly and gasket f...

Page 38: ...tools and with opposite side of helical gear supported press bushing into gear until Tool J 8474 1 contacts gear 4 Remove tool and repeat Steps 2 and 3 for second bush ing Inter Axle Shift Fork Push R...

Page 39: ...nsert push rod through opening in cover as shown in figure 106 Align clutch splines with input shaft splines and slide the clutch and push rod forward into cover 3 Place compression spring gasket and...

Page 40: ...493 pull gear from pinion shaft fig 19M 5 Remove Ring Gear and Differential Assembly and Pinion Assembly in the same manner as outlined under Single Speed Eaton Rear Axles Repairs Output Shaft Bushing...

Page 41: ...shaft O rings and install two new rings Assem bly 1 Install bushings on spider journals and install pinions on bushings 2 Set spider and pinion assembly in one half of case and place other half of ca...

Page 42: ...utput shaft as outlined under Repairs Insert end of output shaft in carrier and start bearing straight in counterbore fig 25M Using Tool J 0358 press bear ing into position Fig 25M lnstalling Output S...

Page 43: ...e performance of vital components and systems and or could result in major repair expense It must be replaced with one of the same part number or with an equivalent part if replacement becomes Fig 27M...

Page 44: ...ls 2 0 inch lbs torque Gear Backlash Pinion and ring gears that have been in service for exten sive periods form running contacts due to wear of teeth therefore the original shim pack between pinion c...

Page 45: ...contact C it indicates too much backlash Make correction as for B however loosen right hand differential adjusting nut and tighten left hand adjusting nut to move ring gear toward pinion Backlash mus...

Page 46: ...J 22281 Pinion Flange Oil Seal Installer 5 J 2226 Differential Side Bearing Replacer 14 J 8001 Dial Indicator Set 6 J 22300 Bearing Installer 15 J 0972 Differential Adjusting Nut Wrench 7 J 1488 Diffe...

Page 47: ...Installer 3 J 22283 Pinion Oil Seal Installer 9 J 22283 Pinion Oil Seal Installer 4 J 22303 Rear Pinion Bearing Installer 10 J 6203 Pinion Bearing Remover 5 J 22295 Side Bearing Installer 11 J 22307...

Page 48: ...staller Drive Handle Bushing Remover and Installer Bearing Cup Installer Differential Case Support Fixture 10 J 22377 11 J 21106 12 J 8092 13 J 8477 14 J 8119 15 J 3453 Cup Installer Used W ith J 8092...

Page 49: ...vacuum power chamber which consists of a power diaphragm and a push rod that connects the power diaphragm to the hydraulic piston A hydraulic slave cylinder which contains a hydraulic piston with a d...

Page 50: ...agm return spring 2 Turn rim ofdiaphragm back and still maintaining pres sure with your stomach use both hands and snap ring pliers to remove snap ring 2 from groove inside bore of cylinder 1 CAUTION...

Page 51: ...as shown 4 Install piston parts 2 through 12 on push rod from seal end of push rod in order shown 5 Slide snap ring 7 stop washer 6 bearing 4 with O ring 5 installed in bearing groove push rod seal cu...

Page 52: ...r while tightening bolt to seat band securely on shells After tapping re tighten to 40 60 in lbs 4 Place new seal 2 on control tube 3 as shown and assemble hose 4 to tube 5 of rear shell and to contro...

Page 53: ...poppet 14 and then remove vacuum poppet and stem 1 0 and poppet spring 11 from valve body 12 3 Using 1 3 8 wrench remove end cap 1 and gasket 2 To disassemble residual pressure check valve con tained...

Page 54: ...inside end cap Place new gasket 2 on end cap 1 and install end cap securely tight ened in cylinder Piston and Push Rod Fig 4D 1 To install a new push rod seal 13 in push rod 8 place a new seal rubber...

Page 55: ...adily identified by referring to name plate attached to cylin der block Plate will indicate either type 400 or 500 Capacity of TU FLO 400 is 7 1 4 cubic feet per minute Capacity of TU FLO 500 is 12 cu...

Page 56: ...Bearing Insert 15 C rankcase Front Bearing Cap 16 Oil Seal 17 Crankshaft Nut 18 Crankshaft Key 19 Connecting Rod 20 Unloader Piston 21 Unloader Plunger Guide 22 Unloader Plunger 23 Piston Pin Lockwir...

Page 57: ...acting against reduced governor pressure forces pistons away from inlet valves As inlet valve springs in turn over come reduced plunger pressure the inlet valves reseat and compression is resumed Fig...

Page 58: ...information is explained later in this manual Cylinder Head Removal and Disassem bly 1 Remove all cylinder head cap screws then lift off cylin der head assembly Tap head lightly with soft hammer if n...

Page 59: ...ar Driven Type Fig 8G 1 Remove cotter pin and nut from front end of crankshaft and pull drive hub off shaft Remove drive hub key from keyway in shaft 2 Remove cap screws attaching rear end cover to cr...

Page 60: ...old lubricant Blow bearing dry with compressed air and wrap in clean cloth Avoid spinning bearing with air blast as spin ning might damage bearing Crankcase and Bottom Cover On gear driven compressors...

Page 61: ...arance should not be less than 0 002 or more than 0 004 Piston over 0 004 smaller than cylinder bore must be replaced with an oversize piston NOTE When measuring the outside diameter of the piston mak...

Page 62: ...1 ridged or scored If grinding is necessary do not grind fillets at ends of journals Connecting rod bearing in serts are available in 0 010 0 020 0 030 undersize for reground crankshafts Check main be...

Page 63: ...oward shoulder on shaft with the oil passages in the connecting rods Bushings must then be reamed honed or bored to provide 0 0 0 0 1 to 0 0006 clearance on piston pin Wipe the bushing which has been...

