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SECTION 4

DIFFERENTIAL CASE AND DRIVE PINION


INDEX
Page Page

I
Conventional Differential Case and Drive Pinion. 4-1 Positraction Differential Case and Drive Pinion
Removal 4-1 (Dana) 4-9
Inspection 4-2 Disassembly 4-9
Repairs 4-2 Inspection 4-9
Pinion and/or Bearing Replacement 4-2 Reassembly 4-10
Differential Bearing Replacement 4-3 Positraction Differential Case and Drive Pinion
Ring Gear or Differential Case Replacement. 4-3 (Eaton) 4-11
Installation 4-5 Disassembly 4-11
Drive Pinion and Bearing 4-5 Inspection 4-12
Differential Bearing Preload 4-5 Reassembly 4-12
Ring Gear and Pinion Adjustment 4-6 Special Tools 4-14
Ring Gear and Pinion Contact Pattern . . . . 4-7

CONVENTIONAL DIFFERENTIAL CASE AND 5. Place left and right bearing cups and shims with
DRIVE PINION bearing caps so that they may be reinstalled in orig-
inal positions.
Removal
6. Install Tool J-8614-1 on pinion flange and remove
1. Raise vehicle and remove axle shafts. pinion flange nut and w a s h e r (fig. 2). (Position
2. Roll out the differential pinions and thrust washers, J-8614-1 on flange so that the four notches are to-
then remove side gears and thrust washers. Mark ward flange.) Discard nut and use a new one upon
pinions and side gears so that they can be r e - reassembly.
assembled in original position. 7. Thread pilot end of Tool J-8614-3 into small O.D.
3. Mark one bearing cap and housing for reassembly in end of J-8614-2. Then with J-8614-1 installed as in
same position. Remove bearing cap bolts and bearing Step 6, insert J-8614-2 into J-8614-1 and turn it 45
caps-tap surface of bearing caps to loosen them. degrees to locked position. Remove flange by turning
CAUTION: Do not attempt to pry caps off as J-8614-3 while holding J-8614-1 (fig. 3).
this may damage machined face of caps. 8. Pry old seal out of bore, using a screw driver or a
hammer and chisel.
4. Using a pry bar as s h o w n in Figure 1, pry dif- 9. If deflector requires replacement, remove by tapping
ferential case out of carrier. Exercise caution in from flange, clean up stake points; install new
prying on carrier so that gasket sealing surface is deflector, and stake deflector at three new equally
not damaged. If the bearings are preloaded, the case spaced positions.
will suddenly fall free when it is pried past a certain
point; therefore, make sure case is properly sup- NOTE: Staking operation must be performed in
ported to prevent damage. The bearing caps may be such a manner that the seal operating surface is
loosely installed, as shown in Figure 1, to prevent not damaged.
case from falling. 10. Remove drive pinion by tapping on front end with a
soft faced hammer. Then remove pinion front bear-
ing cone from carrier bore. Discard pinion bearing
spacer and use a new one upon reassembly.

Fig. 1—Differential Case Removal Fig. 2—Drive Pinion Nut Removal

CHEVROLET CHASSIS OVERHAUL MANUAL


DIFFERENTIAL CASE AND DRIVE PINION 4-2

their positions in the carrier, using a brass drift of


suitable length.
2. Install new bearing cups in the carrier, using Tool
J-7817 for light-duty axle and Tool J-7137 for heavy-
duty axle to install front cup. Use Tool J-0270-14 for
light-duty axle and Tool J-8608 for heavy-duty axle
to install rear cup (fig. 4). Check installation to make
sure cups are seat^d properly.
3. Remove p i n i o n rear b e a r i n g cone and roller
assembly, using Tools J-7028 and J-0358-1 for light-
duty axle and Tools J-9771 and J-0358-1 for heavy-
duty axle as shown in Figure 5. Record thickness of
shim removed from between bearing cone and pinion
head.
4. If the original ring gear and pinion and the pinion
V rear bearing assembly will all be reinstalled, the

i original shim or one of the same thickness may be


used. If the ring gear and pinion or the pinion rear
bearing assembly are replaced, the correct shim
thickness may be determined as follows:
Fig. 3—Drive Pinion Flange Removal
a. Lubricate p i n i o n bearing cone and roller as-
Inspection semblies and position them in proper cups.
1. Inspect all bearing cups, races and rollers for scor- b. Position Adapter J-6266-35 for light-duty axle
ing, chipping or evidence of excessive wear. On and Tool J-6266-36 for heavy-duty axle in pinion
pinion bearing rollers, inspect large end of rollers rear bearing (fig. 6)J insert clamp screw through
for wear. This is where wear is most evident on adapter and both of the pinion bearings, position
taper roller bearings. J-6266-25 on threaded end of clamp screw and
NOTE: The pinion bearings are of the tapered index it in front bearing, install hex nut and rotate
type, and the natural wear pattern is a frosted bearings several times to make sure that they are
condition with occasional slight scratches on seated.
races or rollers. This does not indicate a defec- c. Tighten hex nut until 20 to 30 in. lbs. of torque is
tive bearing. required to rotate bearings (fig. 7).
2. Inspect pinion splines and flange splines for evidence d. After torque has been established, position gauge
of excessive wear. adapter in carrier as shown in Figure 6.
3. Inspect ring gear and pinion teeth for possible e. Position dial indicator (Tool J-8001-3) on gauge
scoring, cracking or chipping. post of Tool J-6266-28 so that indicator button
4. Inspect differential case for cracks or scores on side rests on top of tool plunger.
gears, thrust washers, and pinion thrust faces. f. Position tool in carrier as shown in Figure 8.
5. Check fit of differential side gears in case. Swing tool body so that plunger does not touch
6. Check fit of side gear and axle shaft splines. gauge plate, and set indicator dial at zero.
7. Inspect differential pinion shaft for scoring or evi-
dence of excessive wear. NOTE: Barrel adapters, Tool J-6266-31 must
Repairs be used when gauging heavy-duty axle. Make
Pin/on and/or Bearing Replacement sure adapters are seated in differential bearing
1. Remove pinion front and rear bearing cups from bores of carrier before measuring depth.

Fig. A—Drive Pinion Front and Rear Bearing Cup Installation

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DIFFERENTIAL CASE AND DRIVE PINION 4-3

J-9771 (HEAVY-DUTY)
J-7028 (LIGHT-DUTY)

Fig. 7— Drive Pinion Depth Setting Gauge Plate Installed

6. Position shim selected in above procedure on pinion


shaft and against pinion head.
7. Install new cone and roller assembly, using Tool
J-5590 for light-duty axle (fig. 9) and Tool J-9772 for
heavy-duty axle (fig. 10). Press cone against shim
and rear face of pinion.
Differential Bearing Replacement
1. Install Tool J-7112 and Adapter Plug J-8107-4,
making sure puller legs are fitted s e c u r e l y in
notches in case and a g a i n s t bearing cone. Then
Fig. 5—Drive Pinion Cone and Roller Assembly Removal tighten puller yoke against puller legs.
2. Tighten puller screw to remove bearing (fig. 11).
g. Slowly swing inner end of tool plunger across 3. Place new bearing on hub with thick side of inner
gauge plate until highest indicator reading is ob- race toward case and drive into place, using Tool
tained. Record this measurement and recheck to J-9537 for light-duty axle and Tool J-8359 for heavy-
see that it is correct. duty axle.
h. All factory and service pinion gears are cut to 4. Before installing bearing on opposite hub, support
one mounting distance and have a master gear differential case on Adapter Plug J-8107-4. This al-
number (0.045); the difference (obtained by sub- lows differential case to rest on adapter instead of
tracting reading indicated in Step g from 0.045") bearing cage (fig. 12). Install remaining bearing as
determines the required thickness of the pinion instructed in Step 3.
locating shim. Use a shim with a thickness Ring Gear or Differential Case Replacement
closest to the difference obtained above.
1. Remove ring gear screws and lock washers and,
NOTE: Shims are available in .001" increments using a soft faced hammer, tap ring gear off the
from .021" to .033". Each shim has the thick- case.
ness etched on flat surface for easy identifi- NOTE: Do not attempt to pry ring gear from
cation. case, to do so may damage machined surfaces.
5. Remove Tool J-6266 and pinion bearing cone and 2. Install guide pins, made from 3/8"-24 x 1-1/2" long
roller assemblies from carrier.

Fig. 6—Measuring Drive Pinion Bearing Simulated Preload Fig. 8—Measuring Drive Pinion Shim Requirement

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DIFFERENTIAL CASE AND DRIVE PINION 4-4

Fig. 11—Differential Bearing Removal

Install every other ring gear bolt and lock washer,


then draw them up evenly and snugly so that gear
face is flush with face of case.
4. Remove guide pins and install remaining b o l t s -
torque all bolts to specifications.

Fig. 9—Drive Pinion Cone and Roller Assembly Installation


(Light-Duty)
cap screws with heads cut off and ends slotted, to
ring gear (fig. 13).
3. Position ring gear over pilot diameter of the case.

? PROTECTIVE
- * TUBE OR PIPE

J-9772

IT

MUMNUHWN

Fig. 10—Drive Pinion Cone and Roller Assembly Installation


(Heavy-Duty) Fig. 12—Differential Bearing Installation

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DIFFERENTIAL CASE AND DRIVE PINION 4-5

Fig. 15—Drive Pinion Flange Oil Seal Installation (Heavy-Duty)

not apply unnecessary pressure after seal is


seated. To do so will destroy rubber seat and
Fig. 13—Ring Gear Guide Pins Installed distort seal.
5. Install thrust washers and side gears in case, if 3. Position and align pinion flange on pinion shaft, using
same parts are used, replace in original sides. Po- Tools J-9458 and J-8614-1. T o o l J-9458-1 is
sition pinions and thrust washers through loading threaded onto pinion shaft and nut tightened against
hole in case 180 degrees apart so that they engage J-9458-2 to pull flange on shaft (fig. 16). Remove
side gears. Rotate gears until pinion shaft holes are J-9458 after flange is seated.
aligned. Install pinion shaft and lock screw. 4. Pack the cavity between end of pinion splines and
pinion flange with a nonhardening sealer (such as
Installation Permatex Type A) prior to installing washer and nut
Drive Pinion and Bearing on pinion.
1. Position pinion and rear bearing cone and roller as- 5. Install washer and a new self-locking nut on pinion
sembly in carrier, install a new pinion bearing shaft. Tighten nut to remove end play—continue al-
spacer on pinion shaft and install pinion front bearing ternately tightening, in small increments, and check-
cone and roller assembly. ing preload with torque wrench until torque required
2. Pack the cavity between the seal lips of the pinion to rotate pinion is 20-30 in. lbs. for new bearings and
flange oil seal with a lithium-base extreme pressure seal, or 5-15 in. lbs. when used parts are reinstalled
lubricant, position seal in bore, then using Tools (fig. 17).
J-21468 and J-9458 for light-duty axle and Tool Differential Bearing Preload
J-21057 for heavy-duty axle, press seal into bore un- 1. Place differential case and b e a r i n g assembly in
til it seats against shoulder (figs. 14 and 15). carrier—if same bearings and case are used, select
CAUTION: Pinion oil seal flange must not bot- new right and left adjusting shims e a c h 0.002"
tom against carrier. Press seal into carrier thicker than original shim—if new bearings and/or
bore until it seats against internal shoulder—do case are being installed, loosely install left bearing
cap and select preload shim as follows:
a. Select two shims of known thickness and position
them between the right bearing cup and the cup
seat in the carrier. (Select shims with a total
thickness that will permit a feeler gauge of at

Fig. 14-Drive Pinion Flange Oil Seal Installation (Light-Duty) Fig. 16—Drive Pinion Flange Installation

CHEVROLET CHASSIS OVERHAUL MANUAL


DIFFERENTIAL CASE A N D DRIVE PINION 4 - 6

least 0.010" to be inserted between shim and cup


seat in carrier.) Make sure left bearing cup and
case are against left cup seat, then determine
distance between shim and cup seat, using feeler
gauge as shown in Figure 18. See shim chart, for
shim availability and identification.
NOTE: When determining proper preload shim
thickness, do not apply pressure on bearings so
as to preload them. Shim thickness is deter-
mined by line-to-line measurement—preload on
bearings will, in effect, produce an incorrect
shim t h i c k n e s s , thereby causing excessive
preload.
b. Add 0.010" to total of both shims and feeler gauge
thickness used in Step a, then select two shims of
equal thickness which in total are equal to value Fig. 17—Measuring Drive Pinion Bearing Preload
obtained in Step a plus the additional 0.010".
chamfered side is outward or next to cup seat in car-
Example: rier). Tap shim into position, using a soft faced
Shim thickness used in Step a hammer, while rotating differential case with free
(0.076" x 2) 0.152" hand (fig. 19).
Thickness of feeler gauge used in NOTE: If insertion of left shim causes pinion-
Step a 0.012" to-ring gear contact, select thinner shim and add
Nominal thickness added for proper difference to right shim. Keep total shim thick-
preload 0.010" ness at a value equal to that obtained in Step lb.
TOTAL SHIM THICKNESS 3. Install bearing caps and torque them alternately and
REQUIRED 0.174" evenly to specifications.
SHIM THICKNESS FOR EACH Ring Gear and Pinion Adjustment
SIDE 0.088" 1. Mount a dial indicator on the carrier and check the
NOTE: Use only one shim at each side. backlash (fig. 20) between the ring gear and pinion.
The backlash should be within the range of 0.003"-
0.010" with a reading of O.OO5"-O.OO8" preferred.
Check gear lash at four different equally spaced po-
DIFFERENTIAL BEARING SHIM IDENTIFICATION sitions around the gear. Variation in readings should
not exceed 0.001".
Identification Notches
I. D. O. D. NOTE: Position the dial indicator so that indi-
Thickness cator button is perpendicular to tooth angle and
Light- Heavy- Light- Heavy-
Duty Duty Duty Duty in line with gear rotation.
.064 0 2 0 0 If variation in backlash readings exceed 0.001",
.066 0 3 1 0 measure ring gear and case runout as shown in Fig-
.068 0 4 2 0 ure 21. Gear runout should not exceed 0.002"; should
.070 0 0 3 1
.072 1 1 0 1
.074 1 2 1 1
.076 1 3 2 1
.078 1 4 3 1
.080 2 0 0 2
.082 2 1 1 2
.084 2 2 2 2
.086 2 3 3 2
.088 3 4 0 2
.090 3 0 1 3
.092 3 1 2 3
.094 3 2 3 ' 3
.096 4 «. 0
.098 4 «. 1
.100 4 - 2 -

2. Remove left bearing cap and position shim between


bearing cup and cup seat. Wedge right shim between
bearing cup and cup seat ( p o s i t i o n shim so that Fig. 18—Measuring Differential Shim Requirement

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DIFFERENTIAL CASE AND DRIVE PINION 4-7

Fig. 21—Checking Ring Gear Runout

Rotate pinion through several revolutions in the for-


ward and reverse direction until a definite contact
pattern is developed on the ring gear.
Fig. 19—Installing Differential Shim Inspect the contact pattern produced by the above
procedure. Figure 22 shows the terminology used in
runout exceed this limit check ring gear and case for analyzing contact patterns.
deformation and/or foreign matter between case and The large end of the tooth is called the "heel" and
gear. the small end the "toe". Also, the top of the tooth,
2. If gear lash is not within limits, correct by de- which is the part above the pitch line, is called the
creasing shim thickness on one side and increasing "face," while the part below the pitch line is called
thickness of other shim the same amount. Total shim the "flank". The space between the meshed teeth is
thickness must be maintained at all times to maintain referred to as "backlash".
proper preload. Figure 23 shows correct and incorrect contact
For each 0.001" c h a n g e in backlash required, patterns.
change shim thickness 0.002". If lash is too high, add Contact pattern " A " provides the ideal bearing for
thicker shim to left side and decrease right side by quietness and long life. If the pattern shows a toe
same amount; if lash is too low, add thicker shim to contact " B , " it indicates not enough backlash. To
right side and decrease left side by same amount. correct, move the ring gear away from the pinion by
Ring Gear and Pinion Contact Pattern increasing right shim thickness while decreasing left
1. Thoroughly clean the ring and pinion gear teeth. shim thickness an equal amount.
2. Paint ring gear teeth lightly and evenly with a If the pattern shows a heel contact " C , " it indi-
mixture of powdered red lead and oil of a suitable cates too much backlash. To correct, move the ring
consistency to produce a contact pattern. gear toward the pinion by increasing left shim thick-
3. Remove the differential pinion shaft, and install axle ness while decreasing right shim thickness an equal
shaft and drum—install wheel bolts to retain drum on amount.
axle shaft. Expand brake shoes until a torque of 60 NOTE: Make adjustment increasing and de-
ft. lbs. is obtained at pinion nut. creasing shim thickness by 0.002" at a time,

F\-T FACE
PITCH UNE
/ VT~
/ VST FLANK

BACKLASH .OO5"-.OO8" CLEARANCE

THE HEEL OF THE GEAR


TOOTH IS THE LARGE
END A N D THE TOE IS
THE SMALL END

Fig. 20—Checking Ring Gear Backlash Fig. 22—Gear Tooth Nomenclature

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DIFFERENTIAL CASE AND DRIVE PINION 4-8

CORRECT
TOOTH
CONTA

Fig. 23—Gear Tooth Contact Patterns

check contact with red lead mixture and continue the pinion shim with a .001" thinner shim and recheck
adjustment until tooth contact appears as in contact pattern.
"A". Backlash must remain within limits. In making pinion adjustments, be sure backlash is
If the pattern shows a high face contact " D , " it correct before testing contact pattern. Moving the
indicates that the pinion is too far out, that is, too far pinion in reduces backlash and moving it out in-
toward the front of the car. creases backlash.
To correct a pattern such as " D , " it will be nec- After satisfactory contact pattern is produced as in
essary to install a thicker pinion shim as described "A," clean ring and pinion gear teeth and pour a
under "Pinion and/or Bearing Replacement". A liberal quantity of rear axle lubricant on gears and
.001" thicker shim is recommended as a starting bearings—turn gears to work lubricant into all sur-
point. Continued changes may be necessary to obtain faces.
the correct setting. Install axle shafts, drums and wheel assemblies; fill
If the pattern shows a flank contact " E , " it indi- rear axle with proper lubricant to a level even with
cates that the pinion is in too far. To correct replace bottom of filler hole and road test vehicle.

Fig. 24-Positraction Exploded View (DANA)

1. Differential Case 4. Clutch Disc 7. Side Gear 9. Pinion


2. Cage 5. Clutch Plate 8. Spring and 10. Thrust Washer
3. Lock Pin 6. Spring Seat Spring Cups 11. Pinion Shaft

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DIFFERENTIAL CASE AND DRIVE PINION 4-9

Fig. 25—Spring Removal


Fig. 28—Installing Spring Seat to Side Gear

making sure spring jaws are securely indexed be-


tween spring coils.
2. Compress J-21752 until spring is compressed suf-
ficiently to slide out of retainer seats then remove
spring and spring cups (fig. 25). Repeat on remaining
springs.
3. Remove differential pinions by rotating side gear
with axle shaft until they move around to large open-
ing in case. Pry clutch pack away from pinion until
pinion drops out. Remove pinion thrust washers.
4. Remove clutch packs and side gears (fig. 26).
5. Pry clutch pack cage out of differential case (fig. 27).
Inspection
1. Clean and inspect side gear thrust surfaces, pinion

Fig. 26—Clutch Pack and Side Gear Removal

POSITRACTION DIFFERENTIAL CASE AND


DRIVE PINION (DANA)
The optionally available Dana Positraction differential
unit (fig. 24) is installed in the conventional carrier to
replace the standard differential unit.
Overhaul procedures for the Positraction equipped axle
are the same as on a conventional axle except for the op- Fig. 29-lnstalling Clutch Pack
erations listed below.
Disassembly
1. Remove ring gear and install spring Tool J-21752,

Fig. 27—Clutch Pack Cage Removal Fig. 30—Measuring Positraction Rotating Torque

CHEVROLET CHASSIS OVERHAUL MANUAL


DIFFERENTIAL CASE AND DRIVE PINION 4-10

gear thrust surfaces, thrust washers and spring cup Tilt case on its side to prevent side gear from fall-
for excessive wear and replace where necessary. ing out.
2. Inspect clutch pack for e x c e s s i v e wear or over- 5. Place pinion gear between differential side gears
heating and replace as a unit if necessary. through large opening in case. Rotate side gears and
install second pinion directly opposite first. Install
Reassembly—Refer to Figure 24
pinion thrust washers.
1. Place clutch pack cages into case with side tabs up
and flat sides parallel with flat sides in case. 6. Place spring cup in spring seat bore and install
2. Place aluminum spring seat plate over side gear clutch spring in jaws of J-21752, compress spring to
(fig. 28). approximately 1.90", install spring cup on top of
3. Alternately place clutch plate and clutch disc on side spring and carefully insert into spring seats. Re-
gear until assembly of pack is complete (fig. 29). lease spring and remove tool. Repeat for remaining
Make sure clutch discs index with teeth in side gear. springs.
4. Install clutch pack and side gear assemblies in case. 7. Install ring gear on case as outlined under Ring Gear

Fig. 31-Posi traction Exploded View (EATON)

1. Ring Gear-to-Case Bolt 5. Ring Gear 9. Clutch Plates 13. Pinion Gear
2. Differential Case 6. Shims 10. Side Gear 14. Pinion Shaft
3. Side Bearing 7. Clutch Pack Guide 11. Spring Retainer 15. Preload Spring
4. Pinion Lock Screw and Washer 8. Clutch Disc 12. Pinion Thrust Washer

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DIFFERENTIAL CASE AND DRIVE PINION 4-11

Fig. 32—Removing Preload Spring Pack

or Differential Case Replacement in this section.


8. Place differential in carrier and adjust bearings and
backlash as outlined in this section.
9. Check operation of unit as follows: Fig. 34—"C" Clamp and Bar Stock Installed for Spring Removal
a. Raise rear of vehicle until rear wheels are off the
ground, and remove one wheel and tire assembly. unit (fig. 31) is installed in the conventional carrier to
b. Attach Adapter J-5748 to axle shaft flange and in- replace the standard differential unit.
stall a 1/2-13 bolt into adapter (fig. 30). Overhaul procedures for the Positraction equipped axle
c. With wheel and tire assembly still on vehicle held are the same as on a conventional axle except for the op^
firmly to prevent turning, measure torque r e - erations listed below.
quired to rotate opposite axle shaft with a 0-150
lb. torque wrench attached to J-5748. Torque r e - Disassembly
quired to rotate axle shaft should be no less than 1. Remove ring gear and side 'bearings following the
40 ft. lbs. procedures established for the conventional differen-
tial unit.
POSITRACTION DIFFERENTIAL CASE AND 2. Remove the differential pinion shaft lock screw and
DRIVE PINION (EATON) tap pinion shaft from the case.
The optionally available Eaton Positraction differential 3. Remove the preload spring retainer and springs by
tapping on the spring retainer through the observa-
tion hole in the case (fig. 32). D r i v e the spring
retainer from the case sufficiently to allow insertion
of a 1/4 inch bolt in each of the two front springs.
Secure each bolt with a nut (fig. 33).

Fig. 33—Installing Bolts to Retain Springs Fig. 35—Removing Preload Springs from Pack

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DIFFERENTIAL CASE AND DRIVE PINION 4-12

Fig. 38—Assembling Clutch Pack

vise pressure until spring compression is relieved


(fig. 35).
6. Remove the pinion thrust washers from behind the
pinion gears.
Fig. 36—Removing Differential Pinion Gears 7. Remove pinion gears from the case-pinion gears can
4. After installing the retaining bolts in Step 3, continue be removed by rotating them in one direction only.
to drive spring retainer from the case until enough of Using Figure 36 as a reference, rotate differential
the retainer is exposed to permit installation of bar case clockwise to remove the first gear, then rotate
stock, and " C " clamp (fig. 34). Center the bar stock case counterclockwise to remove the second gear.
over the axle shaft hole in the spring retainer, then To remove second gear, it may be necessary to as-
compress " C " clamp sufficiently to permit with- sist pinion gear upon its seat by prying on gear
drawal of spring pack. through observation hole in case (fig. 36).
8. Remove side gear, clutch pack, shims and guides
5. Position spring pack in vise and remove 1/4 inch from case. Tap the assembly from the case, using a
bolts. Alternately relieve "C» clamp pressure and brass drift as shown in Figure 37. Repeat removal on
opposite gear.
9. Separate clutch pack assembly from side gear. Re-
tain clutch pack assembly with original side gear.
Inspection
1. Check clutch plates and discs for excessive wear and
signs of overheating.
NOTE: Clutch plates or discs are not serviced
separately, if replacement is required, clutch
pack must be replaced as an assembly.
2. Inspect preload springs for distortion and other
defects.
3. Compress springs and determine if they are capable
of properly preloading the c l u t c h pack, replace
springs that are weak or questionable.
4. Examine spring retainer for alignment between the
retainer halves and for excessive wear at spring
seats.
Reassembly
1. Lubricate clutch plates and discs with special posi-
traction lubricant.
2. Alternately position clutch plate and clutch disc on
side gear, beginning and ending with clutch plate, un-
til assembly of clutch pack is complete (fig. 38).
3. Install clutch pack guides on the clutch plate lugs.
Make sure that the clutch disc lugs engage with side
Fig. 37—Removing Clutch Pack gear teeth.

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DIFFERENTIAL CASE AND DRIVE PINION 4-13

4. Select shims of equal thickness as those removed


from the case, or if old shims are suitable, reinstall
them over the side gear hub.
5. Lubricate and assemble opposite side gear as above.
6. Install one side gear, clutch pack assembly and
shim(s) in the differential case.
7. Position pinion gears and thrust washers on side
gears, install pinion shaft through case and gears.
8. Install dial indicator on case so that contact button
rests against pinion gear (fig. 39).
9. Compress clutch pack, using a screw driver as
shown in Figure 39. Move the pinion gear to obtain
tooth clearance.
10. Tooth clearance should be .001" to .006", if required
change shims to obtain proper tooth clearance.
11. Remove side gear assembly and repeat tooth clear-
ance procedure for other side gear on opposite side
of case.
12. Remove pinion shaft, gears and thrust washers.
13. Install remaining side gear, clutch pack assembly
and shims in case.
14. Install pinion gears and thrust washers. Installation
of pinion gears can be performed by reversing the
pinion gear removal procedure.
15. Assemble springs in spring retainer and clamp as-
sembly in vise. Install "C" clamp and bar stock on
spring retainer then install a 1/4 inch bolt and nut in
each front spring (fig. 40). Fig. 40—Spring Pack Compressed for Installation
16. Position spring pack between side gears and remove
bar stock and " C " clamp. backlash as outlined in this section.
17. Drive spring pack into side gears sufficiently to r e - 22. Check operation of unit as follows:
tain front springs, then remove 1/4 inch bolts from a. Raise rear of vehicle until rear wheels are off the
springs. Drive spring pack into position (fig. 41). ground, and remove one wheel and tire assembly.
18. Install the pinion shaft and lock screw. Torque lock
screw to specifications.
19. Check alignment of spring retainer with side gears.
Slight movement of the spring pack can be made if
necessary.
20. Install side bearings and ring gear to case using pro-
cedure outlined for the conventional differential.
21. Place differential in carrier and adjust bearings and

Fig. 39—Measuring Pinion Gear Tooth Clearance Fig. 41-lnstalling Spring Pack

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DIFFERENTIAL CASE AND DRIVE PINION 4-14

b. Attach Adapter J-5748 to axle shaft flange and in- quired to rotate opposite axle shaft with a 0-150
stall a 1/2-13 bolt into adapter (fig. 30). lb. torque wrench attached to J-5748. Torque r e -
c. With wheel and tire assembly still on vehicle held quired to rotate axle shaft should be no less than
firmly to prevent turning, measure torque r e - 40 ft. lbs.

Fig. 42—Special Tools

1. J-6266 Pinion Setting Gauge - Consists of J-6266-28 15. J-0358-1


Press Plate Holder
Barrel Adapter, and J-6266-25 Plug - Used 16. J-8001 Dial Indicator Set
with J-6266-31 Sleeves. 17. J-5748 Positraction Torque Measuring Adapter
2. J-6266-35 Pinion Setting Gauge Plate 18. J-1313 0-150ft. Lbs. Torque Wrench
3. J-6266-36 Pinion Setting Gauge Plate-Heavy Duty Axle- 19. J-21468Drive Pinion O i l Seal Installer-Light Duty
(Used with J-6266-31). Axle (Used with J-9458).
4. J-6266-31 Pinion Setting Gauge Sleeves 20. J-21057 Drive Pinion O i l Seal Installer-Heavy Duty
5. J-21752 Positraction Spring Compressor Axle
6. J-9537 Differential Bearing Installer-Light Duty Axle- 21. J-8359 Differential Bearing Installer-Heavy Duty
(Used with J-7079-2). Axle (Used with J-8092).
7. J-9458 Companion Flange Installer 22. J-5810 Torque Wrench Adapter (3/4" male to 3/8" female)
8. J-5590 Pinion Rear Bearing Cone and Roller Assembly 23. J-5853 0-50 In. Lbs. Torque Wrench
. Installer-Light Duty Axle 24 J-0270-14 Pinion Rear Bearing Cup Installer
9. J-7079-2 Driven Handle (Insert Type) (Used with J-8092).
10. J-8092 Driver Handle (Threaded Type) 25. J-7137 Pinion Front Bearing Cup Installer-Heavy Duty
11. J-7112 Differential Bearing Remover- Axle (Used with J-8092).
(Used with J-8107-4 Adapter) ' 26. J-7817 Pinion Front Bearing Cup Installer-Light Duty
12. J-9772 Drive Pinion Rear Bearing Installer-Heavy Axle (Used with J-8092).
Duty Axle 27. J-8107-4 Differential Bearing Remover/Installer Adapter
13. J-7028 Pinion Rear Bearing Cone and Roller Assembly (Used with J-9537 and J-7112).
Remover-Light Duty Axle-(Used with J-0358-1) 28. J-8614 Companion Flange Holder and Remover
14. J-9771 Pinion Rear Bearing Cone and Roller Assembly
Remover-Heavy Duty Axle-(Used with J-0358-1)

CHEVROLET CHASSIS OVERHAUL MANUAL


SECTION 5
POWER BRAKE CYLINDERS
CONTENTS OF THIS SECTION
Page
Bendix Power Brake Cylinder 5-1
Moraine Power Brake Cylinder 5-5
Special Tools 5-10

BENDIX POWER BRAKE CYLINDER


INDEX
Page
Disassembly 5-1
Cleaning 5-2
Inspection 5-2
Assembly 5-3

- NOTE -

The following service procedures applies to the Chevrolet passenger car; Chevelle is the same as Chevrolet
passenger car except for an added mounting bracket; Chevy II is the same as Chevrolet except for an unadjustable
air valve push rod. A complete new valve assembly should always be used on Chevy II Power brake cylinders
whenever removed from the power piston.

DISASSEMBLY and main cylinder push rod from front shell (fig. 1)--
pulling the push rod from front shell will also r e -
The following procedure applies to the power brake unit move the filter and seal assembly.
only—for removal and installation procedures for power 3. Position and secure Tool J-9576-1 (fig. 2) to main
brakes refer to the "Service Manual". Main hydraulic cylinder mounting studs, and place tool and power
cylinders are also covered in the applicable portion of unit in a vise. Be sure to align tool so that check
Standard Brakes in the same "Service Manual". valve in front shell is not damaged.
1. Remove the hydraulic main cylinder from the power 4. Disconnect at air valve push rod.
unit, and place main cylinder aside. 5. Remove rubber boot and retainer plate from rear
2. Remove main cylinder filter, piston seal assembly shell.

Fig. 1—Bendix Power Cylinder Components (Typical)

1. Rubber Boot 6. Air Cleaner Filter 1.0. Diaphragm Plate 14. Front Shell
2. Retainer Plate 7. Air Valve Push Rod 11. Reaction Disc 15. Grommet
3. Bearing Seal Assembly 12. Hydraulic Push Rod 16. Check Valve
4. Rear Shell 8. Rolling Diaphragm 13. Power Piston Return 17. Push Rod Seal
5. Filter Retainer 9. Air Valve Lock Spring 18. Main Cylinder Filter

CHEVROLET CHASSIS OVERHAUL MANUAL


POWER BRAKE CYLINDERS 5-2

are loosened. If shells do not begin to separate, tap


rear shell with a soft faced hammer. After shells
begin to separate, remove nuts from through bolts.
CAUTION: Hold rear shell firmly when remov-
ing nuts from through bolts. Pressure exerted
by internal diaphragm spring may cause rear
shell to fly off when shells are in the released
position.
11. Remove power p i s t o n from front shell, separate
power piston from rear shell, and remove Tool
J-9504 from unit.
12. Disassemble power piston (See Figure 3).
a. Remove rolling diaphragm from the groove in the
diaphragm plate hub.
b. Hold the diaphragm plate so that the push rod is
in its normal (horizontal) installed position, de-
press the push rod slightly (approximately 1/16
inch), and rotate piston so the air valve lock will
fall from its location in the piston hub.
c. Remove the air valve push rod assembly from the
piston.
Fig. 2-Separating Shells with Tools J-9504 and J-9576-1 d. Remove the reaction disc from its location in the
diaphragm plate bore. (Insert the main cylinder
6. Remove filter retainer from end of diaphragm plate push rod or other suitable tool through diaphragm
extension, and remove air filter element from loca- plate extension and push disc from its seat.) Ex-
tion within the diaphragm plate extension. ercise care so as not to chip surface of passages
NOTE: To prevent chipping of the plastic dia- in the diaphragm plate.
phragm plate, exercise extreme caution when NOTE: Perform Step 13 only if seal is defec-
removing the air filter retainer. Use a small tive and a new seal is available. Do not reuse
screw driver or other suitable tool, and pry at seal once it has been removed from the unit.
several peripheral locations until the retainer
is freed. 13. Support outer surface of rear shell on blocks of wood
or other suitable material and drive out seal with a
7. Scribe alignment mark across surface of front and punch or a thin blade screw driver. Discard seal.
rear shells.
14. Remove check valve from grommet; then remove
8. Position bar wrench (Tool J-9504) over studs of the grommet from front shell.
rear shell so that holes in bar wrench line up with
holes in holding f i x t u r e (Tool J-9576-1). Install 15. Remove front shell and holding fixture from vise;
through bolts in aforementioned holes, and tighten then remove holding fixture from front shell.
nuts until a slight compression is obtained. Cleaning
9. Rotate Tool J-9504 until cutouts of rear shell are Use an approved nontoxic cleaning solvent to clean all
aligned with lances in front shell. metal parts. Use alcohol or an approved commercial
10. Loosen, but do not remove, the nuts on the through cleaning solvent for cleaning rubber and plastic parts.
bolts. The shells should begin to separate as the nuts Immerse parts in cleaning solvent and use a hair brush
to remove foreign matter. Blow out all passages, orifices
and valve holes. Air dry and place cleaned parts on clean
paper or lint-free cloth. If slight rust is found on inside
surface of p o w e r cylinder housing, polish clean with
crocus cloth or fine emery cloth, then follow with a
thorough cleaning.

The use of gasoline, kerosene, antifreeze alcohol or


any other cleaner with even a trace of mineral oil will
damage rubber parts. Be particularly careful during r e -
assembly that no grease or mineral oil comes in contact
with these rubber parts.

Inspection
Carefully inspect each part for damage and wear in-
Fig. 3—Power Piston spect rubber parts for cuts, nicks and distortion. These
5. Air Valve Lock
rubber parts are the key to control of air flow and should
1. Filter Retainer
2. Air Cleaner Filter 6. Diaphragm Plate account for the majority of trouble traceable to leakage.
3. Rolling Diaphragm 7. Reaction Disc If there is any question whatever as to serviceability of
4. Air Valve Push Rod Assembly any part, replace it.

CHEVROLET CHASSIS OVERHAUL MANUAL


POWER BRAKE CYLINDERS 5-3

ASSEMBLY
The following procedure refers to the power section of
the power brake unit only—for assembly procedure of the
main cylinder, refer to applicable portion of "Standard
Brakes".
During assembly, make sure all parts are free of
foreign material before applying lubricant. If there is any
doubt of cleanliness, rewash and air dry. When applying
lubricant as specified in assembly procedure, use an ap-
proved lubricant of known quality and composition that
will not be harmful to rubber and plastic materials.
1. Install check valve grommet in front shell—beveled
edge of grommet is to be inside shell. Dip check Fig. 5—Adjustment of Push Rod
valve in clean alcohol and install in grommet—check
valve stem is to be outside shell. Chevy II: Replace complete valve assembly.
2. Position and secure Tool J-9576-1 (fig. 2) to main b. Depress the push rod slightly, and install the air
cylinder mounting studs, and place tool and front valve lock. Make sure the lock indexes and r e -
shell in a vise. Be sure to align tool so that check tains the air valve.
valve is not damaged. c. Install the rolling diaphragm in the groove of dia-
phragm plate hub.
NOTE: If either or both of the shells are r e - d. Apply lubricant to surface of reaction disc and
placed, make sure alignment marks are trans- position disc in center bore of diaphragm plate.
ferred to new shell. Use main cylinder push rod to seat disc in bore.
3. Place rear shell on block, to back up plate around Make sure disc is fully seated before removing
center hole, and position bearing seal in center hole. push rod.
Use Tool J-9540 (fig. 4) to seat seal in recess of NOTE: If reaction disc is not f u l l y seated,
rear shell. Tool bottoms against shell when seal is it will result in an erroneous push rod height
in place. adjustment.
4. Assemble the power piston assembly. (See Figure 3).
a. Apply lubricant to outside diameter of diaphragm 5. Apply lubricant to I.D. of bearing seal and diaphragm
plate and extension, to bearing surfaces of valve bead contact surface of rear shell. Install power pis-
and plunger, and to outer edge of valve poppet. ton assembly in rear shell.
Insert valve and rod assembly in extension of dia- 6. Position bar wrench (Tool J-9504) over studs of rear
phragm plate. shell so that holes in bar wrench will line up with
holes in holding fixture (Tool J-9576-1).
Place power piston return spring in front shell and
position rear shell assembly on front shell. Position
shell so that when shells are locked scribe marks on
front and rear shells will be in alignment.
Depress rear shell assembly and install through
bolts to the fixture. Tighten through bolts sufficiently
to bring scallops on rear shell slightly below lances
on front shell. Rotate Tool J-9504 until scribe marks
on front and rear shells are in alignment. Remove
Tool J-9504 from unit.
9. Install air cleaner element and retainer to piston
extension.