Page 64: ...End Cover 30 Stud 31 Oil Seal 32 Crankshaft Nut 33 Screw 34 Cover 35 F ilter 36 Housing 37 Bolt 38 W asher 39 Screw 40 Crankshaft 41 Cap Screw 42 Washer 43 Crankcase 44 Gasket 45 Insert Bearing 46 Con...

Page 65: ...e connecting rod cap prong insert fig 21G Install the special hardened bolt and tighten to 100 to 115 inch pounds of torque Bend prongs of lock washers over heads of bolts Refer to figure 21G 8 Instal...

Page 66: ...firmly Place inlet valves inlet valve guides and inlet valve springs in top of cylinder block Install new cylinder head gasket on cylinder block Carefully align inlet valve springs with inlet valve g...

Page 67: ...or air supply system between the desired predetermined maximum and minimum pressures The air compressor runs continually while the engine runs but ac tual compression of air is controlled by the gover...

Page 68: ...Spring Fig 25G Type D 2 Governor Cutaway Disassem bly Refer to Fig 26G 1 Using cleaning solvent and a brush clean dirt and grease from exterior of governor 2 Using fingers remove rubber cover from go...

Page 69: ...en using Snap Ring Pliers install the retaining ring 9 Install rubber cover on governor body over adjusting screw 10 If previously removed install two pipe plugs in governor body 11 After the governor...

Page 70: ...l new foam filter element into air strainer body 2 Install air strainer cover to body using two cross recess screws 3 Install air strainer unit with a new gasket to compressor by using two cap screws...

Page 71: ...e governor incorporated on this carburetor fig H3 provides a positive means of controlling engine speed The throttle lever controls the engine until the governing speed is reached at this time the gov...

Page 72: ...s 7 Slide governor assembly off throttle shaft Remove throttle shaft seal 8 Remove secondary throttle operating rod E ring clip and remove assembly 9 Remove throttle body to main body screw and remove...

Page 73: ...throttle shaft lever screw and remove lever 8 File off staked ends of the throttle valve screws Drive out primary throttle valve screws pin 9 Scribe primary and secondary throttle plates along shafts...

Page 74: ...IL T E R FU EL IN LET NUT M AIN W E L L A IR B L E E D FUEL IN L E T SYSTEM MAIN METERING SYSTEM ID L E TRANSFER A IR B L E E D DIAPH RAG M C H A M B E R ID L E TRANSFER FE E D R ESTR IC TIO N PR IM...

Page 75: ...rimary and secondary throttle valves for gouges and other deformations If these or any other conditions exist which would prevent full seating re place the faulty valve 9 Inspect all mating surfaces o...

Page 76: ...tighten screws Assemble Main Body 1 Install pump discharge valve 2 Install pump discharge nozzle Use new gaskets 3 Install choke rod seal and choke rod in main body 4 Install choke shaft in main body...

Page 77: ...ket Fuel Valve Seat Screw 21 Diaphragm Accelerating Pump 31 Jets Main 13 Nut Adjusting Fuel Valve Seat 22 Spring Accelerating pump 32 Bowl Fuel 14 Gasket Fuel Valve Seat diaphragm 33 Retainer Vent Val...

Page 78: ...L O W W E A K E N S V A C U U M I N D I A P H R A G M C H A M B E R P E R M I T T I N G S P R I N G T O C L O S E S E C O N D A R Y T H R O T T L E P L A T E S W H E N G O V E R N O R V A L V E C L O...

Page 79: ...ain body gasket then position throttle body assembly and install the screws and tighten securely 2 Using a new gasket install secondary throttle operating assembly on main body and tighten securely In...

Page 80: ...CONDARY TH R O TTL E DIAPHRAGM ASSEM BLY CO M PLETE TH ESE PARTS INCLUDED AS A COM PLETE ASSEM BLY NOTE ONLY NUM BERED PARTS INCLUDING 119 TH R U 123 SERVICED SEPARATELY UNLESS OTHERW ISE NOTED SERVIC...

Page 81: ...r Swivel 34 Tube Fuel 99 Screw Choke Cable Clamp 35 Body Main 100 Clamp Choke Cable 36 Gasket Main Body 101 Cover Governor Housing 37 Screw 102 Nut Choke Cable Clamp Screw 38 Retainer 103 Gasket Gover...

Page 82: ...screw until it just touches the throttle lever and turn one half turn more to position the valves Adjust Air Vent Valve Fig H17 1 Back off idle speed screw until throttle valves are fully closed Chok...

Page 83: ...C K SCREW THROTTLE OPERATING HOUSING PLATE THROTTLE SHAFT PRIMARY THROTTLE SHAFT THROTTLE CONNECTING ROD Fig H 14 Governor Control Linkage Fig H 16 Secondary Throttle Stop Screw CHEVROLET OVERHAUL M...

Page 84: ...4 CARBURETORS SEE S P E C IF IC A T IO N S Fig H 17 A ir Vent Valve Adjustment Fig H18 Fast Idle Adjustment WRENCH J 10176 SCREW Fig H 19 Accelerator Pump Adjustment CHEVROLET OVERHAUL M ANUAL SUPPLEM...

Page 85: ...g Tool J 9789 Universal Carburetor Kit J 10176 Fast Idle Wrench J 22973 Ther Mac Thermometer J J 1 137 J 4552 J 5197 1137 J 4 5 5 2 BENDING TOOLS Choke Rod Bending Choke Rod Bending 1 and 2 bbl Unload...

Page 86: ......

Page 87: ...ain on the lead wire 5 Remove three slip ring end frame attaching bolts and tab nuts 6 Carefully pry the end frame and case apart using a screw driver slowly all the way around the circumfer ence to r...

Page 88: ...ly enough material to make the rings smooth and concen tric Finish with 400 grain polishing cloth and blow dry 5 Slip rings are not replaceable excessive damage will require rotor assembly replacement...

Page 89: ...f lamp fails to light or if ohmmeter reads high when successively connected between each pair of stator leads the windings are open Short Circuit A short in the stator windings is difficult to locate...

Page 90: ...2 2 and press out diode with diode removal Tool J 9717 1 and an arbor press or vise CAUTION Do not strike diode as shock may dam age other diodes 3 Select diode with proper color marking NOTE Diodes i...

Page 91: ...ube or pipe as in Step 1 4 Install retainer plate Use new retainer plate if felt seal is hardened or excessively worn Bearing Replacement Slip Ring End Frame 1 Remove bearing from rotor shaft using To...

Page 92: ...h Replacement 6 Y 8 End Frame Replacement 6Y 9 Bearing Replacement 6Y 9 Drive End F ram e 6Y 9 Assembly 6Y 9 insert one of the thru bolts into the end frame open ing and physically lift brushes agains...

Page 93: ...reading is low the field windings are grounded Open Circuit Connect one test lamp or ohmmeter lead to each slip ring If the lamp fails to light or if the ohmmeter reading is high the windings are open...

Page 94: ...iode into sink or frame Torque diode to 160 190 in lbs 5 Connect flexible lead s to diode as follows a Place the clip over the diode lead and tightly crimp the flexible leads into the clip b Solder th...

Page 95: ...pressing bearing out using suitable tube or pipe on outer race 2 Refill bearing one quarter full with Delco Remy No 1948791 grease or equivalent Do not overfill 3 Press bearing into end frame using tu...

Page 96: ...n 47 k u m i i i iin I ll II I...

Page 97: ...mbly on floor or bench resting on front pressure plate side remove 4 drive strap to front pres sure plate bolts and the washers 2 Lift the cover and rear pressure plate off front pressure 4 plate and...

Page 98: ...lve the lubricant 3 Inspect pressure plate and flywheel for scores on the Fig 3E Disassembly of Clutch Fig 4E Removing Levers Step 1 contact surfaces Use a straight edge and check for flat ness of con...

Page 99: ...ery important that each group be arranged in like sequence 7 Assemble anti rattle springs in cover as shown in Fig ure 9E The spring to the left is in operating position 8 Lower the cover on top of th...

Page 100: ...heel in position normally occupied by driven plate NOTE It is recommended that a spare flywheel be obtained so that this operation may be performed at the bench 2 Bolt cover on flywheel with gauge pla...

Page 101: ...rotation of inner race noisy or sticking that indicates worn or chipped bearings or races If it is necessary to replace the bearing proceed as follows 1 Assemble Tool J 5822 on slide hammer J 2619 and...

Page 102: ...mission in holding fixture Tool 5750 and remove propeller shaft band and linkage assembly from back of transmission 2 Shift transmission into 3rd gear then remove gearshift lever from transmission cov...

Page 103: ...nd pins are not lost as the shifter shafts are removed Assem bly 1 In reassembling the transmission cover care should be used in reinstalling the shifter shafts They should be installed in order rever...

Page 104: ...Remove 2nd and 3rd synchronizer ring and clutch as sembly 4 pieces 6 Depress lock pin into recess in mainshaft turn thrust washer to clear splines on washer on mainshaft fig 9NP and remove thrust wash...

Page 105: ...rth Speed Gear 70 Countershaft Front 52 Third Speed Gear Bearing Snap Ring Retainer Ring 71 Countershaft Front 53 Third Speed Gear Bearing 54 Second and Third 72 Countershaft Spacer Speed Outer Washer...

Page 106: ...If float is more than 090 select different outer ring fo decrease the float c If float is less than 070 remove synchronizer as sembly and using a belt sander remove the re quired amount from the smal...

Page 107: ...wear the gear and bushing assembly should be replaced Assembly of Transmission Refer to Figure 2NP for releative location of all parts 1 Lower countershaft assembly into case with rear of shaft throu...

Page 108: ...n the 1st speed sliding gear will butt against the low speed teeth on the countershaft as the sliding gear is pushed rearward This will prevent the sliding gear from moving too far rearward 3 Put shif...

Page 109: ...h 9 Thrust Washer 25 M ainshaft 2nd Speed 39 Countershaft Rear Speed Gear 10 4th and 5th Shift Gear Bearing Nut 54 Snap Ring Fork 26 1st and Reverse Shift 40 Snap Ring 55 Countershaft 1 1 Control Towe...

Page 110: ...d from case tap out bearing and spacer plug from inside case INSPECTION Prior to assembly of the transmission the individual parts should be carefully checked to eliminate those damaged from previous...

Page 111: ...s or breaks or other damage Since repairs by welding brazing etc are not recommended replace all damaged parts 2 Check bores for wear Replace components worn over size 3 Check bearing caps for end thr...

Page 112: ...verse longest shifter shaft through hole in front of cover through forward boss Then slide shifter head on shaft with slot in head toward center of cover fig 12R Push shaft through rear boss and insta...

Page 113: ...ear end of shaft Remove snap ring from mainshaft and slide thrust washer and fourth speed gear off gear sleeve Support rear face of third speed gear on suitable press plates and press shaft from gear...

Page 114: ...J 6419 1 as shown in Figure 19R press hub onto shaft tight against shoulder on shaft Install snap ring Fig 16R Removing Mainshaft from 3rd Gear 3 Slide second and third speed synchronizer on hub with...

Page 115: ...bly Key Numbers Refer to Figure 21R 1 Position first countershaft gear key 9 in slot of coun tershaft 8 Using a suitable sleeve press 2nd speed gear 7 on countershaft 2 Place 2nd and 3rd gear spacer...

Page 116: ...position Tool J 5740 under bearings as shown in Figure 23R and press gear and shaft out of bearing To install new bearing start bearing straight on end of gear with snap ring toward shaft end of gear...

Page 117: ...installed slide fourth and fifth speed synchronizer assembly on front of mainshaft 9 Start rear bearing straight on mainshaft with snap ring toward rear Move shaft and gear forward to start bear ing s...