2"/i6 - - N O . 15 OR 16
U.S.S. GAUGE
SHEET STEEL
1.200
1.195

— 1%2 • — VA —

Fig. 4—Installing Piston Bearing Seal Fig. 6—Push Rod Gauge

CHEVROLET CHASSIS OVERHAUL MANUAL


POWER BRAKE CYLINDERS 5-4

10. Install boot retainer and boot over piston extension 15. Place ToolJ-7723-01 over the push rod so that it fits
and secure boot to air cleaner retainer. between studs on front shell (fig. 5). Gauge should be
11. Align and install mounting bracket to rear shell. parallel to studs and resting on surface of front
Connect linkage to air valve push rod. shell. Cutout portion of gauge should just match
12. Remove unit from holding fixture (Tool J-9576-1). height of push rod. Any variation may be compen-
13. Apply lubricant sparingly to the hydraulic push rod, sated for by turning adjusting screw.
keeping lubricant away from adjusting screw end of NOTE: If push rod height adjustment gauge is
rod. Guide push rod into center bore of power piston not available, the required dimensions for fab-
until it is fully seated against reaction disc. rication are given in Figure 6.
14. Install seal and main cylinder filter and press filter 16. After push rod adjustment is correct, assemble main
and seal into front shell until seal is bottomed in r e - cylinder to front shell and securely tighten retaining
cess of shell. nuts.

CHEVROLET CHASSIS OVERHAUL MANUAL


POWER BRAKE CYLINDERS 5-5

MORAINE POWER BRAKE CYLINDER


INDEX
Page Page

Disassembly 5-6 Inspection 5-8


5-9
Cleaning 5-8 Assembly

- NOTE -
The following service procedures applies to the Chevrolet passenger car; Chevelle is the same as Chevrolet
passenger car except for an added mounting bracket; Chevy II is the same as Chevrolet except for an unadjustable
air valve push rod and two air valve springs instead of one. A complete new valve assembly should always be used
on Chevy II Power brake cylinders whenever removed from the power piston.

Fig. 7—Moraine Vacuum Power Cylinder (Typical)

1. Front Shell 7. Lock Ring 14. Reaction Bumper 22. Li miter Washer
2. Power Piston Return 8. Diaphragm 15. Snap Ring 23. Floating Control Valve
Spring 9. Support Plate 16. " O " Ring Assembly
3. Reaction Retainer 10. Rear Shell 17. Air Valve 24. Floating Control Valve
4. Master Cylinder 11. Power Piston 18. Air Filters Retainer
Piston Rod 12. Reaction Levers 19. Boot 25. Air Valve Spring
5. " O " Ring 13. Air Valve Spring 20. Push Rod Retainer
6. Reaction Plate (Two for Chevy II only) 21. Silencer

CHEVROLET CHASSIS OVERHAUL MANUAL


POWER BRAKE CYLINDERS 5-6

Fig. 8—Moraine Power Unit

1. Retainer 5. Rear Housing 8. Front Housing 11. Vacuum Check


2. Boot 6. Power Piston Assembly 9. Check Valve Valve
3. Silencer 7. Power Piston Return Grommet 12. Main Cylinder
4. Seal Spring 10. Front Housing Seal Assembly

DISASSEMBLY
The following procedure applies to the power section of 3. Lift the power piston assembly and rear housing
the power brake unit only (fig. 7) - for service of the main from the unit.
cylinder refer to applicable portion of "Standard Brakes" 4. Remove the boot retainer and boot from the rear
in the "Service" manual. housing.
1. Place the unit in a vise and firmly clasp the vise on 5. Remove the silencer from inside the boot (fig. 8).
the main cylinder reservoir. 6. Remove the power piston return spring from the
front housing.
NOTE: Scribe alignment marks on top center of 7. Reposition the main cylinder assembly in the vise
front and rear shell to facilitate reassembly. and remove the main cylinder from the power brake
unit and place main cylinder aside.
2. With metal bar in position, press down on bar and 8. Remove the front housing seal from the center of the
rotate rear shell counter-clockwise until rear shell front housing.
is separated from front shell. 9. Remove the check valve and grommet from the front
housing.
CAUTION: Care must be exercised not to dam-
age or loosen studs in shell. Also, take care that CAUTION: Extreme c a r e must be taken in
no pressure is brought to bear on plastic power handling the diaphragm of the power piston as-
piston extension. sembly (fig. 9). The d i a p h r a g m should be

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2 1 2 2 23

AIR VALVE AND


FLOATING CONTROL
CHEVY I ONLY VALVE

Fig. 9—Power Piston and Components

1. Lock Ring 8. Reaction Bumper 15. Air Valve 19. Floating Control Valve
2. Master Cylinder Piston 9. Air Valve Spring 16. Floating Control Valve Cup
Rod Retainer Rubber 20. Floating Control Valve
3. " O " Rings 10. Snap Ring 17. Floating Control Valve Retainer
4. Reaction Retainer 11. Power Piston Spring Retainer 21. Limiter Washer
5. Reaction Plate 12. Support Plate 18. Floating Control Valve 22. Air Filters
6. Reaction Levers 13. Diaphragm Spring 23. Silencer
7. Air Valve Spring 14. " O " Ring

CHEVROLET CHASSIS OVERHAUL MANUAL


POWER BRAKE CYLINDERS 5-7

guarded against grease, oil, foreign matter and


must be protected from nicks, scratches and
gouges.
10. Remove the lock ring from the power piston by pry-
ing one of the ends out from under the large divided
locking lug, and then pull it from under the remaining
two small lugs.
11. Remove the reaction retainer, piston rod, reaction
plate, three reaction levers, air valve spring, (Chevy CAUTION:
II has two air valve springs) small reaction bumper, DO NOT CLAMP TIGHT
and air valve spring retainer. ON POWER PISTON.

12. Place square shank of Tool J-21524 in a vise and po-


sition the assembly down on the tool so that the three
lugs on the tool fir into the three notches in the power
piston.
13. Pull the diaphragm edges away from the support plate
and grip the steel support plate by hand, press down
and rotate counter-clockwise to separate the plate
from the power piston (fig. 10).
14. Remove the diaphragm from the support plate and lay
both parts aside.
15. Remove the silencer from the neck of the power pis-
ton tube.
16. Position the power piston in a vise padded with shop-
towels, with the tube down (fig. 11).
17. Using Pliers J-4880 remove the snap ring from the Fig. 11— Removing Air Valve Snap Ring
air valve.
18. Place the power piston with tube down in an arbor
press. Using a rod not exceeding 1/2" in diameter Chevy II
press the air valve assembly from the power piston
(fig, 12). NOTE: A new valve assembly should always be
used whenever it is removed from the power
piston.
Chevrolet and Chevelle 19. Push the main cylinder piston rod from the reaction
NOTE: A new floating c o n t r o l valve should retainer and remove the two " O " rings from the rod.
always be used whenever it is removed from the
power piston.

Fig. 10—Separating Power Piston from Support Plate Fig. 12—Removing Air Valve Assembly from Power Piston

CHEVROLET CHASSIS OVERHAUL MANUAL


POWER BRAKE CYLINDERS 5-8

Cleaning majority of troubles traceable to leakage. If there is any


Use Declene or clean brake fluid to clean all metal, question whatever as to serviceability of any part, r e -
plastic and rubber parts of the power cylinder. Immerse place it.
parts in cleaning fluid and use a hair brush to remove
foreign matter. Blow out all passages, orifices and valve ASSEMBLY (Figs. 7, 8 and 9)
holes. Air dry and place cleaned parts on clean paper or
lint-free cloth. If slight rust is found on inside surface of Be sure that all parts are clean. If there is any doubt
power cylinder housing, polish clean with crocus cloth or of cleanliness, rewash and air dry. Lubricate rubber
fine emery cloth, then follow with a thorough cleaning. parts with an approved rubber lubricant. Lubricate all
Dirt is the major cause of trouble and wear in service. plastic and metal friction p o i n t s with an approved
Be certain to keep parts c o m p l e t e l y clean until lubricant.
reassembly. 1. Replace the vacuum check valve, using a new grom-
met, if old one is cracked or damaged.
If there is any. suspicion of contamination or evidence 2. Place new front housing seal in the center of the
of corrosion, completely flush hydraulic brake system as front housing so that the flat surface of the cup lies
described in this section. Failure to clean hydraulic sys- against the bottom of depression in the housing.
tem can result in early repetition of trouble.
Use of gasoline, kerosene, anti-freeze alcohol or any 3. Assemble the master cylinder onto the front housing
other cleaner with even a trace of mineral oil will dam- with the scribe mark on the top of the housing lining
age rubber parts. Be p a r t i c u l a r l y careful during up with the center of the master cylinder cover. In-
reassembly that no grease or mineral oil comes in con- stall lock washers and nuts and tighten finger tight
tact with these rubber parts. only.
4. Install a new "O" ring in the groove on the main cyl-
Inspection inder piston rod. Apply a thin film of lubricant to
Wipe cleaning fluid from all parts and carefully inspect " O " ring.
each part for damage and wear. Inspect rubber parts for 5. Insert main cylinder piston rod through the reaction
cuts, nicks and distortion. These rubber parts are the retainer with r o u n d end of rod at tube end of
key to control of air flow and should account for the retainer.
6. Place the square shank of Tool J-21524 in a vise and
position power p i s t o n on tool with the three lugs
fitting into the notches of the power piston.

SCRIBE LINE ON
TOOL J-21601

Fig. 13—Installing Air Valve and Retainer Fig. 14—Installing Power Piston to Support Plate

CHEVROLET CHASSIS OVERHAUL MANUAL


POWER BRAKE CYLINDERS 5-9

Fig. 17—Adjustment of Push Rod

Chevy II: A new valve should always be used when-


ever it is removed from the power piston.
11. Start the floating control valve and retainer into the
power piston tube.
12. Seat retainer in the power piston tube by pressing it
in place with Tool J-21601. (Scribe line on tool
should line up with top edge to power piston tube,
Fig. 13.)
13. Install the push rod limiter washer over the push rod
and then the two air filter elements.
Fig. 15—Installing Reaction Retainer on to Power Piston 14. Install the power piston diaphragm on the support
plate (opposite side of locking tang).
7. Install a new "O" ring on the air valve in the second NOTE: Make sure the support plate is in the
groove from the push rod end. groove in the center flange of the diaphragm.
8. Coat the new floating control valve rubber and the air
valve " O " ring with a thin film of lubricant. 15. Holding the s u p p o r t plate on the bare metal, with
9. Press the air valve assembly (air valve first) to its locking tangs down, place the support plate assembly
seat in the power piston tube. over the tube of the power piston.
10. Install a new floating control valve retainer over the NOTE: The flange of the diaphragm will fit into
push rod, (flat side toward the floating control valve). the groove on the power piston.
16. Press down and rotate the support plate assembly
clockwise, until the lugs on the power piston come
against the stops on the support plate.
17. Place this assembly tube down in a padded vise, (Do
Not Clamp).
18. Install snap ring in groove of air valve with Pliers
J-4880 (fig. 11).
19. Install the air valve spring retainer to seat on the
snap ring.
20. Install the reaction bumper into the groove in the end
of the air valve.
21. Position the air valve return spring, (large end down)
on the spring retainer. (Chevy II has two air valve
springs—position larger spring over the smaller.)
22. Install the 3 reaction levers into the slots of the
power piston with the small end resting on the air
valve return spring.
23. Install main cylinder piston rod through the reaction
retainer with round end out tube side.
24. Center reaction plate on the reaction levers (num-
bered side up), and place reaction retainer down on
power piston. (Make sure small end of push rod en-
gages in center hole of reaction plate), (fig. 15).
25. Push reaction retainer down and line up the lugs with
the notches in the power piston.
26. Secure with lock ring making sure ends of lock ring
are set in place on the large divided lug of the power
Fig. 16—Installing Retainer Lock Ring piston, (one end on each side of lug), (fig. 16).

CHEVROLET CHASSIS OVERHAUL MANUAL


POWER BRAKE CYLINDERS 5-10

27. Install a new power piston bearing in the center of NOTE: If unit is not easily locked, hold shells
the rear housing (large flange of bearing on stud side together and apply vacuum to check valve in
of housing). Lubricate the inside of the bearing. front shell. Do not put pressure on power piston
NOTE; Make sure flange on rear housing is extension.
engaged in groove of power piston bearing. 34. Install felt silencer over push rod to seat against end
28. Install air silencer over the holes on the power of power piston tube, secure with snap ring retainer,
piston tube and lubricate tube. and place plastic boot with large holes in center of
29. Install power piston tube through rear housing, (from brackets. Install locknut and clevis on push rod.
side opposite of studs). 35. Remove unit from vise and remove master cylinder
30. Clamp front housing in a vise with main cylinder from power cylinder assembly.
down and place power piston return spring over the 36. Place power unit in a vise so that master cylinder
inset in the front housing. push rod is up.
31. Lubricate the I.D. ol the support plate seal and the
reaction retainer tube. Talcum powder the beaded 37. Place Tool J-7723-01 over the push rod so that it fits
edge of the diaphragm. between the studs on front housing. Gauge should be
32. Place the rear housing a s s e m b l y over the front parallel to studs resting on surface of housing. The
housing assembly (with m a i n cylinder push rod cutout portion of the gauge should never be lower
down), and align the s c r i b e d marks of the two than the end of the piston rod, and the gap should
housings so they will match when in locked position. never be more than .010 inch (fig. 17).
33. Position adjustable wrenches on rear shell brackets; 38. Any variation beyond these two limits would require
press down and check to be sure that bead on edge of replacement of the piston rod with the service ad-
rolling diaphragm is positioned correctly between the justable piston rod, and adjusting the screw in the
shells. If this is satisfactory, apply,additional down- end of the rod to match the height of the gauge.
ward pressure and rotate rear shell clockwise into 39. Position main cylinder to power cylinder. Install lock
locked position. washers and nuts and torque to 15-20 foot pounds.

POWER BRAKES

SPECIAL TOOLS

Fig. 18—Power Brake Special Tools

1. J-9540 Vacuum Power Cylinder Seal Installer 4. J-7723-01 Push Rod Height Gauge 6. J-4880 Truarc Pliers (External Type)
2. J-21524 Powe* Pfcton Remover and Installer 5. J-9576-1 Vacuum Power Cylinder 7. J-21601 Power Brake Retainer
3. J-9504 Vacuum Power Cylinder Spanner Wrench Holder and Compressor Installer

CHEVROLET CHASSIS OVERHAUL AAANUAL


SECTION 6
ENGINE MECHANICAL
CONTENTS OF THIS SECTION
Page
In-Line Engines 6-1
V-8 Engines (283 and 327 cu. in.) 6-27
V-8 Engines (409 cu. in.) 6-48
Special Tools 6-70

IN-LINE ENGINES
(L-4 153 CU. IN. AND L-6 194 AND 230 CU. IN.)
INDEX
Page Page
General Description 6-1 Replacement 6-15
Repair Procedures 6-3 With Crankshaft Removal 6-15
Engine Assemblies 6-3 Without Crankshaft Removal 6-16
Disassembly. 6-3 Connecting Rod Bearings 6-16
Cleaning and Inspection 6-3 Inspection and Replacement 6-16
Assembly 6-3 Connecting Rod and Piston Assemblies 6-17
6 4
Cylinder Head Assemblies ~ Removal : 6-17
6 4
Disassembly . . " Disassembly 6-17
6 4
Cleaning " Cleaning and Inspection 6-18
6 4
Inspection ~ Connecting Rods 6-18
6 5
Repairs " Pistons 6-18
6 5
Valve Guide " Piston Pins 6-18
6 5
Rocker Arm Studs ~ Assembly 6-18
6 5
Valve Seats " Piston Rings 6-18
6 6
Valves " Installation 6-20
6 7
Assembly " Crankshaft 6-20
6 7
Valve Stem Oil Seal " Removal 6-20
6 8
Replacement ~ Cleaning and Inspection 6-20
6 8
Valve Lifters (Hydraulic) " Installation 6-21
6 8 6 21
Disassembly ~ Flywheel "
6 9
Cleaning and Inspection ~ Removal ,. . . . 6-21
Assembly ^-9 Installation 6-21
6 10 6 21
Oil Pump " Camshaft and Timing Gear ~
6 10
Disassembly ~ Measuring Lobe Lift at Push Rod 6-21
Cleaning and Inspection 6-10 Inspection 6-22
Assembly 6-11 Oil Nozzle Replacement 6-22
Q 11 6 22
Oil Filter By-Pass Valve ~ Disassembly ~
Inspection and Replacement 6-11 Assembly 6-23
Distributor Lower Bearing 6-11 Camshaft Bearings .' 6-23
Replacement 6-11 Inspection 6-23
Oil Seal—Crankcase Front Cover 6-13 Removal 6-23
Replacement . 6-13 Installation 6-24
With Cover Removal 6-13 Cylinder Block 6-24
Without Cover Removal 6-13 Inspection 6-24
Oil Seal—Rear Main Bearing 6-13 Repairs . 6-25
Replacement 6-13 Cylinder Conditioning 6-25
Main Bearings 6-14 Cylinder Boring 6-25
Inspection 6-14 Cylinder Honing and Piston Selection 6-25
Checking Clearances 6-14

GENERAL DESCRIPTION
The In-Line, overhead valve engines covered in this The L-4 crankshaft has five main bearings, the L-6
section are the 153 cu. in. L-4 and the 194 and 230 crankshafts have seven. The L-4 camshaft has three
cu. in. L-6 engines used in the Chevrolet, Chevelle bearings, the L-6 camshafts have four.
and Chevy II passenger car vehicles.
The cylinders are numbered front to rear. Firing Full pressure lubrication, through a full flow oil filter,
order is 1-3-4-2 for the L-4 engine and 1-5-3-6-2-4 for is furnished by a gear-type oil pump. The distributor,
the L-6 engines. Crankshaft rotation as viewed from the driven by a helical gear on the camshaft, drives the
rear is counter-clockwise. oil pump. The main oil gallery feeds oil, through drilled

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-2

OIL PRESSURE
SENDING UNIT

DISTRIBUTOR SHAFT
OILING . -|

TIMING GEAR
OIL NOZZLE

FILTER BY-PASS
SYSTEM

Fig. 1L—Engine Lubrication

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-3

passages, to the camshaft and crankshaft to lubricate the lifters which, through hollow push rods, feed the in-
bearings. The main oil gallery also feeds the valve dividually mounted rocker arms (fig. 1L).