Page 118: ...24 Snap Ring 33 Bearing 6 Synchronizer 2nd and 15 Nut 25 Countershaft 4th 34 Reverse Idler Gear 3rd Speed 16 Snap Ring Speed Gear 35 Bearing 7 Synchronizer Hub 17 Thrust Washer 26 Countershaft 3rd 36...

Page 119: ...RTANT Cleanliness is extremely important and an absolute must when repairing or overhauling the transmission Before attempting overhaul proce dures thoroughly clean exterior of the transmission with c...

Page 120: ...sion case to expose rear bearing Remove snap ring from bearing using a suitable puller remove rear bearing fig 8 N 7 Raise front end of mainshaft to clear case then remove the mainshaft assembly Rever...

Page 121: ...lunger Nut 17 Shift Fork Bushing 37 Reverse Latch 18 Shift Fork Bushing Plunger Nut Cotter 19 Shift Fork Bushing 38 Backup Switch Hole 20 Shift Fork Lock Pin Plug 21 2nd and 3rd Fork 39 Backup Switch...

Page 122: ...7 26 TRANSMISSION AND CLUTCH Fig 3N Transmission Assembly Exploded View CHEVROLET OVERHAUL M ANUAL SUPPLEMENT...

Page 123: ...p Gasket Bearing Cap Oil Seal 49 Speedometer Drive 71 Main Drive Gear Gear Bearing Cap Gasket 50 Mainshaft Rear 72 Main Drive Gear Bearing Bearing Cap 51 Transmission Case 73 Main Drive Gear 52 P T O...

Page 124: ...do not have ground or polished surfaces Parts should remain in solution Fig 5N Removing Rear Bearing Cap Fig 6N Removing Countershaft Rear Bearing Retainer Ring long enough to be thoroughly cleaned a...

Page 125: ...d Replacement of all parts show Fig 9N Removing Reverse Idler Shaft TRANSMISSION AND CLUTCH 7 29 Fig 10N Removing Idler Gear and Bearings ing indication of wear or stress will eliminate costly and avo...

Page 126: ...ts of the assembly Sealing members should be handled carefully particularly when be Fig 14N Removing 2nd and 3rd Shift Hub Sleeve Retainer Ring ing installed Cutting scratching or curling under of lip...

Page 127: ...ting surfaces bear Fig 18N Main Drive Gear Assembly ing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or condition which would cause subsequent oil leaks or f...

Page 128: ...N Installing 2nd Speed Gear 4 Install 2nd and 3rd shift rod through shift support Install over shift spacer shift fork and interlock cross pin 5 Install 2nd and 3rd shift fork to shift rod roll pin Mo...

Page 129: ...4 Install 2nd and 3rd synchronizer assembly 5 Install 3rd speed gear with clutching teeth down Install 3rd gear locating washer fig 23N 6 Install 3rd gear retainer ring 7 Install 4th gear with clutchi...

Page 130: ...ig 26N NOTE Countershaft drive gear must be supported on each side with a 1 4 flat bar to prevent damage to countershaft pilot bearing Install bearing re tainer ring 5 Use heavy grease on reverse idle...

Page 131: ...ap use caution as not to cover oil return grooves in bearing cap Install bearing cap with oil grooves lined up with oil holes in case Tighten bolts 20 to 25 ft lbs torque Install parking brake and dru...

Page 132: ...ear 38 Countershaft Drive Gear Spacer 5 Drive Gear Bearing 22 Mainshaft 39 Snap Ring 6 Mainshaft Pilot Bearing 23 Mainshaft Rear Bearing 40 Countershaft Drive Gear 7 4th and 5th Synchronizer Assy 24 M...

Page 133: ...from transmission case fig 2P Discard gasket 4 Shifting by hand engage transmission into two speeds at the same time to lock up the transmission Mainshaft Removal 1 Remove parking brake parts if used...

Page 134: ...ive gear bearing cap and gasket Dis card gasket 8 Remove main drive gear and bearing assembly from front of transmission case Use care as mainshaft pilot bearing consisting of 1 2 rollers and a bearin...

Page 135: ...rse Latch 21 Lock Pin 4 1st Reverse Shift Bar 10 Poppet Spring Plunger 22 1st Reverse Shift Rod 5 Lock Screw 11 2nd 3rd Shift Fork 17 1st Reverse Latch 23 4th 5th Shift Rod 6 Poppet Spring 12 Shift Fo...

Page 136: ...Shift Fork DISASSEM BLY OF SUBASSEM BLIES Control Tower Fig 6P Fig 8P Shift Bar Housing Assembly 3 Raise front end of the countershaft and lift the assembly from transmission case 4 Remove clutch hous...

Page 137: ...o force 4th speed gear bushing sleeve off mainshaft After bushing sleeve has loosened remove it with 4th speed gear locating washer from shaft When bushing is removed the locating pin will come off sh...

Page 138: ...7 42 TRANSMISSION AND CLUTCH Fig lOP Transmission Exploded View CHEVROLET OVERHAUL M ANUAL SUPPLEMENT...

Page 139: ...h or scraper Inspection 1 Inspect rods and shafts for evidence of fatigue Check bearing surfaces for scoring or wear 2 Inspect all parts for discoloration or warpage due to heat 3 Examine all gear tee...

Page 140: ...bearing pocket Use caution when installing drive gear and pilot bearing on pilot end of mainshaft and into transmission clutch hous ing Countershaft 1 Install Woodruff keys in 3rd and 4th gear slots...

Page 141: ...ure adjustment with cotter pin fig 13P 4 Fig 12P Slecting 4th Speed Gear Variable Thickness Retainer 5 Washer Fig 13P Adjusting Latch Plunger b Starting at left side of shift bar housing push 1st and...

Page 142: ...ol tower 3 Position dust cover on gearshift lever 4 Install gearshift lever knob A SSEM BLY OF TRAN SM ISSIO N Refer to Figure 1P Countershaft Installation 1 Install countershaft front bearing in tran...

Page 143: ...nd Bearings 7 49 Mainshaft and Gears 7 49 Countershaft Gears and Bearings 749 Cover and Shifting Mechanism 749 Cleaning and Inspection 749 DISA SSEM BLY OF TRANSM ISSIO N NOTE Refer to Figure 1F 1 Rem...

Page 144: ...r Bearing Assy 15 Shift Housing Cover 27 Mainshaft Rear Retainer Cap Assy 28 Speedometer Drive 41 Countershaft 2nd iear Speed Gear 29 Oil Seal 42 Drain Plug 30 Mainshaft 43 Countershaft 1st 31 Mainsha...

Page 145: ...g 2F Pressing Mainshaft Out of Case Fig 3F Cover and Shifting Mechanism 3 Remove shift rods from cover stripping off forks as shift rods are removed Tip cover on one side and jar interlock out of shif...

Page 146: ...nt as rod is moved into position 4 Install clamp screw move rod to neutral position and tighten clamp screw Install lock wire retaining clamp screw 5 Insert interlock in rod support boss then insert d...

Page 147: ...lean case cover 7 Wash all shift control parts and examine thoroughly before reassembly 1 1 Assembly 1 2 1 If shift rod oil seals 10 were discarded use 1 1 2 13 tubing and assemble new oil seals into...

Page 148: ...y on flange and press drive gear free of bearing cap bearings and spacer 7 Move drive gear bearing spacer 9 aside and use drift to tap outer roller bearing and oil seal 1 0 out front of bearing cap Re...

Page 149: ...r 28 Countershaft Front 35 Countershaft Bearing Retainer Ring Bearing 36 M ainshaft Figure 5F Transmission Assembly Cross Section 9 Slide 1st speed gear 4 and lst 2nd speed clutch collar 3 off rear of...

Page 150: ...urn the steel blue or straw color and damage the heat treated gears If heat is not used it is advisable to coat the gear bores heavily with white lead to prevent galling or seizing of parts When in do...

Page 151: ...sembly into case and slide end of shaft and 1st speed gear out through rear case bearing bore Lower front of countershaft into its approximate position and maintain alignment with a cable support or...

Page 152: ...for end in vise and clamp on 3rd 4th speed clutch gear 5 Assemble lst 2nd speed clutch collar 7 with longer hub down toward 2 nd speed gear 2 Slide 1st speed gear sleeve 8 in position on mainshaft and...

Page 153: ...mesh with 4th speed gear 4 Drive Gear Figure 8F 1 Position drive gear bearing cap 1 in press rear bearing 2 in bearing cap Secure with snap ring 3 Position drive gear 4 on bed of press with spline or...

Page 154: ...ISSION INDEX M 7 92 Modulator Vacuum I n sta ll 7 101 o 7 98 7 99 Overhaul T ransm ission 7 59 7 89 P 7_83 Pan Oil Remove 7 60 Pinion Replacement 7 86 7 80 Pipes Governor In sta ll 7 100 7 77 Pipes Go...

Page 155: ...paper 2 Avoid nicking marring or burring all sur faces particularly those precision finished At many points in the transmission a metal to metal contact without gasket is depended upon to prevent lea...

Page 156: ...r Retainer Figure 4 Removing Vacuum M odulator and Valve REMOVAL OF GOVERNOR SPEEDOMETER DRIVEN GEAR PAN FILTER AND INTAKE PIPE 1 Remove attaching screws governor cover and gasket fig 5 Discard gasket...

Page 157: ...pring assembly fig 9 NOTE Do not remove solenoid attaching screws Figure 8 Removing Filter and O Ring Assembly Figure 9 Removing Detent Roller and Spring Assembly CAUTION IF TRANSMISSION IS IN VEHICLE...

Page 158: ...ause of malfunction fig 131 NOTE There are six selective pins identified as shown in figure 14 Selecting proper pin is equivalent to adjusting band a Attach band apply pin selection gauge J 21370 9 an...

Page 159: ...LOWER STEP USE PIN NO 8627192 0 o n IE Note The Identification Rings are 030 and 100 wide Figure 14 Rear Band A p ply Pin Identification 6 Withdraw electrical connector and O ring seal fig 16 7 Remov...

Page 160: ...brass rod on the outside race of bearing An arbor press can be used if tool to press bear ings out is located on outer race of bearing CAUTION DO NOT locate against inner race or balls FRONT UNIT END...

Page 161: ...to measure washer for its actual thickness REMOVAL OF OIL PUMP FORWARD CLUTCH DIRECT CLUTCH MANUAL LINKAGE AND GEAR UNIT 1 If necessary to replace pry front seal from pump fig 21 2 Remove pump attachi...

Page 162: ...anual shaft c Remove manual shaft jam nut and detent lever from case fig 26 CAUTION Be sure manual shaft flats fo r detent lever are free of burrs before removing from case 8 Remove front band fig 27...

Page 163: ...move intermediate clutch backing plate three 3 composition and three 3 steel clutch plates fig 30 14 Remove center support to case retaining snap ring fig 31 15 Remove entire gear unit assembly by lif...

Page 164: ...and thrust bearing NOTE One race may have been removed with center support Figure 33 Removing Selective Washer Figure 3 4 Rem oving Case Center Support Assem bly 4 Remove reaction carrier and roller c...

Page 165: ...utput shaft b Install speedometer gear removing tool Figure 3 8 Rem oving Output Shaft to Carrier Snap Ring J 21427 01 and 3 8 16 bolts with suitable puller J 9539 on output shaft and remove speedomet...

Page 166: ...Internal Gear and Mainshaft ASSEMBLY OF UNITS sembly in order to replace driven gear D isas sembly may also be necessary due to foreign ma terial causing improper operation In such cases proceed as f...