REPAIR PROCEDURES
ENGINE ASSEMBLIES cover) until the diaphragm spring pressure is re-
leased. Remove cover assembly and disc.
Disassembly 22. Remove the flywheel.
1. With engine removed from the vehicle and trans- 23. Remove main bearing caps and lift crankshaft out of
mission and/or clutch housing removed from the cylinder block. Remove the main bearings from the
< engine, mount engine in overhaul stand and clamp cylinder block and main bearing caps.
securely. 24. All further disassembly is covered under the part
2. Remove engine ground strap and oil dip stick. or sub-assembly being serviced.
3. Remove Delcotron and mounting bracket as an
assembly. Cleaning and Inspection.
4. On engines so equipped, remove power steering 1. Wash cylinder block thoroughly in cleaning solvent
pump. and clean all gasket surfaces.
5. Disconnect fuel pump-to-carburetor line and re- 2. Remove oil gallery plugs and clean all oil passages.
move fuel pump and discard gasket.
6. Disconnect choke rod, fuel lines, spark advance NOTE: These plugs may be removed with a
line, and crankcase vent line: then remove car- sharp punch or they may be drilled and pried
buretor and discard gaskets. out.
7. Remove distributor cap and spark plug wire as- 3. Clean and inspect water passages in the cylinder
sembly, then remove distributor and coil. block.
8. Remove water pump, water outlet, thermostat and 4. Inspect the cylinder block for cracks in the cylinder
thermostat housing and discard gaskets. walls, water jacket, valve lifter bores and main
9. Remove intake and exhaust manifolds and discard bearing webs.
gaskets. 5. All further cleaning and inspection is outlined under
10. Remove push rod covers and discard gaskets. the part or sub-assembly being serviced.
11. Remove rocker arm nuts, rocker arm balls, rocker
arms and push rods, then remove valve lifters. Assembly
NOTE: Valve lifters rocker arms, rocker arm NOTE: Use new gaskets and seals on engine
balls and push rods should be placed in a rack assembly.
in their proper sequence so they can be in-
stalled in their same positions during build-up. 1. Apply sealer to new oil gallery plugs and install
plugs.
12. Remove cylinder head and discard gaskets.
13. Remove starter, clutch housing cover plate and oil 2. Install the crankshaft and flywheel as outlined in
filter. this section.
14. Remove oil pan and discard gaskets and seals.
15. Remove crankshaft pulley and hub or harmonic 3. Install the connecting rod and piston assemblies as
balancer using Tool J-6978. outlined in this section.
16. Remove crankcase front end cover and discard 4. Install the following as outlined in the Service
gasket. Manual.
17. Remove two camshaft thrust plate screws through
holes in the camshaft gear and remove camshaft a. Camshaft, timing gear and crankcase front end
gear and camshaft through the front of the block. cover.
CAUTION: All camshaft journals are the same b. Oil pump, and oil pan.
diameter and caution must be used in removing c. Starting motor and oil filter.
camshaft to avoid damage to bearings. d. Fuel pump.
e. Harmonic balancer or crankshaft hub and pulley.
18. Remove oil pump. f. Water pump, thermostat housing, thermostat, and
19. Check the connecting rods and caps for cylinder water outlet.
number identification and if necessary, mark them. g. Cylinder head, valve lifters, push rods and rocker
20. Remove connecting rod journal bearing caps and arms.
install Tool J-6305 on studs. Push piston assemblies h. Intake and exhaust manifolds and push rod
out of top of cylinder block. If piston rings strike covers,
ridge at top of cylinder, remove ridge to prevent i. Carburetor, crankcase vent line, spark advance
damaging piston ring lands. line, fuel line and choke rod.
NOTE: It will be necessary to turn the crank- j . Distributor, coil, distributor cap and spark plug
shaft slightly to disconnect some of the rods wire assembly.
and to push them out of the cylinder. k. On engines so equipped, power steering pump.
1. Delcotron and mounting bracket as an assembly,
21. On engines so equipped, loosen clutch to flywheel m. Oil dip stick and ground strap,
bolts a turn at a time (to prevent distortion of clutch n. Clutch assembly.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-4

CYLINDER HEAD ASSEMBLIES


Disassembly
1. With cylinder head removed, remove valve rocker
arm nuts, balls and rocker arms.
2. Using Tool J-8062, compress the valve springs and
remove valve keys (fig. 2L). Release the spring
compressor tool and remove spring caps, shields,
oil seals, springs and spring dampers.
3. Remove valves from bottom of cylinder head and
place them in a rack in their proper sequence so
they can be assembled in their original positions.
4. Remove water outlet, thermostat and thermostat
housing.
Cleaning
1. Clean all carbon from combustion chambers and
valve ports using Tool J-8089 (fig. 3L).
2. Thoroughly clean the valve guide bores using Tool
J-8101 (fig. 4L).
3. Clean all carbon and sludge from push rods and Fig. 3L—Removing Carbon From Combustion Chambers
rocker arms.
4. Clean valve stems and heads on a buffing wheel.
5. Clean carbon deposits and sealer from head gasket Valve stem to bore clearance may be checked
mating surfaces. by using a micrometer and a suitable telescope
hole gauge. Using a micrometer measure the
Inspection diameter of the valve stem in three places, top,
1. Inspect the cylinder head for cracks in the exhaust center and bottom. Insert telescope hole gauge
ports, combustion chambers, or external cracks to in valve guide bore, measuring at the top center
the water chamber. and bottom. Determine the minimum and maxi-
2. Inspect the valves for burned heads, cracked faces mum clearances. If clearance is not within
or damaged stems. limits (see specifications) use next oversize
3. Check fit of valve stems in their respective bores. valve and ream valve guide bore.
NOTE: Excessive valve stem to bore clearance
will cause excessive oil consumption. Insuffi-
cient clearance will result in noisy and sticky 4. Check valve spring tension with Tool J-8056 spring
functioning of the valve and disturb engine tester (fig. 5L).
smoothness.
NOTE: Springs should be compressed to the
specified height and checked against the specifi-
cations chart. Springs should be replaced if
not within 10 lbs. of the specified load without
dampers.

Fig. 2L—Compressing Valve Springs Fig. 4L—-Cleaning Valve Guide Bores

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-5

Fig. 5L—Checking Valve Spring Tension

Fig. 7L—Removing Rocker Arm Stud

Repairs
Valve Guide Bores
Valves with oversize stems are available (see specifi-
cations). To ream the valve guide bores for oversize
valves use Tool set J-5830 (fig. 6L).

Rocker Arm Studs


Rocker arm studs that have damaged threads or are
loose in cylinder heads should be replaced with new
studs available in .003" and .013" oversize. Studs may be
installed after reaming the holes as follows:
1. Remove old stud by placing Tool J-5802-1 over the
stud, installing nut and flat washer and removing stud
by turning nut (fig. 7L).
2. Ream hole for oversize stud using Tool J-5715 for
.003" oversize and Tool J-6036 for .013" oversize
(fig. 8L).
CAUTION: Do not attempt to install an over-
size stud without reaming stud hole.
3. Coat press-fit area of stud with hypoid axle lubri-
cant. Install new stud, using Tool J-6880 as a guide.
Gauge should bottom on head (fig. 9L).

Valve Seats
Reconditioning the valve seats is very important,
because the seating of the valves must be perfect for
the engine to deliver the power and performance built
into it.
Another important factor is the cooling of the valve
Fig. 6L—Reaming Valve Guide Bores heads. Good contact between each valve and its seat

CHEVROLET CHASSIS OVERHAUL MANUAI


ENGINE MECHANICAL 6-6

1. Install expanding pilot in the valve guide bore and


expand pilot by tightening nut on top of pilot.
2. Place roughing stone or forming stone over pilot
and just clean up the valve seat. Use a stone cut
to 46°.
3. Remove roughing stone or forming stone from pilot,
place finishing stone, cut to 46°, over pilot and cut
just enough metal from the seat to provide a smooth
finish.
4. Narrow down the valve seats to the specified width
(see specifications).
NOTE: This operation is done by grinding the
port side with a 30° stone to lower seat and a
60° stone to raise seat.
5. Remove expanding pilot and clean cylinder head
carefully to remove all chips and grindings from
above operations.
6. Measure valve concentricity (fig. 10L).
NOTE: Valve seats should be concentric to
within .002" total indicator reading.
Valves
Valves that are pitted can be refaced to the proper
angle, insuring correct relation between the head and
stem on a valve refacing machine. Valve stems which
show excessive wear, or valves that are warped exces-
sively should be replaced. When a valve head which is
warped excessively is refaced, a knife edge will be
ground on part or all of the valve head due to the amount
Fig. 8L—Reaming Rocker Arm Stud Hole
of metal that must be removed to completely reface.
Knife edges lead to breakage, burning or pre-ignition due
in the head is imperative to insure that the heat in the to heat localizing on this knife edge. If the edge of the
valve head will be properly carried away. valve head is less than 1/32" thick after grinding, r e -
Several different types of equipment are available for place the valve.
reseating valve seats. The recommendations of the man- Several different types of equipment are available for
ufacturer of the equipment being used should be carefully refacing valves. The recommendations of the manu-
followed to attain proper results. facturer of the equipment being used should be carefully
Regardless of what type of equipment is used, however, followed to attain proper results.
it is essential that valve guide bores be free from carbon 1. If necessary, dress the valve refacing machine
or dirt to insure proper centering of pilot in the guide. grinding wheel to make sure it is smooth and true.

Fig. 9L—-Installing Rocker Arm Stud Fig. 10L—Measuring Valve Seat Concentricity

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-7

INTERFERENCE

Fig. 11L—Relation of Valve and Seat Angles

Set chuck at 45° mark for grinding valves (fig. 11L).


2. Clamp the valve stem in the chuck of the machine. Fig. 12L—Valve Spring Installation
3. Start the grinder and move the valve head out in
line with the grinder wheel by moving the lever to NOTE: Grease may be used to hold the locks
the left. in place while releasing the compressor tool.
4. Turn the feed screw until the valve head just con-
tacts wheel. Move valve back and forth across the 6. Install the remaining valves.
wheel and regulate the feed screw to provide light 7. Check each valve stem oil seal by placing a vacuum
valve contact. cup or similar device over the end of the valve stem
5. Continue grinding until the valve face is true and and against the cap. Operate the vacuum cup and
smooth all around the valve. If this makes the valve make sure no air leaks past the oil seal.
head thin the valve must be replaced as the valve A vacuum cup can be made from a small syringe and
will overheat and burn. a high voltage shield (fig. 13L).
6. Remove valve from chuck and place stem in "V" 8. Measure the installed height of the valve springs,
block. Feed valve squarely against grinding wheel using a narrow thin scale. Measure from the top
to grind any pit from rocker arm end of stem. of the shim Or the spring seat to the top of the valve
spring shield. If this is found to exceed the specified
NOTE: Only the extreme end of the valve height, install a valve spring seat shim approxi-
stem is hardened to resist wear. Do not grind mately 1/16" thick. At no time should the spring be
end of stem excessively. shimmed to give an installed height under the mini-
7. After cleaning valve face and cylinder head valve mum specified (fig. 14L).
seat of grinding particles, make pencil marks about 9. Install thermostat housing, thermostat and water
1/4" apart across the valve face, place the valve in outlet.
cylinder head and give the valve 1/2 turn in each
direction while exerting firm pressure on head of NOTE: If springs and/or seals are to be
valve. changed with the cylinder head installed, Tool
8. Remove valve and check face carefully. If all pencil J-5892 may be used to compress the springs.
marks have not been removed at the point of contact Compressed air, through the spark plug hole,
with the valve seat, it will be necessary to repeat may be used to hold the valves in place.
the refacing operation and again recheck for proper VALVE STEM OIL SEAL
seating.
9. Grind and check the remaining valves in the same Valve stem oil seals can be replaced with the cylinder
manner. head installed.

Assembly
1. Insert a valve in the proper port.
2. Set the valve spring, valve damper, valve shield
and valve cap in place (fig. 12L). The close coiled ft
end of the spring is installed against the cylinder
head.
3. Compress the spring with Tool J- 8062.
3siiiS L 1 ,*M
4. Install oil seal in the lower groove of the stem,
making sure the seal is flat and not twisted.
5. Install the valve locks and release the compressor
tool, making sure the locks seat properly in the
upper groove of the valve stem. Fig. 13L—Vacuum Cup

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-8

Fig. 14L— Measuring Valve Spring Installed Height

Replacement

1. Remove the valve cover and spark plug on cylinder


to be serviced.
2. Apply compressed air to the spark plug hole to hold Fig. 161.—Compressing Valve Spring
the valves in place.
5. To replace, set the valve spring and damper, valve
NOTE: A tool to apply air to the cylinder is shield and valve cap in place. The close coiled end
available through local jobbers or may be manu- of the spring is installed against the cylinder head.
factured. In manufacturing this Tool a AC-46N Compress the spring with Tool J-5892 and install oil
Spark Plug or its equivalent is recommended. seal in the lower groove of the stem, making sure
This will make the Tool u n i v e r s a l for all the seal is flat and not twisted.
Chevrolet engines. Chisel the spark plug as
shown, then drive the porcelain out of the plug NOTE: A light coat of oil on the seal will
by tapping the center electrode against a hard help prevent twisting.
block. Using a 3/8" pipe tap, cut threads in the 6f Install the valve locks and release the compressor
remaining portion of the spark plug and assem- tool, making sure the locks seat properly in the
ble as shown (fig. 15L). upper groove of the valve stem.
3. Using Tool J-5892 to compress the valve spring, NOTE: Grease may be used to hold the locks
remove the valve locks, valve cap, valve shield and in place while releasing the compressor tool.
valve spring and damper (fig. 16L).
7. Check valve stem oil seals as outlined under cylinder
4. Remove the valve stem oil seal. head assembly and replace valve cover and spark
plug.

VALVE LIFTERS (HYDRAULIC)


Two types of Hydraulic lifters are used. Both types
of lifters operate on the same principle and are serviced
basically in the same manner. The complete lifter
assemblies are interchangeable but parts from one lifter
are not interchangeable with another. Both lifters are
easily identified by the outside configuration of the lifter
body. For purposes of identification we refer to them
as lifter ''A" and lifter "B" (fig. 17L).

Disassembly
1. Hold the plunger down with a push rod, and using the
blade of a small screw driver, remove the push rod
seat retainer.
2. Remove the push rod seat and metering valve (lifter
"A") or the push rod seat and inertia valve assem-
Fig. 15L— Air Adapter Tool bly (lifter "B").

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-9

Fig. 18L—Removing Ball Check Valve

Assembly
1. Place the check ball on small hole in bottom of the
plunger.
2. Insert check ball spring on seat in ball retainer
and place retainer over ball so spring rests on the

Fig. 17L—Hydraulic Valve Lifters


1. Lifter Body 5. Check Ball Retainer
2. Push Rod Seat 6. Push Rod Seat Retainer
3. Metering Valve (Lifter A) 7. Plunger
Inertia Valve (Lifter B) 8. Check Ball Spring
4. Check Ball 9. Plunger Spring

3. Remove the plunger, ball check valve assembly and


the plunger spring.
4. Remove the ball check valve and spring by prying
the ball retainer loose from the plunger with the
blade of a small screw driver (fig. 18L).
Cleaning and Inspection
Thoroughly clean all parts in cleaning solvent, and
inspect them carefully. If any parts are damaged or
worn the entire lifter assembly should be replaced.
NOTE: Inertia valve and retainer (lifter "B")
should not be removed from the push rod seat.
To check the valve, shake the push rod seat and
inertia valve assembly and the valve should
move. Fig. 19L-lnstalling Ball Check Valve

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-10

ball. Carefully press the retainer into position in


plunger with blade of a small screw driver (fig.
19L).
3. Place the plunger spring over the ball retainer
and slide the lifter body over the spring and plunger,
being careful to line up the oil feed holes in the
lifter body and plunger.
4. Fill the assembly with SAE 10 oil, then insert the
end of a 1/8" drift pin into the plunger and press
down solid. At this point oil holes in the lifter body
and plunger assembly will be aligned (fig. 20L).
CAUTION: Do not attempt to force or pump
the plunger.
5. Insert a 1/16" drift pin through both oil holes to
hold the plunger down against the lifter spring
tension (fig. 20L).
NOTE: On lifter "B", the drift pin must not
extend inside the plunger.
6. Remove the 1/8" drift pin, refill assembly with SAE
10 oil.
7. Install the metering valve and push rod seat (lifter
"A") or the push rod seat and inertia valve as-
sembly (lifter "B").
8. Install the push rod seat retainer, press down on the
push rod seat and remove the 1/16" drift pin from
the oil holes. The lifter is now completely as-
sembled, filled with oil and ready for installation.
NOTE: Before installing any new lifters, coat
the bottom of the lifter with Molykote or its Fig. 21L—Oil Pump Exploded View
equivalent.
1. Pressure Regulator Valve 6. Cover Gasket
2. Spring 7. Idler Gear
OIL PUMP 3. Retaining Pin 8. Drive Gear and Shaft
4. Screws 9. Pump Body
The oil pump consists of two gears and a pressure 5. Pump Cover 10. Pick-up Screen and Pipe
regulator valve enclosed in a one-piece housing. The
oil pump is driven by the distributor shaft which is driven by a helical gear on the camshaft (fig. 21L).
A baffle is incorporated on the pick-up screen to
eliminate pressure loss due to sudden or surging stops.
Disassembly
1. With the oil pump removed, remove the pump cover
attaching screws, pump cover and pump cover
gasket.
NOTE: Mark gear teeth so they may be re-
assembled with the same teeth indexing.
2. Remove the idler gear and the drive gear and shaft
from the pump body.
3. If pressure regulator valve or related parts need
replacing remove the pressure regulator valve re-
taining pin, pressure regulator valve and related
parts from the pump body.
4. If the pick-up screen and pipe assembly need re-
placing, mount the pump body in a soft-jawed vise
and using Tool J-8369, extract pipe from pump body.
CAUTION: Do not disturb the pick-up screen
on the pipe. This is serviced as an assembly.
Cleaning and Inspection
1. Wash all parts in cleaning solvent and dry with
compressed air.
2. Inspect the pump body for cracks or excessive wear.
Fig. 20L—Assembling the Hydraulic Lifters 3. Inspect pump gears for damage or excessive wear.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-11

4. Check the drive gear shaft for looseness in the pump Some engines have a thrust washer at the upper end
body. of the bushing bore. The thrust washer, where used,
5. Inspect inside of pump cover for wear that would may be replaced at the same time the bushing is
permit oil to leak past the ends of the gears. replaced.
6. Inspect and clean the pick-up screen and pipe as- The lower bushing will ordinarily require only a
sembly for damage to screen, . pipe or relief clearance or wear check during engine overhaul. When
grommet. distributor shaft-to-bushing clearance exceeds .0035",
7. Check the pressure regulator valve for fit in the the bushing should be replaced as follows with oil pump
pump body. and distributor removed:
NOTE: The pump gears to body are a selective Replacement
fit. If the pump gears or body are damaged or 1. Install Tool J-9534 into bushing and using a slide
worn replacement of entire oil pump assembly hammer, remove the bushing (fig. 23L).
is necessary. 2. Using a drift up through bushing bore, drive thrust
washer (if installed) out of bore and remove from
Assembly
block (fig. 24L).
1. If the pick-up screen and pipe assembly was re-
3. Clean bushing bore in block and check' for burrs
moved, mount the pump body in a soft-jawed vise, or damage.
apply sealer to end of pipe, and using Tool J-8369
tap the pipe in place with a plastic hammer.
CAUTION: Be careful of twisting, shearing or
collapsing pipe while installing in pump body.
Pick-up screen must be parallel to bottom of
oil pan when oil pump is installed.
2. Install the pressure regulator valve and related parts
in the pump body. Valve should drop freely in pump
body.
3. Install the drive gear and shaft in the pump body.
4. Install the idler gear in the pump body with the
smooth side of gear towards pump cover opening
and with gears properly indexed.
5. Install the pump cover with a new gasket and torque
attaching screws to specifications.