Page 167: ...manner 1 Drive out governor gear retaining split pin using small punch fig 45 2 Support governor on 7 64 plates installed in exhaust slots of governor sleeve place in arbor press and with a long punch...

Page 168: ...gure 46 Do not remove the teflon oil seal ring from the front servo piston un less the oil seal ring requires replacement For service the oil seal ring will be aluminum 1 Inspect servo pin for damage...

Page 169: ...ed 4 Install outer and inner oil rings on accum ulator piston if removed and assemble into bore of servo piston CONTROL VALVE 4 Remove front accumulator piston and spring fig 51 NOTE Refer to figure 5...

Page 170: ...all springs for distortion or collapsed coils 5 Inspect accumulator piston and oil ring for damage ASSEMBLY 1 Install front accumulator spring and piston into valve body 2 Install special tool J 2188...

Page 171: ...next bore up install 1 2 valve stem end out 14 Install 1 2 regulator valve spring and detent valve into bushing aligning spring in bore Figure 5 6 Rem oving Pressure Regulator Valve of detent valve a...

Page 172: ...lows a Using tool J 21465 17 and driver handle J 8092 remove bushing b From front side of pump using tool J 21465 17 and driver handle J 8092 install new bushing flush to 0 010 below machined surface...

Page 173: ...plug and retaining pin into opposite end of bore 8 Install previously selected front unit se lective thrust washer over pump cover delivery sleeve 9 Install two 2 hook type oil seal rings 10 Assemble...

Page 174: ...for cracks 5 Inspect clutch housing for wear scoring open oil passages and free operation of ball check 6 Inspect turbine shaft a Inspect for open lubrication passages at each end b Inspect splines fo...

Page 175: ...utch housing using arbor press 7 Install forward clutch hub washers on for ward clutch hub Retain with petrolatum 8 Place forward clutch hub into forward clutch Figure 6 9 Installing Forw ard Clutch P...

Page 176: ...lutch operation fig 71 DIRECT CLUTCH AND INTERMEDIATE SPRAG DISASSEMBLY Refer to Fig 72 1 Remove intermediate sprag retainer snap ring and retainer fig 86 2 Remove sprag outer race bushings and sprag...

Page 177: ...assembly for popped or loose sprags 2 Inspect bushings for wear or distortion 3 Inspect inner and outer races for scratches or wear 4 Inspect clutch housing for cracks wear proper opening of oil pass...

Page 178: ...ce spring retainer and snap ring on re tainer 7 Using clutch compressor tools J 4670 01 CHECK BALLS BLIND HOLE DIRECT CLUTCH Figure 8 2 Installing Direct Clutch Backing Plate Composition Plates and St...

Page 179: ...l feed hole This is con sidered normal Apply air through left oil feed hole to actuate piston and move direct clutch CASE CENTER SUPPORT DISASSEMBLY 1 Remove three 3 hook type cast iron oil seal rings...

Page 180: ...rt 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 bore until bushing i...

Page 181: ...6129 compress springs andinstall snap ring fig 89 6 Install three 3 hook type cast iron oil seal rings on the center support if the teflon ring was not removed If the teflon ring was removed install f...

Page 182: ...a tapered punch drive or press pin ion pins out of carrier fig 97 4 Remove pinions thrust washers and roller needle bearings 5 Inspect pinion pocket thrust faces for burrs and remove if present 6 Ins...

Page 183: ...hing journals for damage 5 Be sure oil lubrication hole is open Main Shaft 1 Inspect shaft for cracks or distortion 2 Inspect splines for damage 3 Inspect ground bushing journals for damage 4 Inspect...

Page 184: ...se intake bore pump case face etc Replace case if internal porosity or damage is found 3 Inspect for missing or loose intermediate clutch cup plug fig 103 If loose or missing re place as directed late...

Page 185: ...acement 1 Remove With case properly supported remove bushing using tool J 21465 8 with driver handle J 8092 2 Installation Using installer tool J 21465 8 adapter ring J 21465 9 driver handle J 8092 an...

Page 186: ...Extension to Case All 25 64 3 8 16 UNC 2B 3 8 16 STI NC Governor Cover to Case All 21 64 5 16 18 UNC 2B 5 16 18 STI NC Modulator Retainer to Case 21 64 5 16 18 UNC 2B 5 16 18 STI NC Speedometer Drive...

Page 187: ...the counterclockwise direction 4 Check converter for excessive end play as follows a Fully release collet end of tool J 21371 8 b Install collet end of tool J 21371 8 into converter hub until it botto...

Page 188: ...h petrolatum a Place large race against internal gear with flange facing forward or up fig 108 b Place thrust bearing against race c Place small race against bearing with inner flange facing into bear...

Page 189: ...t output shaft hangs downward 11 Install reaction carrier to output carrier plastic thrust washer with tabs facing down in pockets THRUST BEARING I D FLANGED RACE Figure 108 Installing Rear Internal G...

Page 190: ...ange up over sun gear shaft b Install thrust bearing against race c Install second race center flange up fig 113 17 Install rollers that may have come out of roller clutch cage by compressing energizi...

Page 191: ...gure 119 Installing Rear Band CAUTION DO NOT confuse this spacer 0 040 thick and both sides flat with either the center support to case snap ring one side is beveled or the in te r mediate clutch back...

Page 192: ...locating gap opposite band anchor pin NOTE Both sides of this snap ring are flat and it is 0 093 thick 10 Check rear end play as follows a Install a 3 8 16 bolt J 9539 into an ex tension housing atta...

Page 193: ...bine shaft cannot be rotated as pump is being pulled into place forward or direct clutch housing has not been properly installed to index with all clutch plates This condition must be corrected before...

Page 194: ...nstall detent solenoid assembly with con nector facing outer edge of case fig 15 Do not tighten bolts at this time 7 Install front servo spring and spring re tainer into transmission case Figure 127 L...

Page 195: ...check freeness of selective pin Torque attaching screws to 15 foot pounds and recheckpin to make certain it does not bind 2 Apply 25 foot pounds torque to the lever on tool J 21370 6 fig 131 Selection...

Page 196: ...icle before installing the control valve assembly and governor pipes as outlined in Step 4 below insert governor screen closed end first into governor feed pipe This pipe locates in the governor feed...

Page 197: ...be replaced 3 Install filter retainer bolt 4 Install new oil pan gasket on oil pan and attach pan to case with attaching screws Torque to 11 13 foot pounds Figure 138 Installing Speedometer Driven Gea...

Page 198: ...ge Plate 8 J 21169 Pilot Arbor and Alignment Stud 3 J 1522 Pilot Bearing Driver 2 Plate Clutch 4 J 5824 Clutch Pilot Tool 9 J 7126 Release Lever Adjusting Tool 5 J 1448 Pilot Bearing Puller 10 J 7816...

Page 199: ...1453 Clutch Gear Bearing Replacer 4 J 8107 TR 278 R Countershaft Rear 11 J 2228 Clutch Gear Bearing Remover Bearing Remover Plate 5 J 6416 Rear Bearing Retainer Seal 12 J 8106 K342 Clutch Gear Bearin...

Page 200: ...everse Idler Shaft Remover 3 J 8107 TR 278 R Differential Side Bearing Remover Synchronizer Hub Remover Bearing Installer J 996 Bearing Remover Bearing Remover 4 J 6418 5 J 6419 6 J 0996 7 J 5740 Fig...

Page 201: ...C TRANSMISSION 7 105 1 J 1619 Mainshaft Bearing Remover 2 J 6382 Reverse Idler Gear Shaft Remover 3 J 6419 Bearing Installer Set Fig 4ST Clark Transmission Special Tools CHEVROLET OVERHAUL M ANUAL SUP...

Page 202: ...tector J 21465 17 J 21364 Gear Unit Holding Fixture Adapter J 21664 J 21368 Oil Pump Aligning Strap J 21795 J 21369 2 J 21885 J 21369 6 Converter Air Checking Tool J 21370 6 J 22182 J 21370 9 Band App...

Page 203: ...djuster a few turns counter clockwise This will remove the load from the worm bearings caused by the close meshing of the rack and sector teeth 3 Tilt Cab Models Only Loosen the back up adjuster lockn...

Page 204: ...BALL RETURN GUIDES AND BALLS ADJUSTER PLUG SEAL WORM BEARING UPPER BEARING CUP WORMSHAFT LOCKNUT BACK UP ADJUSTER BEARING CUP EXPANSION PLUG SIDE COVER SHIM LASH ADJUSTER SCREW PITMAN SHAFT BUSHINGS S...

Page 205: ...led wash all parts in cleaning solvent Dry them thoroughly with air With a magnifying glass inspect the bearings and bearing cups for signs of indentation Also check for any signs of chipping or break...

Page 206: ...0 lb Axle 1 Support the steering gear in an arbor press and press the pitman shaft bushing from the horising using Tool J 9226 and Handle J 7079 2 fig 5 2 Press the new bushing into position using Too...

Page 207: ...Make sure that the plug is tight in the housing or lubricant leakage could occur 3 Position the new bearing cup squarely over the recess in the gear housing and press the cup in until it is firmly an...

Page 208: ...and nut by sighting through the ball guide holes 4 Count 53 balls all except TE 60 Models with 9000 lb axle 45 balls TE 60 Models with 9000 lb axle into a suitable container This is the proper number...

Page 209: ...ings bushings and ball nut teeth 1 Place the steering gear housing in a vise with the worm shaft horizontal and the side cover up 2 Check that the pitman shaft and wormshaft seals pit man shaft bushin...

Page 210: ...t there is some lash between the ball nut and sector teeth assemble and tighten the cover bolts to 30 ft lbs 10 On models so equipped install the back up adjuster Screw the adjuster in until it bottom...

Page 211: ...d NOTE When assembling pressure plate and springs install one spring over each dowel pin see figure 16 Fig 16 Installing Pressure Plate Springs 5 8 9 10 11 13 24 i i i i v 12 14 0 CS3 dUJUiUJUl t t I...

Page 212: ...pulling it out of the top cover assembly fig 19 7 Remove the top cover bolts and carefully withdraw the top cover wormshaft and ball nut assemblies as a unit fig 20 Remove and discard the top cover g...

Page 213: ...ug Dust S e a l 2 5 T o p C o ve r Valve S e a l 6 V a lv e S p o o l 16 B e a rin g Race 26 Back up W a sh e r 7 S p o o l D am p e n e r O Ring 1 7 U p p e r Thrust B earing 27 Top C over Valve B ea...

Page 214: ...e bearing retainer 4 If the needle bearing is to be replaced remove the re taining ring using Internal Pliers J 4245 Remove the seal back up washer Remove the thrust bearing as ou Fig 22 Removing Thru...

Page 215: ...ing servicing of the valve assembly NOTE It is very uncommon to have to make any service repairs to the valve assembly with the possi ble exception of replacing the valve spool dampener 0 ring DO NOT...

Page 216: ...ots If any are found the entire valve assembly should be replaced As on the spool a slight polishing is normal on the valving surfaces 7 Check the fit of the spool in the valve body without the valve...

Page 217: ...e spool after several tries make sure the spool is free to rotate place the valve body on a flat surface notched end up and tap the spool with a wooden or plastic rod until the O ring seal is cut and...

Page 218: ...ion a few turns The filling of the circuit can then be con tinued It may be necessary to work the worm back and forth holding the balls down first in one hole then the other to close up the spaces bet...