OIL FILTER BY-PASS VALVE


Inspection and Replacement (Fig. 22L)
With the oil filter removed, check the spring and fibre
valve for operation. Inspect for a cracked or broken
valve. If replacement is necessary, remove valve by
prying it out with a screw driver. Install and seat a new
valve by taping it in place, using a 9/16 thin-wall deep
socket.

DISTRIBUTOR LOWER BEARING Fig. 23L—Removing Distributor Lower Bearing


The distributor lower bearing is a bronze bushing
pressed into the lower side of the engine block. Its 4. If thrust washer was removed, start new washer in
upper inside diameter pilots the distributor shaft and position in bore and drive into place using Tool
the outside diameter extending below the block pilots J-9535 (fig. 25L).
the oil pump. 5. Using Tool J-9535 with driver-bolt in driver handle,
install driver into new bushing from large inside
diameter.
6. Position bushing and driver to block and drive the
bushing in position (fig. 26L), which is determined
by tool bottoming against the block.
7. Remove tool from bushing. It is possible that the
bushing with minimum I.D. will collapse enough,
during installation, to slightly seize the installer
arbor. If this happens, remove installer tool using
slide hammer in driver bolt hole of driver handle.
NOTE: This will not damage the bushing and
tool is designed for this purpose, should it
Fig. 22L-OH Filter By-Pass Valve occur.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-12

Fig. 24L—Removing Distributor Shaft Thrust Washer Fig. 26L—Installing Distributor Lower Bearing

Fig. 25L-lnstalling Distributor Shaft Thrust Washer Fig. 27L—Installing Oil Seal (Cover Removed)

CHEVROLET CHASSIS OVERHAUL MANUAL


ENIGNE MECHANICAL 6-13

OIL SEAL-CRANKCASE FRONT COVER


Replacement
With Cover Removal
1. With cover removed, pry old seal out of cover from
the front with a large screw driver.
2i Install new seal so that open end of the seal is
toward the inside of cover and drive it into position
with Tool J-995 (fig. 27L).
CAUTION: Support cover at sealing area. (Tool
J-971 may be used as support.)

Without Cover Removal


1. With crankshaft pulley and hub or harmonic balancer
removed, pry old seal out of cover from the front
with a large screw driver, being careful not to
damage the seal surface on the crankshaft.
2. Install new seal so that open end of seal is toward
the inside of cover and drive it into position with
Tool J-8340 (fig. 28L).
Fig. 29L—Rear Main Bearing Oil Seal (Rear View)
OIL SEAL-REAR MAIN BEARING thumb, using light pressure so beads on seal O.D.
Replacement are not cut by seal groove at cap parting line. Be
The rear main bearing oil seal can be replaced (both sure tabs on seal are properly located in cross
halves) without removal of the crankshaft (fig. 29L). grooves.
NOTE: Always replace the upper and lower 4. To remove the upper half of the seal, use a small
seal as a unit. Install with the lip facing toward hammer to tap a brass pin punch on one end of seal
the front of the engine. until it protrudes far enough to be removed with
pliers (fig. 31L).
1. With the oil pan removed, remove the rear main
bearing cap.
2. Remove oil seal from the groove by lifting the end
tab (fig. 30L) then clean seal groove.
3. Lubricate the lip and O.D. of a new seal with engine
oil. Keep oil off the parting line surface. Insert
seal in cap and roll it into place with finger and

Fig. 28L-lnstalling Oil Seal (Cover Installed) Fig. 30L—Removing O i l Seal (Lower Half)

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-14

In production, the use of undersize main bearings is


limited to .001" undersize bearing halves as required to
obtain specified clearance between the crankshaft journal
and case bore. The use of .001 undersize bearing halves
in production does not affect the service procedure
outlined.
NOTE: If, for any reason, main bearing caps
are replaced, shimming may be necessary.
Laminated shims for each cap are available for
service. Shim requirement will be determined
by bearing clearance.
Inspection
In general, the lower half of the bearing shows a
greater wear and the most distress from fatigue. If
upon inspection the lower half is suitable for use, it
can safely be assumed that the upper half is also satis-
factory. If the lower half shows evidence of wear or
damage, both upper and lower halves should be replaced.
Never replace one half without replacing the other half.

Checking Clearance
To obtain the most accurate results with Plastigage,
(or its equivalent) a wax-like plastic material which will
compress evenly between the bearing and journal sur-
faces without damaging either surface, certain precau-
tions should be observed. If the engine is out of the
vehicle and upside down, the crankshaft will rest on the
upper bearings and the total clearance can be measured
between the lower bearing and journal. If the engine is
to remain in the vehicle, the crankshaft should be sup-
ported both front and rear (balancer and flywheel) to
remove the clearance from the upper bearing. The total
clearance can then be measured between the lower
bearing and journal.
NOTE: To assure the proper seating of the
crankshaft all bearing cap bolts should be at

Fig. 31L—Removing Oil Seal (Upper Half)

NOTE: Always wipe crankshaft surface clean


before installing a new seal. Also clean seal
groove.
5. Lubricate the lip and O.D. of a new seal with engine
oil. Keep oil off the parting line surface. Gradually
push with a hammer handle, while turning crank-
shaft, until seal is rolled into place. (Similar to
installing a main bearing.) Be careful that seal
bead on O.D. is not cut. Compress seal towards
crankshaft as much as possible.
6. Install the rear main bearing cap (with new seal)
and torque to specifications. Be sure cross seal
tabs are in place and properly seated.

MAIN BEARINGS
Main bearings are of the precision insert type and do
not utilize shims for adjustment. If clearances are found
to be excessive a new bearing, both upper and lower
halves, will be required. Bearings are available in
standard size and .002" undersize for use with new and
used standard size crankshafts, and in .010", .020" and
.030" undersize for use with reconditioned crankshafts. Fig. 32L—Gauging Plastic on Journal

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-15

their specified torque. In addition, preparatory irregularity of the bearing or journal. Be sure
to checking fit of bearings, the surface of the to measure the journal with a micrometer if the
crankshaft journal and bearing should be wiped flattened gauging plastic indicates more than
clean of oil. .001" difference.
6. If the bearing clearance is within specifications, the
1. With the oil pan and oil pump removed, and starting bearing insert is satisfactory. If the clearance is
with the rear main bearing, remove bearing cap and not within specifications, replace the insert. Always
wipe oil from journal and bearing cap. replace both upper and lower insert as a unit.
2. Place a piece of gauging plastic the full width of the
bearing (parallel to the crankshaft) on the journal NOTE: If a new bearing cap is being installed
(fig. 32L). and bearing clearance is less than .001", in-
spect for burrs or nicks; if none are found then
CAUTION: Do not rotate the crankshaft while install shims as required.
the gauging plastic is between the bearing and
journal. 7. A .002" undersize bearing may produce the proper
clearance. If not, it will be necessary to regrind the
3. Install the bearing cap and evenly torque the re- crankshaft journal for use with the next undersize
taining bolts to specifications. bearing.
4. Remove bearing cap. The flattened gauging plastic 8. Proceed to the next bearing. After all bearings have
will be found adhering to either the bearing shell been checked rotate the crankshaft to see that there
or journal. On the edge of gauging plastic envelope is no excessive drag.
there is a graduated scale which is correlated in 9. Measure crankshaft end play (see specifications) by
thousandths of an inch. forcing the crankshaft to the extreme front position.
5. Without removing the gauging plastic measure its Measure at the front e?nd of the rear main bearing
compressed width (at the widest point) with the with a feeler gauge (fig. 34L).
graduations on the gauging plastic envelope (fig. 10. Install a new rear main bearing oil seal in the cyl-
33L). inder block and main bearing cap.
NOTE: Normally, main bearing journals wear NOTE: Insert seal in real groove and roll it
evenly and are not out-of-round. However, if a into place with finger and thumb, using light
bearing is being fitted to an out-of-round pressure so beads on seal O.D. are not cut by
journal, be sure to fit to the maximum diameter seal groove at parting line. Be sure tabs on
of the journal. If the bearing is fitted to the seal in bearing cap are properly located in
minimum diameter and the journal is out-of - cross grooves.
round .001", interference between the bearing
and journal will result in rapid bearing failure. Replacement
If the flattened gauging plastic tapers toward
the middle or ends, there is a difference in NOTE: Main bearings may be replaced with or
clearance indicating a taper, low spot or other without removing the crankshaft.
With Crankshaft Removal
1. Remove and inspect the crankshaft.

Fig. 33L—Measuring Gauging Plastic Fig. 34L— Measuring Crankshaft End Play

CHEVROLET CHASSIS OVERHAUL MANUAL


ENIGNE MECHANICAL 6-16

Remove the main bearings from the cylinder block c. Oil new selected size upper bearing and insert
and main bearing caps. plain (unnotched) end between crankshaft and
Coat new, correct size, main bearings (on bearing indented or notched side of block.
surface only), with oil and install in the cylinder d. Use pliers as in removing to rotate bearing into
block and main bearing caps. place. The last 1/4" movement may be. done by
4. Install the crankshaft. holding just the slinger with the pliers or tap in
place with a drift punch.
Without Crankshaft Removal
1. With oil pan, oil pump and spark plugs removed. Oil new selected size lower bearing and install in
2. Remove cap on main bearing requiring replacement bearing cap.
and remove bearing from cap. 6. Torque main bearing cap to specifications.
3. To replace all except the rear main bearing upper
half: CONNECTING ROD BEARINGS
a. Install a main bearing removing and installing Connecting rod bearings are of the insert type and do
tool in oil hole in crankshaft journal. not utilize shims for adjustment. DO NOT FILE CON-
NOTE: If such a tool is not available, a cotter NECTING RODS OR CONNECTING ROD CAPS. If clear-
pin may be bent as required to do the job. ances are found to be excessive a new bearing will be
required. Bearings are available in standard size and
b. Rotate the crankshaft clockwise as viewed from .001" and .002" undersize for use with new and used
the front of engine. This will roll upper bearing standard size crankshafts, and in .010" and .020" under-
out of block. size for use with reconditioned crankshafts.
c. Oil new selected size upper bearing and insert
plain (unnotched) end between crankshaft and Inspection and Replacement
indented or notched side of block. Rotate the 1. With oil pan and oil pump removed, remove the
bearing into place and remove tool from oil hole connecting rod cap and bearing.
in crankshaft journal. 2. Inspect the bearing for evidence of wear or
damage. (Bearings showing the above should not
NOTE: The crankshaft rear main bearing be reinstalled.)
journal has no oil hole drilling and the rear 3. Wipe the bearings and crankpin clean of oil.
main bearing, upper halve can not be replaced 4. Measure the crankpin for out of round or taper with
in the above manner. a micrometer. If not within specifications replace
4. To replace the rear main bearing upper half: or recondition the crankshaft. If within specifica-
a. Use a small drift punch and hammer to start the tions and a new bearing is to be installed, measure
upper bearing half rotating out of block. the maximum diameter of the crankpin to'determine
b. Use a pair of pliers (with taped jaws) to hold the new bearing size required.
bearing thrust surface to the oil slinger and 5. If within specifications measure new or used bearing
rotate the crankshaft to remove bearing (fig. clearances with Plastigage or its equivalent.
35L). NOTE: If a bearing is being fitted to an out-of -
round crankpin, be sure to fit to the maximum
diameter of the crankpin. If the bearing is fitted
to the minimum diameter and the crankpin is
out-of-round .001", interference between the
bearing and crankpin will result in rapid bearing
failure.

Fig. 35L—Rear Main Bearing Replacement (Upper Half) Fig. 36L—Gauging Plastic on Crankpin

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-17

a. Place a piece of gauging plastic the full width of CONNECTING ROD AND PISTON ASSEMBLIES
the crankpin (parallel to the crankshaft) (fig.
Removal
36L).
b. Install the bearing in the connecting rod and cap. 1. With oil pan, oil pump and cylinder head removed,
c. Install the bearing cap and evenly torque to use a ridge reamer to remove any ridge and/or
specifications. deposits from the upper end of the cylinder bore.
NOTE: Before ridge and/or deposits are re-
CAUTION: Do not turn the crankshaft with the moved, turn crankshaft until piston is at the
gauging plastic installed. bottom of stroke and place a cloth on top of
d. Remove the bearing cap and using the scale on piston to collect the cuttings. After ridge and/or
the gauging plastic envelope, measure the gauging deposits are removed, turn crankshaft until
plastic width at the widest point (fig. 37L). piston is at top of stroke and remove cloth and
cuttings.
2. Inspect connecting rods and connecting rod caps for
cylinder identification. If necessary mark them.
3. Remove connecting rod cap and install Tool J-6305
on studs. Push connecting rod and piston assembly
out of top of cylinder block (fig. 39L).
NOTE: It will be necessary to turn the crank-
shaft slightly to disconnect some of the con-
necting rod and piston assemblies and push
them out of the cylinder.

Fig. 37L—Measuring Gauging Plastic

6. If the clearance exceeds specifications select a new,


correct size, bearing and remeasure the clearance.
7. Coat bearing surface of the bearing with oil, install
the rod cap and torque to specifications.
8. When all connecting rod bearings have been installed
tap each rod lightly (parallel to the crankpin) to
make sure they have clearance.
9. Measure all connecting rod side clearances (see
specifications) between the connecting rod cap and
side of crankping (fig. 38L).

Fig. 39L—Removing Connecting Rod and Piston Assemblies

Disassembly
1. Remove connecting rod bearings from connecting
rods and caps.
NOTE: If connecting rod bearings are being
reused, place them in a rack so they may be
reinstalled in their original rod and cap.
2. Remove piston rings by expanding them and sliding
them off the pistons. Tools J-8020 and J-8021 are
available for this purpose.
3. Place connecting rod and piston assembly in an
Fig. 38L—Measuring Connecting Rod Side Clearance arbor press with piston on support (J-9510-1) and

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-18

should be measured with a dial bore gauge or an inside


micrometer. If clearance is in excess of specifications
and the .001" wear limit, the piston and piston pin as-
sembly should be replaced.
Assembly (Fig. 41L)
1. Lubricate piston pin holes in piston and connecting
rod to facilitate installation of pin.
2. Position connecting rod in its respective piston so
that flange or heavy side of rod at the bearing end
will be towards front of piston (cast depression in
top of piston head).
3. Place support (J-9510-1) with spring and pilot
(J-9510-2) in place on an arbor press.
4. Place piston on support, indexing pilot through piston
and rod.
5. Place installer (J-9510-3) on piston pin, start piston
pin into piston and press on installer until pilot
bottoms in support.
6. Remove installer from connecting rod and piston
assembly and check piston for freedom of movement
on piston pin.
Piston Rings
All compression rings are marked on the upper side
of the ring. When installing compression rings, make

Fig. 40L—Removing Piston Pin

using remover (J-9510-3), press piston pin out of REMOVER AND


connecting rod and piston (fig. 40L). INSTALLER "
4. Remove assembly from arbor press and remove
Tools J-9510-1, J-9510-3 and piston pin, connecting
rod and piston.
Cleaning and Inspection
Connecting Rods PISTON
Wash connecting rods in cleaning solvent and dry with PIN
compressed air.
Check for twisted or bent rods and inspect for nicks
or cracks. Replace connecting rods that are damaged.
Pistons
Clean varnish from piston skirts and pins with a
cleaning solvent. DO NOT WIRE BRUSH ANY PART
OF THE PISTON. Clean the ring grooves with a groove
cleaner and make sure oil ring holes and slots are
clean.
Inspect the piston for cracked ring lands, skirts or
pin bosses, wavy worn ring lands, scuffed or damaged
skirts, eroded areas at top of the piston. Replace pistons
that are damaged or show signs of excessive wear.
Inspect the grooves for nicks or burrs that might
cause the rings to hang up.
Piston Pins
The piston pin clearance is designed to maintain ade-
quate clearance under all engine operating conditions. SUPPORT-*
Because of this, the piston and piston pin are a matched
set and not serviced separately.
Inspect piston pin bores and piston pins for wear.
Piston pin bores and piston pins must be free of varnish
or scuffing when being measured. The piston pin should
be measured with a micrometer and the piston pin bore Fig. 41L—Piston Pin and Tool Layout

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-19

sure the marked side is toward the top of the piston. The
top ring is chromed for maximum life.
The oil control rings used are of the three piece type,
consisting of two segments (rails) and a spacer.
Chevrolet piston rings are furnished in standard sizes
as well as .020", .030" and .040" oversizes.
1. Select rings comparable in size to the piston being
used.
2. Slip the compression rings in the cylinder bore; then
using the head of a piston, press the ring down into
the cylinder bore about two inches.
NOTE: Using a piston in this way will place
the ring square with the cylinder walls.
3. Measure the space or gap between the ends of the
ring with a feeler gauge (fig. 42L).
4. If the gap between the ends of the ring is below
specifications, remove the ring and try another
for fit.
5. Fit each compression ring separately to the cylinder
in which it is going to be used.
6. If the pistons have not been cleaned and inspected Fig. 43L—Checking Ring in Groove
as previously outlined, do so.
7. Install the oil ring spacer in the oil ring groove and be determined and removed by carefully dressing
position gap 90° from piston pin hole. (Anti rotation with a fine cut file. However, if the binding is caused
tang will lock in oil slot.) Hold spacer ends butted by a distorted ring, check a new ring. Install ring
and install steel rail on lower side of spacer. and position gap 45° from piston pin hole.
Position gap 45° to left of spacer gap, then install
second rail on upper side of spacer. Position gap NOTE: Tools J-8020 and J-8021 are available
45° to right of spacer gap. for installing rings.
8. Flex the oil ring assembly in its groove to make
sure ring is free and does not bind in the groove at 10. Repeat step nine with the top compression ring and
any point. If binding occurs, the cause should be position gap 90° from second compression ring.
determined and removed by carefully dressing with 11. Proper clearance of the piston ring in its piston
a fine cut file. However, if the binding is caused by ring groove is very important to provide proper
a distorted ring, install a new ring. ring action and reduce wear. Therefore, when fitting
9. Slip the outer surface of the second compression new rings, the clearances between the top and bottom
ring into the piston ring groove and roll the ring surfaces of the ring grooves should be measured
entirely around the groove to make sure that the (fig. 44L). (See specifications.)
ring is free and does not bind in the groove at any
point (fig. 43L). If binding occurs, the cause should

Fig. 42L—Measuring Ring Gap Fig. 44L—Measuring Ring Groove Clearance

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-20

Installation NOTE: Use a hammer handle and light blows


NOTE: Be sure to install new pistons in the to install the piston into the bore. Hold the
same cylinders for which they were fitted, and ring compressor firmly against the cylinder
used pistons in the same cylinder from which block until all piston rings have entered the
they were removed. cylinder bore.

Each connecting rod and bearing cap should be marked, 5. Guide the connecting rod bearing into place on the
beginning at the front of the engine. The numbers on the crankshaft journals with Tool J-6305-2 Connecting
connecting rod and bearing cap must be on the same side Rod Guide Set.
when installed in the cylinder bore. If a connecting rod 6. Install the bearing caps and torque to specifications.
is ever transposed from one block or cylinder to another, NOTE: If bearing replacement is required refer
new bearings should be fitted and the connecting rod to "Connecting Rod Bearings".
should be numbered to correspond with the new cylinder
number. CRANKSHAFT
NOTE: Cylinder bores must be clean before The crankshaft can be replaced while the engine
piston installation. This may be accomplished is disassembled for overhaul, or without complete
with a hot water and detergent wash or with a disassembly.
light honing as necessary. After cleaning, the
bores should be swabbed several times with Removal
light engine oil and a clean cloth and then wiped 1. With the engine removed from the vehicle and the
with a clean dry cloth. transmission and/or clutch housing removed from
the engine, mount engine in overhaul stand and
1. Lubricate connecting rod bearings and install in rods clamp securely.
and rod caps. 2. Remove the oil dip stick.
2. Lightly coat pistons, rings and cylinder walls with 3. Remove the starting motor, clutch assembly (if
light engine oil. equipped) and flywheel.
3. With bearing caps removed, install Tool J-6305 on 4. Remove the spark plugs.
connecting rod bolts. 5. Remove crankshaft pulley and hub or harmonic
CAUTION: Be sure ring gaps are properly balancer.
positioned as previously outlined. 6. Remove oil pan and oil pump.
7. Remove crankcase front end cover.
4. Install each piston in its respective bore, using 8. Check the connecting rod caps for cylinder number
Tool J-6305 on each assembly. The side of the identification. If necessary mark them.
piston with the cast depression in the head should 9. Remove the connecting rod caps and push the pistons
be * to the front of the cylinder block. Use Tool to top of bores.
J-8307 to compress the rings for installation (fig. 10. Remove main bearing caps and lift crankshaft out of
45L). cylinder block.
11. Remove rear main bearing oil seal and main bear-
ings from cylinder block and main bearing caps.
12. Remove crankshaft gear using Tool J-8105 (fig. 46L).
Cleaning and Inspection
1. Wash crankshaft in solvent and dry with compressed
air.
2. Measure dimensions of main bearing journals and
crankpins with a micrometer for out-of-round, taper
or undersize (see specifications).

Fig. 45L—Installing Connecting Rod and Piston Assemblies Fig. 46L—Removing Crankshaft Gear

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-21

3. Check crankshaft for run-out by supporting at the 8. Measure connecting rod side clearances (see speci-
front and rear main bearing journals in "V" blocks fications) (fig. 38L).
and check at the front and rear intermediate journals 9. Install the flywheel as outlined in this section.
with a dial indicator (see specifications). 10. Install the following as outlined in the Service
4. Replace or recondition the crankshaft if out of Manual:
specifications. a. Install the crankcase front end cover.
b. Install the oil pump, oil pan, and oil dip stick.
Installation c. Install the harmonic balancer or crankshaft hub
1. Install the crankshaft gear using Tool J-5590 (fig. and pulley.
* 47L)- d. Install spark plugs, starting motor and clutch
assembly.
2. Lubricate and install main bearings and a new rear
main bearing oil seal in cylinder block and main FLYWHEEL
bearing caps. Main bearing halves with the oil holes
are the upper halves and are installed in the cylinder Removal
block. With transmission and/or clutch housing and clutch
NOTE: Whenever a new or reconditioned crank- removed from engine, remove the flywheel.
shaft is installed, new connecting rod bearings Installation
and main bearings of the correct size should be 1. Clean the mating surfaces of flywheel and crankshaft
installed. to make certain there are no burrs.
3. Install crankshaft in block being careful not to dam- 2. Install flywheel on crankshaft and position to align
age bearing surfaces. (Line up timing marks as dowel hole of crankshaft flange and flywheel (fig.
outlined under Camshaft Replacement in the Service 48L).
Manual.)
NOTE: Main bearing caps are marked with an
arrow for identification purposes. The caps
are installed with arrows pointing toward the
front of engine.
4. Install all main bearing caps and torque all except
the rear to specifications. When tightening the rear
main bearing cap, torque bolts 10-12 ft. lbs. first,
then tap end of crankshaft rearward, with a lead
hammer, (this will locate bearing cap and bearing).
Then tap end of crankshaft forward (this will line up
upper and lower crankshaft thrust surfaces). Proceed
with final torquing of all main bearing caps to
specifications.
5. Measure crankshaft end play by forcing the crank-
shaft to the extreme front position. Measure at the
front end of rear main bearing with a feeler gauge
(see specifications) (fig. 34L).
6. Lubricate connecting rod bearings and install in
connecting rods and connecting rod caps.
7. Install the connecting rod caps and torque to
specifications. Fig. 48L—Flywheel Installation

NOTE: On Powerglide equipped engines, the


flywheel must be installed with the flange collar
to transmission side (fig. 49L).

CAMSHAFT AND TIMING GEAR


Measuring Lobe Lift at Push Rod
Refer to Figure 50L
NOTE: Procedure is similar to that used for
checking valve timing. If improper valve opera-
tion is indicated, measure the lift of each push
rod in consecutive order and record the
readings.
1. Remove valve rocker cover and gasket.
2. Remove rocker arm nuts, balls and rocker arms.
Fig. 47L—Installing Crankshaft Gear 3. Attach Tool J-8520 to stud.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-22

CONVERTER RING GEAR


BOLT AREA
DEPRESSED

WELDS

Fig. 50L—Measuring Camshaft Lobe Lift


ENGINE TRANS.
Inspection
The camshaft bearing journals should be measured
with a micrometer for an out-of-round condition. If the
journals exceed .001" out-of-round, the camshaft should
Fig. 49L—Powerglide Flywheel Installation
be replaced.
The camshaft should also be checked for alignment.
4. Position clamp on Tool J-8520. The best method is by use of "V" blocks and a dial
5. Position indicator with ball socket adapter on Tool indicator (fig. 51L). The dial indicator will indicate the
J-8520 to push rod. exact amount the camshaft is out of true. If it is out
more than .002" dial indicator reading, the camshaft
NOTE: Make sure push rod is in the lifter should be replaced.
socket. Inspect the camshaft gear and thrust plate for wear
Rotate the crankshaft balancer slowly in the direction or damage. Measure the camshaft end play. This should
of rotation until the lifter is on the heel of the cam be .001" to .005" (fig. 52L).
lobe. At this point, the push rod will be in its lowest Oil Nozzle Replacement
position. 1. Remove nozzle with pliers (fig. 53L).
Set dial indicator on zero, then rotate the balancer 2. Drive new nozzle in place (oil hole in vertical posi-
slowly, or attach an auxiliary starter switch and tion) using a suitable light plastic or rubber hammer.
"bump" the engine over, until the push rod is in the
fully raised position. Disassembly
1. If the inspection indicated that the shaft, gear or
CAUTION: The primary distributor lead must plate should be replaced, the gear must be removed
be disconnected from the negative post on the
coil and the ignition switch must be in the on
position. Failure to do this will result in a
damaged grounding circuit in the ignition switch.
8. Compare the total lift recorded from the dial indi-
cator Tool J-8520 with specifications.
9. Continue to rotate the engine until the indicator reads
zero. This will be a check on the accuracy of the
original indicator reading.
10. If camshaft readings for all lobes are within speci-
fications, remove dial indicator assembly Tool FUEL PUMP DISTRIBUTOR-
J-8520 from cylinder head stud. DRIVE ECCENTRIC DRIVE GEAR
11. Install valve rocker arms, and balls. Adjust valves
as outlined in the Service Manual.
12. Replace valve rocker cover and new gasket. Fig. 51L—Checking Camshaft Alignment

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-23

A-
\
tf t f
iamimi,,,,,

i\[ P
1

f r m

f m^
i
?
^ ^ 1
"r ''H;
mi ••'•• .%•;•••-.-'Si

Fig. 52L—Measuring Camshaft End Play

from the shaft. This operation requires the use of


camshaft gear remover Tool J-971.
2. Place the camshaft through the gear remover, place
end of remover on table of a press and press shaft
out of gear (fig. 54L).
CAUTION: Thrust plate must be so positioned
that woodruff key in shaft does not damage it
when the shaft is pressed out of gear. Also,

Fig. 54L—Removing Camshaft Timing Gear

support the hub of the gear or the gear will be


seriously damaged.
Assembly
To assemble camshaft gear, thrust plate and gear
spacer ring to camshaft, proceed as follows:
1. Firmly support shaft at back of front journal in an
arbor press.
2. Place gear spacer ring and thrust plate over end
of shaft, and install woodruff key in shaft keyway.
3. Install camshaft gear and press it onto the shaft
until it bottoms against the gear spacer ring. The
end clearance of the thrust plate should be .001"
to .005".
CAMSHAFT BEARINGS
Inspection
With the camshaft removed, inspect the bearings for
evidence of wear or damage. (Bearings showing the
above should be replaced.)
Removal
Camshaft bearings can be replaced while the engine
is disassembled for overhaul, or without complete dis-
Fig. 53L—Oil Nozzle Replacement assembly of the engine after camshaft and flywheel have

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-24

been removed. Operation is easier if crankshaft is r e - NOTE: The front bearing must be driven ap-
moved also. proximately 1/8" behind front of cylinder block
1. With camshaft flywheel and oil pan removed, drive to uncover oil hole to timing gear oil nozzle.
camshaft rear plug from cylinder block.
2. Using Tool Set J-6098, with nut (J-6098-5) then
NOTE: This procedure is based on removal of thrust washer installed to end of threads, index
the bearings nearest center of the engine first. pilot in front camshaft bearing and install puller
With this method a minimum amount of turns screw through pilot.
are necessary to remove all bearings. 3. Index number two camshaft bearing in bore, then
2. Using Tool Set J-6098, with nut (J-6098-5) then install Tool J-6098-1 on puller screw with shoulder
thrust washer installed to end of threads, index toward bearing.
pilot in front camshaft bearing and install puller 4. Using two wrenches, hold puller screw while turning
screw through pilot. nut (J-6098-5). When bearing has been pulled into
3. Install Tool J-6098-1 with shoulder toward number bore, remove Tool J-6098-1 from puller screw,
two bearing, making sure a sufficient amount of then remove puller screw and pilot from cylinder
threads are engaged. block and check alignment of oil hole in camshaft
4. Using two wrenches, hold puller screw while turning bearing.
nut (J-6098-5). When bearing has been pulled from 5. On L-6 engines:
bore, remove Tool J-6098-1 and bearing from puller a. Index pilot in rear camshaft bearing and install
screw and remove puller screw and pilot from puller screw through pilot.
cylinder block. b. Index number three camshaft bearing in bore,
5. On L-6 engines: reinstall Tool J-6098-1 on puller screw and pull
a. Index pilot in rear camshaft bearing and install bearing into bore.
puller screw through pilot. c. Remove Tool J-6098-1 from puller screw, r e -
b. Install Tool J-6098-1 with shoulder toward num- move puller screw and pilot from cylinder block
ber three bearing and pull bearing. When bearing and check alignment of oil hole in camshaft
has been pulled from bore, remove Tool J-6098-1 bearing.
and bearing from puller screw and remove puller 6. Install a new camshaft rear plug.
screw and pilot from cylinder block, NOTE: Plug should be installed flush to 1/32"
6. Assemble Tool J-6098-1 on driver handle (J-6098-4) deep and be parallel with rear surface of cyl-
and remove front and rear camshaft bearings by inder block.
driving towards center of cylinder block.
CYLINDER BLOCK
Installation
Inspection
Refer fa Figure 55L and 561
1. Inspect the cylinder block for cracks in the cylinder
The front and rear camshaft bearings should be in- walls, water jacket valve lifter bores and main
stalled first. These bearings will act as guides for the bearing webs.
pilot and center the remaining bearings being pulled 2. Measure the cylinder walls for taper, out-of-round
into place. or excessive ridge at top of ring travel. This should
1. Assemble Tool J-6098-1 on driver handle (J-6098-4) be done with a dial indicator. Set the gauge so that
and install front and rear camshaft bearings by
driving towards center of cylinder block.
CAUTION: Oil holes in bearings must line up
with oil holes in cylinder block.

mk *»!^M™.-»«wi#»«/B'Wft/»5& x^ifv^^^ii^vvmx ^^^ii^^^^i

Fig. 551—Replacing No. 2 Camshaft Bearing Fig. 56L—Replacing Front Camshaft Bearing

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-25

the thrust pin must be forced in about 1/4" to enter 3. The instructions furnished by the manufacturer of
gauge in cylinder bore. Center gauge in cylinder the equipment being used should be carefully
and turn dial to " O " . Carefully work gauge up and followed.
down cylinder to determine taper and turn it to Cylinder Honing and Piston Selection
different points around cylinder wall to determine 1. When pistons are being fitted and honing is not
the out-of-round condition. If cylinders were found necessary cylinder bores may be cleaned with a
to exceed specifications honing or boring will be hot water and detergent wash. After cleaning, the
necessary (fig. 57L). bores should be swabbed several times with light
Repairs engine oil and a clean cloth and then wiped with a
Cylinder Conditioning clean dry cloth.
The performance of the following operation is con- 2. When cylinders are to be honed follow the hone
tingent upon engine condition at time of repair. manufacturer's recommendations for the use of the
if the cylinders were found to have less than .005" hone and cleaning and lubrication during honing.
taper or wear they can be conditioned with a hone and 3. Occasionally during the honing operation, the cyl-
fitted with the high limit standard size pistons. A cyl- inder bore should be thoroughly cleaned and the
inder bore of less than .005" wear or taper may not piston selected for the individual cylinder checked
entirely clean up when fitted to a high limit piston. If it for correct fit.
is desired to entirely clean up the bore in these cases, When finish honing a cylinder bore, the hone should
it will be necessary to rebore for an oversize piston. If be moved up and down at a sufficient speed to obtain
more than .005" taper or wear, they should be bored and very fine uniform surface finish marks in a cross-
honed to the smallest oversize that will permit complete hatch pattern of approximately 45° to 65° included
resurfacing of all cylinders. angle. The finish marks should be clean but not
Cylinder Boring
sharp, free from imbedded particles and torn or
1. Before using any type boring bar, the top of the folded metal (fig. 58L).
cylinder block should be filed off to remove any NOTE: Replacement pistons are available in a
gasket sealer, dirt or burrs. This is very important. range of four standard sizes and four each
Otherwise, the boring bar may be tilted which would (.020", .030" and .040") oversize and the size
result in the rebored cylinder wall not being at identification is marked, in ink, on the piston
right angles to the crankshaft. top.
2. The piston to be fitted should be measured with a 4. To determine the correct size of piston needed,
micrometer, measuring at the center of the piston measure the cylinder bore with a telescope gauge
skirt and at right angles to the piston pin. The cyl- and subtract the base cylinder bore diameter from
inder should be bored to the same diameter as the the measured diameter, then locate this dimension
piston and honed to give the specified clearance. on the Piston Selection Chart (fig. 59L). The number
NOTE: Hone cylinder as outlined under "Cyl- shown on the chart in the box above the dimension
inder Honing and Piston Fitting". is the marking on the piston which should be used.