Page 219: ...refully guide the assembly into the gear housing until the wormshaft contacts the worm thrust bearing fig 32 Rotate the worm so that the ball nut return guide clamp faces the back up adjuster open ing...

Page 220: ...il at the other end The axle mounted cylinder is bracketed to the front axle at one end and to the steering tie rod at the other end Metal tubes and flexible hoses connect the power cylinder to the po...

Page 221: ...bottom of the opening in the guide 2 Lubricate a new O ring with transmission fluid and install it onto a new scraper assembly 3 Install the scraper and O ring assembly in the guide O ring towards gui...

Page 222: ......

Page 223: ...00 400 9 is 12 115 150 i v r i 8 700 900 Corporation v z 800 1100 4 13 H 13 5 160 170 Corporation 2 13 H 15 0 80 105 1H 18 160 280 4 13 T 15 0 80 105 D I F F E R E N T I A L C A R R IE R T O H O U S I...

Page 224: ...0 5 10 6 0 20 25 Rear Axle Bumper Bolt Nuts All Except T Series 6 8 T Series 10 12 H E N D R IC K S O N T A N D E M S U S P E N S IO N S P E C IF IC A T IO N S Spring Eye Bushing CHEVROLET OVERHAUL M...

Page 225: ...T T O H A N G E R A T T A C H IN G P A R T S 7 i 6 x 20 N u t 25 30 ft lbs P R O P E L L E R S H A F T T O R EA R A X L E Vs x 24 N u t 1350 1410 20 24 ft lbs M e x 20 Nu t 1480 32 37 ft lbs 58 W B 4...

Page 226: ...with Optional Split Brake System have a 13 A Master Cylinder Bore FRONT BRAKES CE CS40 CE CS50 SE SS50 Duo Servo Automatic 14 x IVi IVi 2 136 4 REAR BRAKES CE CS40 1 CE CS50 SE SS50 TE TS50 Twin Acti...

Page 227: ...Vs Adjust Travel to Short as possible w o brakes dragging STOPMASTER BRAKE SPECIFICATIONS Brake S ize 15 x 7 Brake Shoe Lining Width 7 Thickness Crescent Area sq in per axle 440 Brake Chamber Standard...

Page 228: ...elerator Pum p Air Vent 0 015 Min 0 060 Bottom of Sight Plug 0 015 Min 0 060 Fast Idle Mechanical 0 035 0 035 Running 1800 2400 RPM 1800 2400 RPM Main Metering Jet Primary 56 56 Secondary 71 71 Thrott...

Page 229: ...6 Min 2 6 Min Load Test Amp Load 180 160 210 180 240 Voltage and Temperature Chart No 1 No 1 No 1 No 1 No 1 Voltage Must Not Drop Below Minimum Listed at Given Temperature When Battery is Subjected t...

Page 230: ...5 5 Volts 5 5 5 5 Hold ln Winding Amps 14 5 16 5 14 5 16 5 14 5 16 5 14 5 16 5 Volts 10 10 10 10 1108485 1108486 STARTER MODEL 1108483 1108484 1108487 1113686 Make Delco Remy Delco Remy Delco Remy Del...

Page 231: ...6 54 3 2 1 8 4 3 6 5 7 2 1 8 4 3 6 5 7 2 1 84 3 6 5 7 2 1 Set with vacuum in full retard 2 Satisfactory Range When Adjusting Set to 30i Gives 016 Point Opening Ignition Timing Idle Speed RPM 700 700...

Page 232: ...2 1116378 62 AMP TG 50 1117782 1116374 100 AMP SE SG SM SS 50 1117141 Integral NON INTEGRAL TYPE GENERATOR SPECIFICATIONS GENERATOR MO DE L 1100838 1100842 1100849 1117754 1117782 1117128 M ake Delco...

Page 233: ...RANSISTOR TYPE REGULATOR MODEL 1116378 M A K E DELCO R EMY M O D EL 1116378 Field Relay Closing Voltage Range 2 0 3 0 Voltage Chart a No 2 a Allowable Range at 0 Position of Adjusting Screw T E M P E...

Page 234: ...0 50 Tighten Pivot Bolts prior to tightening other mounting bolts ALTERNATING CURRENT GENERATING SYSTEM INTEGRAL TYPE MODEL APPLICATION CHART AMPERAGE TRUCK SERIES GENERATOR STANDARD 42 Amp CE ME 60 1...

Page 235: ...IVE SPEED C L A R K M O D E L 325 and 327 Shift Lever Attaching Nut 28 ft lbs Selector Finger to Shifter Shaft Screw 25 ft lbs Companion Flange or Yoke N u t 425 ft lbs A U X ILIA R Y 4 SPEED SP IC ER...

Page 236: ...lt 15 20 S T E E R IN G S H A F T S T O P C LA M P B O LT All M o de ls Nut 8 12 S T E E R IN G S H A FT T O W O R M S H A F T C LA M P B O LT T M odels Nut 40 50 S M o de ls Nut 30 40 C M o de ls Bol...

Page 237: ...50 6 0 235 P 20 Vane HYDRAULIC PUMP SPECIFICATIONS VANE TYPE PUMP M ake Saginaw Steering Gear Division T yp e Vane Models 235 P 19 235 P 20 235 P 36 Capacity Per Minute M axim um 3 5 G P M of Power St...

Page 238: ..._________ P A R T _____________________ F T LB S Steering Gear to Fram e Bolt Conventional Cab and S M odels Tilt Cab Models Pitman Arm to Pitman Shaft Conventional Cab and S M odels Pinch B olt Steel...

Page 239: ...t Cab Models Bolt 40 50 Power Steering Pum o Pullev CE CS 40 C E C S S E S S 50 Nut 65 95 CG 50 Nut 25 30 TE 50 C E M E T E 6 0 Nut 40 55 TS50 Nut 55 65 Power Steering Pum p Mounting Bracket to Engine...

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