EXAMPLE "A":
Cylinder bore measurement 3.8775 Worn standard bore
Base cylinder bore diameter 3.8745 153 cu. in. engine
Difference .0030
Number on Chart S7 Standard piston
(+.003") marked S7

EXAMPLE " B " :


Cylinder bore measurement 3.9065 Rebored bore
Base cylinder bore diameter 3.8745 153 cu. in. engine
Difference .032
Number on Chart 4 .030 oversize
(+.002") marked 4

Fig. 571— Measuring Cylinder Bores Fig. 58L-—Cylinder Finish Marks

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-26

5. Permanently mark the piston for the cylinder to


which it has been fitted and proceed to hone cyl- BASE CYL. D I A . - 194 ENGINE = 3.5620-153,230 =3.8745
inders and fit the remaining pistons. EXAMPLE " A " p,STON MARK|NG EXAMPLE "B'
CAUTION: Handle the pistons with care and
do not attempt to force them through the cyl- 0
inder until the cylinder has been honed to o .020 S « .030 S S .040 ^ §"
BASE 9 O.S. °' 9 O.S. 6 9 O.S. 9 9
correct size as this type piston can be dis- CYL.
torted through careless handling. DIA. CYLINDER OVERSIZE

6. Thoroughly clean the cylinder bores with hot water


and detergent. Scrub well with a stiff bristle brush Fig. 59L—Piston Selection Chart
and rinse thoroughly with hot water. It is extremely
essential that a good cleaning operation be per-
formed. If any of the abrasive material is allowed engine oil and a clean cloth and then wiped with a
to remain in the cylinder bores, it will rapidly wear clean dry cloth. Cylinders should not be cleaned
the new rings and cylinder bores in addition to the with kerosene or gasoline. Clean the remainder of
bearings lubricated by the contaminated oil. The the cylinder block to remove the excess material
bores should be swabbed several times with light spread during the honing operation.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-27

V-8 ENGINES
(283 AND 327 CU. IN.)
INDEX
Page Page
General Description 6-27 Checking Clearances 6-37
Repair Procedures 6-27 Replacement . 6-38
Er%ine Assemblies 6-27 With Crankshaft Removal 6-39
Disassembly 6-27 Without Crankshaft Removal 6-39
Cleaning and Inspection 6-29 Connecting Rod Bearings 6-39
Assembly . . '. 6-29 Inspection and Replacement 6-39
Cylinder Head Assemblies 6-30 Connecting Rod and Piston Assemblies 6-39
Disassembly 6-30 Removal 6-39
Cleaning 6-30 Disassembly 6-40
Inspection 6-30 Cleaning and Inspection 6-40
Repairs 6-30 Connecting Rods 6-40
Valve Guide Bores 6-30 Pistons 6-40
Rocker Arm Studs 6-31 Piston Pins 6-40
Valve Seats 6-31 Assembty 6-41
Valves 6-32 Piston Rings 6-41
Assembly 6-32 Installation 6-42
Valve Stem Oil Seal 6-33 Crankshaft 6-43
Replacement 6-33 Removal 6-43
Valve Lifters (Hydraulic) 6-34 Cleaning and Inspection 6-43
Disassembly 6-34 Installation 6-43
Cleaning and Inspection 6-34 Flywheel 6-44
Assembly 6-35 Removal 6-44
Oil Pump 6-35 Installation 6-44
Disassembly 6-35 Camshaft 6-44
Cleaning and Inspection 6-35 Measuring Lobe Lift at Push Rod 6-44
Assembly 6-36 Inspection 6-45
Oil Filter By-Pass Valve 6-36 Camshaft Bearings 6-45
Inspection and Replacement 6-36 Inspection 6-45
Oil Seal—Crankcase Front Cover 6-36 Removal 6-45
Replacement 6-36 Installation 6-45
With Cover Removal 6-36 Cylinder Block 6-46
Without Cover Removal 6-36 Inspection 6-46
Oil Seal—Rear Main Bearing 6-36 Repairs 6-46
Replacement 6-36 Cylinder Conditioning 6-46
Main Bearings. 6-37 Cylinder Boring 6-47
Inspection 6-37 Cylinder Honing and Piston Selection 6-47

GENERAL DESCRIPTION
The V-8, overhead valve engines covered in this Full pressure lubrication, through a full flow oil
section are the 283 and 327 cu. in. engines used in the filter, is furnished by a gear-type oil pump. The dis-
Chevrolet, Chevelle and Chevy II passenger car vehicles. tributor, driven by a helical gear on the camshaft,
The cylinders are numbered front to rear, 1-3-5-7 drives the oil pump. The main oil gallery feeds oil,
on the left bank and 2-4-6-8 on the right bank. Firing through drilled passages, to the camshaft and crankshaft
order is, 1-8-4-3-6-5-7-2. Crankshaft rotation as viewed to lubricate the bearings. The valve lifter oil gallery
from the rear is counter-clockwise. feeds the valve lifters which, through hollow push rods,
The crankshaft has five main bearings and the cam- feed the individually mounted rocker arms (fig. IV).
shaft has five bearings.

REPAIR PROCEDURES
ENGINE ASSEMBLIES 4. On engines so equipped, remove power steering
pump.
Disassembly 5. Disconnect fuel pump-to-carburetor line and re-
1. With engine removed from the vehicle and trans- move fuel pump, then remove mounting plate and
mission and/or clutch housing removed from the pump push rod from block and discard gaskets.
engine, mount engine in overhaul stand and clamp 6. Disconnect choke rod, fuel lines, spark advance
securely. line, and crankcase vent line; then remove car-
2. Remove engine ground strap, and oil dip stick. buretor and discard gaskets.
3. Remove Delcotron and mounting bracket as an 7. Remove distributor cap and spark plug wire as-
assembly. sembly, then remove distributor and coil.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-28

i1 H

\—
f
MTI—

j
DISTRIBUTOR SHAFT
OILING

Sir
*
FUEL PUMP PUSH ROD OILING OIL FILTER A N D
BY-PASS VALVE

Fig. IV—Engine LubricaHon

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-29

8. Remove water pump, water outlet and thermostat


and discard gaskets.
9. Remove intake manifold and exhaust manifolds and
discard gaskets and seals.
10. Remove rocker arm nuts, rocker arms and push
rods, then remove valve lifters.
NOTE: Valve lifters, rocker arms, rocker arm
balls and push rods should be placed in a rack
in their proper sequence so they can be in-
stalled in their same positions during build-up.
11. Remove cylinder heads and discard gaskets.
12. Remove screw retaining crankcase inner ventilator
body to cylinder block and remove ventilator body
from cylinder block.
CAUTION: Do not damage vent body.
13. Remove starter, clutch housing cover plate, oil
filter and oil filter by-pass valve and discard seal.
14. Remove oil pan and discard gaskets and seals.
15. Remove crankshaft pulley and hub or harmonic
balancer using Tool J- 6978.
16. Remove crankcase front end cover and discard
gasket.
17. Remove three camshaft sprocket to camshaft bolts.
18. Remove camshaft sprocket and timing chain together.
Sprocket is a light press fit on camshaft for approxi- Fig. 2V—Compressing Valve Springs
mately 1/8". If sprocket does not come off easily,
a light blow with a plastic-faced hammer on the sharp punch or they may be drilled and
lower edge of the camshaft sprocket should dislodge pried out.
the sprocket. 3. Clean and inspect water passages in the cylinder
19. Install two bolts, 5/16"-18 x 4" in two camshaft block.
bolt holes. Remove camshaft from engine. 4. Inspect the cylinder block for cracks in the cylinder
CAUTION: All camshaft journals are the same walls, water jacket, valve lifter bores and main
diameter and caution must be used in removing bearing webs.
camshaft to avoid damage to bearings. 5. All further cleaning and inspection is outlined under
the part or sub-assembly being serviced.
20. Remove oil pump and extension shaft.
21. Check the connecting rods and caps for cylinder Assembly
number identification and if necessary, mark them. NOTE: Use new gaskets and seals on engine
22. Remove connecting rod journal bearing caps and assembly.
install Tool J-6305 on studs. Push piston assemblies
out of top of cylinder block. If piston rings strike 1. Apply sealer to new oil gallery plugs and install
ridge at top of cylinder, remove ridge to prevent plugs.
damaging piston ring lands. 2. Install the crankshaft, flywheel and oil filter by-pass
valve, as outlined in this section.
NOTE: It will be necessary to turn the crank- 3. Install the connecting rod and piston assemblies as
shaft slightly to disconnect some of the rods outlined in this section.
and to push them out of the cylinder. 4. Install the following as outlined in the Service
23. On engines so equipped, loosen clutch to flywheel Manual.
bolts a turn at a time (to prevent distortion of a. Camshaft, camshaft sprocket, timing chain and
clutch cover) until the diaphragm spring pressure crankcase front end cover.
is released. Remove cover assembly and disc. b. Oil pump, oil pump shaft extension and oil pan.
24. Remove the flywheel. c. Starting motor and oil filter.
25. Remove main bearing caps and lift crankshaft out of d. Fuel pump push rod, fuel pump mounting plate
cylinder block. Remove the main bearings from the and fuel pump.
cylinder block and main bearing caps. e. Harmonic balancer or crankshaft hub and pulley.
26. All further disassembly is covered under the part f. Water pump, thermostat and water outlet.
or sub-assembly being serviced. g. Cylinder heads, valve lifters, push rods and
rocker arms.
Cleaning and Inspection
h. Crankcase inner ventilator body, intake manifold
1. Wash cylinder block thoroughly in cleaning solvent and exhaust manifolds,
i. Carburetor, crankcase vent line, spark advance
and clean all gasket surfaces.
line, fuel line and choke rod.
2. Remove oil gallery plugs and clean all oil passages. j . Distributor, coil, distributor cap and spark plug
NOTE: These plugs may be removed with a wire assembly.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-30

Inspection
1. Inspect the cylinder head for cracks in the exhaust
ports, combustion chambers, or external cracks to
the water chamber.
2. Inspect the valves for burned heads, cracked faces
or damaged stems.
3. Check fit of valve stems in their respective bores.
NOTE: Excessive valve stem to bore clearance
will cause excessive oil consumption, and may
cause valve breakage. Insufficient clearance
will result in noisy and sticky functioning of the
valve and disturb engine smoothness.
Valve stem to bore clearance may be checked
by using a micrometer and a suitable telescope
hole gauge. Using a micrometer measure the
diameter of the valve stem in three places, top,
center, and bottom. Insert telescope hole gauge
Fig. 3V—Removing Carbon From Combustion Chambers in valve guide bore, measuring at the top, center
and bottom. Determine the minimum and maxi-
k. On engines so equipped, power steering pump. mum clearances. If clearance is not within
1. Delcotron and mounting bracket as an assembly, limits (see specifications) use next oversize
m. Oil dip stick tube, oil dip stick and ground strap, valve and ream valve guide bore.
n. Clutch assembly. 4. Check valve spring tension with Tool J-8056 spring
CYLINDER HEAD ASSEMBLIES tester (fig. 5V).
Disassembly NOTE: Springs should be compressed to the
1. With cylinder head removed, remove valve rocker specified height and checked against the specifi-
arm nuts, balls and rocker arms. cations chart. Springs should be replaced if
2. Using Tool J-8062, compress the valve springs and not within 10 lbs. of the specified load without
remove valve keys (fig. 2V). Release the spring dampers.
compressor tool and remove spring caps, shields, Repairs
oil seals, springs and spring dampers.
3. Remove valves from bottom of cylinder head and Valve Guide Bores
place them in a rack in their proper sequence so Valves with oversize stems are available (see Specifi-
they can be assembled in their original positions. cations). To ream the valve guide bores for oversize
valves use Tool set J-5830 (fig. 6V).
Cleaning
1. Clean all carbon from combustion chambers and
valve ports using Tool J-8089 (fig. 3V).
2. Thoroughly clean the valve guide bores using Tool
J-8101 (fig. 4V).
3. Clean all carbon and sludge from push rods and
rocker arms.
4. Clean valve stems and 'heads on a buffing wheel.
5. Clean carbon deposits from head gasket mating
surfaces

« * * •

Fig. 4V—Cleaning Valve Guide Bores Fig. 5V—Checking Valve Spring Tension

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-31

Fig. 6V—Reaming Valve Guide Bores

Rocker Arm Studs Fig. 8V—Reaming Rocker Arm Stud Hole


Rocker arm studs that have damaged threads or are
loose in cylinder heads should be replaced with new heads. Good contact between each valve and its seat
studs available in .003" and .013" oversize. Studs may be in the head is imperative to insure that the heat in
installed after reaming the holes as follows: the valve head will be properly carried away.
1. Remove old stud by placing Tool J-5802-1 over the Several different types of equipment are available for
stud, installing nut and flat washer and removing stud reseating valve seats. The recommendations of the
by turning nut (fig. 7V). manufacturer of the equipment being used should be
2. Ream hole for oversize stud using Tool J-5715 for carefully followed to attain proper results.
.003" oversize and Tool J-6036 for .013" oversize Regardless of what type of equipment is used, however,
(fig. 8V). it is essential that valve guide bores be free from
carbon or dirt to insure proper centering of pilot in
CAUTION: Do not attempt to install an over- the guide.
size stud without reaming stud hole. 1. Install expanding pilot in the valve guide bore and
3. Coat press-fit area of stud with hypoid axle lubri- expand pilot by tightening nut on top of pilot.
cant. Install new stud, using Tool J-6880 as a 2. Place roughing stone or forming stone over pilot
guide. Gauge should bottom on head (fig. 9V). and just clean up the valve seat. Use a stone cut to
Valve Seats 46°.
Reconditioning the valve seats is very important, 3. Remove roughing stone or forming stone from pilot,
because the seating of the valves must be perfect for place finishing stone, cut to 46°, over pilot and
the engine to deliver the power and performance built
into it.
Another important factor is the cooling of the valve

Fig. 7V—Removing Rocker Arm Stud Fig. 9V—Installing Rocker Arm Stud

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-32

refacing valves. The recommendations of the manu-


facturer of the equipment being used should be care-
fully followed to attain proper results.
1. If necessary, dress the valve refacing machine
grinding wheel to make sure it is smooth and true.
Set chuck at 45° mark for grinding valves (fig. 11V).
2. Clamp the valve stem in the chuck of the machine.
3. Start the grinder and move the valve head out in
line with the grinder wheel by moving the lever to
the left.
4. Turn the feed screw until the valve head just contacts
wheel. Move valve back and forth across the wheel
and regulate the feed screw to provide light valve
contact.
5. Continue grinding until the valve face is true and
Fig. 10V—Measuring Valve Seat Concentricity smooth all around the valve. If this makes the
valve head thin the valve must be replaced as the
cut just enough metal from the seat to provide a valve will overheat and burn.
smooth finish. 6. Remove valve from chuck and place stem in " v "
4. Narrow down the valve seats to the specified width block. Feed valve squarely against grinding wheel
(see specifications). to grind any pit from rocker arm end of stem.
NOTE: This operation is done by grinding the NOTE: Only the extreme end of the valve
port side with a 30° stone to lower seat and a stem is hardened to resist wear. Do not grind
60° stone to raise seat. end of stem excessively.
Remove expanding pilot and clean cylinder head 7. After cleaning valve face and cylinder head valve
carefully to remove all chips and grindings from seat of grinding particles, make pencil marks about
above operations. 1/4" apart across the valve face, place the valve in
6. Measure valve concentricity (fig. 10V). cylinder head and give the valve 1/2 turn in each
NOTE: Valve seats should be concentric to direction while exerting firm pressure on head
within .002" total indicator reading. of valve.
8. Remove valve and check face carefully. If all pencil
Valves marks have not been removed at the point of contact
Valves that are pitted can be refaced to the proper with the valve seat, it will be necessary to repeat
angle, insuring correct relation between the head and the refacing operation and again recheck for proper
stem on a valve refacing machine. Valve stems which seating.
show excessive wear, or valves that are warped ex- 9. Grind and check the remaining valves in the same
cessively should be replaced. When a valve head which manner.
is warped excessively is refaced, a knife edge will be
ground on part or all of the valve head due to the amount Assembly
of metal that must be removed to completely reface. 1. Insert a valve in the proper port.
Knife edges lead to breakage, burning or pre-ignition due 2. Set the valve spring with damper, valve shield and
to heat localizing on this knife edge. If the edge of the valve cap in place (fig. 12V). The close coiled end
valve head is less than 1/32" thick after grinding, replace of the spring is installed against the cylinder head.
the valve.
Several different types of equipment are available for

-a
SEAL- 8
SHIELD-JfJ1
SPRING--^
DAMPER-^
M D

INTERFERENCE

Fig. 1IV—Relation of Valve and Seat Angles Fig. 12V—Valve Spring Installation

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-33

Fig. 13V—Vacuum Cup

3. Compress the spring with Tool J-8062.


4. Install oil seal in the lower groove of the stem,
making sure the seal is flat and not twisted.
5. Install the valve locks and release the compressor
tool, making sure the locks seat properly in the Fig. 15V—Air Adopter Tool
upper groove of the valve stem.
head installed. On some vehicles equipped with power
NOTE: Grease may be used to hold the locks brakes it may be necessary to remove the power brake
in place while releasing the compressor tool. unit.
6. Install the remaining valves. Replacement
7. Check each valve stem oil seal by placing a vacuum 1. Remove the valve cover and spark plug on cylinder
cup or similar device over the end of the valve to be serviced.
stem and against the cap. Operate the vacuum cup 2. Apply compressed air to the spark plug hole to hold
and make sure no air leaks past the oil seal. the valves in place.
A vacuum cup can be made from a small syringe
and a high voltage shield (fig. 13V). NOTE: A tool to apply air to the cylinder is
8. Check the installed height of the valve springs, available through local jobbers or may be manu-
using a narrow thin scale. Measure from the top of factured. In manufacturing this Tool a AC-46N
the shim or the spring seat to the top of the valve Spark Plug or its equivalent is recommended.
spring shield. If this is found to exceed the specified This will make the Tool universal for all
height, install a valve spring seat shim approxi- Chevrolet engines. Chisel the spark plug as
mately 1/16" thick. At no time should the spring be shown, then drive the porcelain out of the plug
shimmed to give an installed height under the mini- by tapping the center electrode against a hard
mum specified (fig. 14V). block. Using a 3/8" pipe tap, cut threads in the
remaining portion of the spark plug and assem-
NOTE: If springs and/or seals are to be ble as shown (fig. 15V).
changed with the cylinder head installed, Tool
J-5892 may be used to compress the springs.
Compressed air, through the spark plug hole,
may be used to hold the valves in place.
VALVE STEM OIL SEAL
Valve stem oil seals can be replaced with the cylinder

Fig. 14V—Measuring Valve Spring Installed Height Fig. 16V—Compressing Valve Spring

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-34

tool making sure the locks seat properly in the


upper groove of the valve stem.
NOTE: Grease may be used to hold the locks
in place while releasing the compressor tool.
7. Check valve stem oil seals as outlined under cylinder
head assembly and replace valve cover and spark
plug.
VALVE LIFTERS (HYDRAULIC)
Two types of hydraulic lifters are used. Both types
of lifters operate on the same principle and are serviced
basically in the same manner. The complete lifter
assemblies are interchangeable but parts from one lifter
are not interchangeable with another. Both lifters are
easily identified by the outside configuration of the
lifter body. For purposes of identification we refer to
them as lifter "A" and lifter " B " (fig. 17V).
Disassembly
LIFTER " A " LIFTER "B'
1. Hold the plunger down with a push rod, and using the
blade of a small screw driver, remove the push rod
seat retainer.
2. Remove the push rod seat and metering valve (lifter
"A") or the push rod seat and inertia valve assem-
bly (lifter "B").
3. Remove the plunger, ball check valve assembly and
the plunger spring.
4. Remove the ball check valve and spring by prying
the ball retainer loose from the plunger with the
blade of a small screw driver (fig. 18V).
Cleaning and Inspection
Thoroughly clean all parts in cleaning solvent, and
inspect them carefully. If any parts are damaged or
worn the entire lifter assembly should be replaced.
NOTE: Inertia valve and retainer (lifter "B")
should not be removed from the push rod seat.
To check the valve, shake the push rod seat and

Fig. T7V-Hydraulic Valve Lifters


1. Lifter Body 5. Check Ball Retainer
2. Push Rod Seat 6. Push Rod Seat Retainer
3. Metering Valve (Lifter A) 7. Plunger
Inertia Valve (Lifter B) 8. Check Ball Spring
4. Check Ball 9. Plunger Spring

3. Using Tool J-5892 to compress the valve spring,


remove the valve locks, valve cap, valve shield and
valve spring and damper (fig. 16V).
4. Remove the valve stem oil seal.
5. To replace, set the valve spring and damper, valve
shield and valve cap in place. The close coiled end
of the spring is installed against the cylinder head.
5. Compress the spring with Tool J-5892 and install
oil seal in the lower groove of the stem, making
sure the seal is flat and not twisted.
NOTE: A light coat of oil on the seal will
help prevent twisting.
6. Install the valve locks and release the compressor Fig. 18V-Removing Ball Check Valve

CHEVROLET CHASSIS OVERHAUL /MANUAL


ENGINE MECHANICAL 6-35

inertia valve assembly and the valve should


move.
Assembly
1. Place the check ball on small hole in bottom of
the plunger.
2. Insert check ball spring on seat in ball retainer and
place retainer over ball so spring rests on the ball.
Carefully press the retainer into position in plunger
with the blade of a small screw driver (fig. 19V).
3. Place the plunger spring over the ball retainer and
slide the lifter body over the spring and plunger,
being careful to line up the oil feed holes in the
lifter body and plunger.
4. Fill the assembly with SAE 10 oil, then insert the
end of a 1/8" drift pin into the plunger and press
down solid. At this point oil holes in the lifter body
and plunger assembly will be aligned (fig. 20V).
CAUTION: Do not attempt to force or pump the
plunger.
5. Insert a 1/16" drift pin through both oil holes to
hold the plunger down aginst the lifter spring tension
(fig. 20V).
NOTE: On lifter "B", the drift pin must not
extend inside the plunger. Fig. 20V—Assembling the Hydraulic Lifters
6. Remove the 1/8" drift pin, refill assembly with
push rod seat and remove the 1/16" drift pin from
SAE 10 oil.
the oil holes. The lifter is now completely as-
7. Install the metering valve and push rod seat (lifter
sembled, filled with oil and ready for installation.
"A") or the push rod seat and inertia valve as-
sembly (lifter "B"). NOTE: Before installing any new lifters, coat
8. Install the push rod seat retainer, press down on the the bottom of the lifter with Molykote or its
equivalent.
OIL PUMP
The oil pump consists of two gears and a pressure
regulator valve enclosed in a two-piece housing. The
oil pump is driven by the distributor shaft which is
driven by a helical gear on the camshaft (fig. 21V).
A baffle is incorporated on the pick-up screen to
eliminate pressure loss due to sudden or surging stops.
Disassembly
1. With the oil pump removed, remove the pump shaft
extension, the pump cover attaching screws and
the pump cover.
4"V)A YMItVin /^^IT^T*

NOTE: Mark gear teeth so they may be re-


assembled with the same teeth indexing.
2. Remove the idler gear and the drive gear and shaft
from the pump body.
3. Remove the pressure regulator valve retaining pin,
pressure regulator valve and related parts from
the pump cover,
4. If the pick-up screen and pipe assembly need re-
placing, mount the pump cover in a soft-jawed vise
and using Tool J-8369 extract pipe from pump
cover.
CAUTION: Do not disturb the pick-up screen
on the pipe. This is serviced as an assembly.
Cleaning and Inspection
1. Wash all parts in cleaning solvent and dry with
compressed air.
2. Inspect the pump body and cover for cracks or
Fig. 19V-lnstalling Ball Check Valve excessive wear.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-36

broken valve. If replacement is necessary, remove


valve and seal, clean valve chamber in cylinder block
and install a new valve with a new seal. Torque bolts
to specifications (fig. 22V).
OIL SEAL-CRANKCASE FRONT COVER
Replacement
With Cover Removal
1. With cover removed, pry old seal out of cover from
the front with a large screw driver.
2. Install new seal so that open end of the seal is
toward the inside of cover and drive it into position
with ToolJ-995 (fig. 23V).
CAUTION: Support cover at sealing area. (Tool
J-971 may be used as support).
Without Cover Removal
1. With crankshaft pulley and hub or harmonic balancer
Fig. 21V—Oil Pump (Exploded View) removed, pry old seal out of cover from the front
with a large screw driver, being careful not to
1. Shaft Extension 6. Pressure Regulator Valve damage the seal surface on the crankshaft.
2. Pump Body 7. Pressure Regulator Spring
3. Drive Gear and Shaft 8. Retaining Pin
2. Install new seal so that open end of seal is toward
4. Idler Gear 9. Screws the inside of cover and drive it into position with
5. Pump Cover 10. Pick-Up Screen and Pipe ToolJ-8340 (fig. 24V).
OIL SEAL-REAR MAIN BEARING
3. Inspect pump gears for damage or excessive wear.
Replacement
4. Check the drive gear shaft for looseness in the
pump body. The rear main bearing oil seal can be replaced (both
5. Inspect inside of pump cover for wear that would halves) without removal of the crankshaft (fig. 25V).
permit oil to leak past the ends of the gears. NOTE: Always replace the upper and lower
6. Inspect the pick-up screen and pipe assembly for seal as a unit. Install with the lip facing toward
damage to screen, pipe or relief grommet the front of the engine.
7. Check the pressure regulator valve for fit in the 1. With the oil pan and oil pump removed, remove the
pump cover. rear main bearing cap.
NOTE: The pump gears to body are a selective 2. Remove oil seal from the groove by prying from the
fit. If the pump gears or body are damaged or bottom with a small screw driver (fig. 26V).
worn replacement of the entire oil pump as- 3. Lubricate the lip of a new seal with engine oil.
sembly is necessary. Keep oil off the parting line surface as this is
treated with glue. Insert seal in cap and roll it
Assembly into place with finger and thumb, using light pressure
1. If the pick-up screen and pipe assembly was re- so seal tangs at parting line; do not cut bead on back
moved, mount the pump cover in a soft-jawed vise, of seal.
apply sealer to end of pipe, and using Tool J-8369 4. To remove the upper half of the seal, use a small
tap the pipe in place with a plastic hammer. hammer to tap a brass pin punch on one end of
NOTE: On 327 Hi/Per, engines, tap the pipe seal until it protrudes far enough to be removed
retaining pin in place and stake pin. with pliers (fig. 27V).
CAUTION: Be careful of twisting, shearing or NOTE: Always wipe crankshaft surface clean
collapsing pipe while installing in pump cover. before installing a new seal.
Pick-up screen must be parallel to bottom of 5. Lubricate the lip of a new seal with engine oil. Keep
oil pan when oil pump is installed. oil off the parting line surface as this is treated
2. Install the pressure regulator valve and related
parts in the pump cover.
3. Install the drive gear and shaft in the pump body.
4. Install the idler gear in the pump body with the
smooth side of gear towards pump cover opening.
5. Install the pump cover and torque attaching screws
to specifications.
6. Install pump shaft extension.

OIL FILTER BY-PASS VALVE


Inspection and Replacement
With the oil filter removed, check the spring and
fibre valve for operation. Inspect for a cracked or Fig. 22V-OII Filter By-Pass Valve

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-37

Fig. 25V—Rear Main Bearing Oil Seal (Rear View)

are replaced, shimming may be necessary.


Laminated shims for each cap are available
Fig. 23V—Installing Oil Seal (Cover Removed) for service. Shim requirement will be deter-
mined by bearing clearance.
with glue. Gradually push with a hammer handle,
Inspection
while turning crankshaft, until seal is rolled into
place. (Similar to installing a main bearing.) Be In general, the lower half of the bearing shows a
careful that seal tangs at parting line do not cut greater wear and the most distress from fatigue. If upon
bead on back of seal. inspection the lower half is suitable for use, it can
safely be assumed that the upper half is also satis-
6. Install the rear main bearing cap (with new seal)
factory. If the lower half shows evidence of wear or
and torque to specifications.
damage, both upper and lower halves should be replaced.
MAIN BEARINGS Never replace one half without replacing the other half.
Main bearings are of the precision insert type and do
not utilize shims for adjustment. If clearances are found Checking Clearance
to be excessive a new bearing, both upper and lower To obtain the most accurate results with Plastigage,
halves, will be required. Bearings are available in (or its equivalent) a wax-like plastic material which will
standard size and .002" undersize for use with new and compress evenly between the bearing and journal sur-
used standard size crankshafts, and in .010", .020" and faces without damaging either surface, certain pre-
.030" undersize for use with reconditioned crankshafts. cautions should be observed. If the engine is out of the
In production, the use of undersize main bearings is vehicle and upside down, the crankshaft will rest on
limited to .001" undersize bearing halves as required the upper bearings and the total clearance can be
to obtain specified clearance between the crankshaft measured between the lower bearing and journal. If the
journal and case bore. The use of .001 undersize bearing engine is to remain in the vehicle, the crankshaft should
halves in production does not affect the service procedure be supported both front and rear (balancer and flywheel)
outlined. to remove the clearance from the upper bearing. The
NOTE: If, for any reason, main bearing caps total clearance can then be measured between the lower
bearing and journal.

Fig. 24V-lnstalling Oil Seal (Cover Installed) Fig. 26V-Removing Oil Seal (Lower Half)

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-38

is a graduated scale which is correlated in thou-


sandths of an inch.
5. Without removing the gauging plastic measure its
compressed width (at the widest point) with the
graduations on the gauging plastic envelope (fig.
29V).
NOTE: Normally, main bearing journals wear
evenly and are not out-of-round. However, if a
bearing is being fitted to an out-of-round
journal, be sure to fit to the maximum diameter
of the journal. If the bearing is fitted to the
minimum diameter and the journal is out-of -
round .001", interference between the bearing
and journal will result in rapid bearing failure.
If the flattened gauging plastic tapers toward
the middle or ends, there is a difference in
clearance indicating a taper, low spot or other
irregularity of the bearing or journal. Be sure
Fig. 27V-Removing Oil Seal (Upper Half)
to measure the journal with a micrometer if the
NOTE: To assure the proper seating of the flattened gauging plastic indicates more than
crankshaft all bearing cap bolts should be at .001" difference.
their specified torque. In addition, preparatory 6. If the bearing clearance is within specifications, the
to checking fit of bearings, the surface of the bearing insert is satisfactory. If the clearance is
crankshaft journal and bearing should be wiped not within specifications, replace the insert. Always
clean of oil. replace both upper and lower insert as a unit.
NOTE: If a new bearing cap is being installed
1. With the oil pan and oil pump removed, and starting and clearance is less than .001", inspect for
with the rear main bearing, remove bearing cap burrs or nicks; if none are found then install
and wipe oil from journal and bearing cap. shims as required.
2. Place a piece of gauging plastic the full width of the 7. A .002" undersize bearing may produce the proper
bearing (parallel to the crankshaft) on the journal clearance. If not, it will be necessary to regrind
(fig. 28V). the crankshaft journal for use with the next under-
CAUTION: Do not rotate the crankshaft while size bearing.
the gauging plastic is between the bearing and 8. Proceed to the next bearing. After all bearings have
journal. been checked rotate the crankshaft to see that there
is no excessive drag.
3. Install the bearing cap and evenly torque the re- 9. Measure crankshaft end play (see specifications) by
taining bolts to specifications. forcing the crankshaft to the extreme front position.
4. Remove bearing cap. The flattened gauging plastic Measure at the front end of the rear main bearing
will be found adhering to either the bearing shell or with a feeler gauge (fig. 30V).
journal. On the edge of gauging plastic envelope there 10. Install a new rear main bearing oil seal in the cyl-
inder block and main bearing cap.
Replacement
NOTE: Main bearings may be replaced with or
without removing the crankshaft.

Fig. 28V—Gauging Plastic on Journal Fig. 29V—Measuring Gauging Plastic

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-39

With Crankshaft Removal


1. Remove and inspect the crankshaft.
2. Remove the main bearings from the cylinder block
and main bearing caps.
3. Coat bearing surfaces of new, correct size, main
bearings with oil and install in the cylinder block
and main bearing caps.
4. Install the crankshaft.
Without Crankshaft Removal
1. With oil pan, oil pump and spark plugs removed.
2. Remove cap on main bearing requiring replacement
and remove bearing from cap.
3. Install a main bearing removing and installing tool
in oil hole in crankshaft journal.
NOTE: If such a tool is not available, a cotter
pin may be bent as required to do the job.
4. Rotate the crankshaft clockwise as viewed from the
front of engine. This will roll upper bearing out of Fig. 31V—Gauging Plastic on Crankpin (Typical)
block.
5. Oil new selected size upper bearing and insert plain maximum diameter of the crankpin to determine
(unnotched) end between crankshaft and indented or new bearing size required.
notched side of block. Rotate the bearing into place 5. If within specifications measure new or used bearing
and remove tool from oil hole in crankshaft journal. clearances with Plastigage or its equivalent.
6. Oil new lower bearing and install in bearing cap.
7. Torque main bearing cap to specifications. NOTE: If a bearing is being fitted to an out-of-
CONNECTING ROD BEARINGS round crankpin, be sure to fit to the maximum
diameter of the crankpin. If the bearing is fitted
Connecting rod bearings are of the precision insert to the minimum diameter and the crankpin is
type and do not utilize shims for adjustment. DO NOT out-of-round .001", interference between the
FILE RODS OR ROD CAPS. If clearances are found to bearing and crankpin will result in rapid bearing
be excessive a new bearing will be required. Bearings failure.
are available in standard size and .001" and .002" under-
size for use with new and used standard size crankshafts, a. Place a piece of gauging plastic the full width of
and in .010" and .020" undersize for use with recon- the crankpin (parallel to the crankshaft) (fig.
ditioned crankshafts. 31V).
b. Install the bearing in the connecting rod and cap.
Inspection and Replacement c. Install the bearing cap and evenly torque to
1. With oil pan and oil pump removed, remove the specifications.
connecting rod cap and bearing. CAUTION: Do not turn the crankshaft with the
2. Inspect the bearing for evidence of wear or damage. gauging plastic installed.
(Bearings showing the above should not be installed.)
3. Wipe the bearings and crankpin clean of oil. d. Remove the bearing cap and using the scale on
4. Measure the crankpin for out-of-round or taper with the gauging plastic envelope, measure the gauging
a micrometer. If not within specifications replace plastic width at the widest point (fig. 32V).
or recondition the crankshaft. If within specifications 6. If the clearance exceeds specifications select a new,
and a new bearing is to be installed, measure the correct size, bearing and remeasure the clearance.
7. Coat the bearing surface with oil, install the rod
cap and torque to specifications.
8. When all connecting rod bearings have been installed
tap each rod lightly (parallel to the crankpin) to
make sure they have clearance.
9. Measure all connecting rod side clearances (see
specifications) between the connecting rods (fig.
33V).
CONNECTING ROD AND PISTON ASSEMBLIES
Removal
1. With oil pan, oil pump and cylinder head removed,
use a ridge reamer to remove any ridge and/or
deposits from the upper end of the cylinder bore.
NOTE: Before ridge and/or deposits are re-
moved, turn crankshaft until piston is at the
bottom of stroke and place a cloth on top of
Fig. 30V—Measuring Crankshaft End Play piston to collect the cuttings. After ridge and/or

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-40

NOTE: If connecting rod bearings are being


reused, place them in a rack so they may be
reinstalled in their original rod and cap.
2. Remove piston rings by expanding them and sliding
them off the pistons. Tool J-8021 and Tool J-8032
are available for this purpose.
3. Place connecting rod and piston assembly in an
arbor press with piston on support (J-9510-1) and
using remover (J-9510-3), press piston pin out of
connecting rod and piston (fig. 35V).
4. Remove assembly from arbor press and remove
Tools J-9510-1, J-9510-3 and piston pin, connecting
rod and piston.
Cleaning and Inspection
Connecting Rods
Wash connecting rods in cleaning solvent and dry with
compressed air.
Check for twisted or bent rods and inspect for nicks
or cracks. Replace connecting rods that are damaged.
Pistons
Clean varnish from piston skirts and pins with a
cleaning solvent. DO NOT WIRE BRUSH ANY PART
Fig. 32V—Measuring Gauging Plastic OF THE PISTON. Clean the ring grooves with a groove
cleaner and make sure oil ring holes and slots are clean.
deposits are removed, turn crankshaft until Inspect the piston for cracked ring lands, skirts or
piston is at top of stroke and remove cloth and pin bosses, wavy worn ring lands, scuffed or damaged
cuttings. skirts, eroded areas at top of the piston. Replace pistons
2. Inspect connecting rods and connecting rod caps for that are damaged or show signs of excessive wear.
cylinder identification. If necessary mark them. Inspect the grooves for nicks or burrs that might cause
3. Remove connecting rod cap and install Tool J-6305 the rings to hang up.
on studs. Push connecting rod and piston assembly
Piston Pins
out of top of cylinder block (fig. 34V).
The piston pin clearance is designed to maintain ade-
NOTE: It will be necessary to turn the crank- quate clearance under all engine operating conditions.
shaft slightly to disconnect some of the con- Because of this, the piston and piston pin are a matched
necting rod and piston assemblies and push set and not serviced separately.
them out of the cylinder. Inspect piston pin bores and piston pins for wear.
Disassembly Piston pin bores and piston pins must be free of varnish
1. Remove connecting rod bearings from connecting or scuffing when being measured. The piston pin should
rods and caps. be measured with a micrometer and the piston pin bore
should be measured with a dial bore gauge or an inside

Fig. 33V—Measuring Connecting Rod Side Clearance Fig. 34V—Removing Connecting Rod and Piston Assemblies

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-41

micrometer. If clearance is in excess of specifications


and the .001" wear limit, the piston and piston pin as-
sembly should be replaced.
Assembly (Fig. 36V) REMOVER AND
1. Lubricate piston pin holes in piston and connecting INSTALLER
rod to facilitate installation of pin.
2. Position connecting rod in its respective piston so
that flange or heavy side of rod at the bearing end
will be towards front of piston (cast depression in
top of piston head) on 1, 3, 5 and 7 pistons, and the
rod flange to the rear of the piston on 2, 4, 6 and 8
pistons.
3. Place support (J-9510-1) with spring and pilot
(J-9510-2) in place on an arbor press.
4. Place piston on support, indexing pilot through piston
and rod.
5. Place installer (J-9510-3) on piston pin, start piston
pin into piston and press on installer until pilot
bottoms in support.
6. Remove installer from connecting rod and piston as-
sembly and check piston for freedom of movement
on piston pin.
Piston Rings
All compression rings are marked in the upper side
of the ring. When installing compression rings, make
sure the marked side is toward the top of the piston. The
top ring is chromed for maximum life.
The oil control rings used are of the three piece type,
consisting of two segments (rails) and a spacer.
Chevrolet piston rings are furnished in standard sizes
as well as .020", .030" and (.040" 283 only) oversizes.
SUPPORT
1. Select rings comparable in size to the piston being
used.
2. Slip the compression ring in the cylinder bore; then

Fig. 36V—Piston Pin and Tool Layout

using the head of a piston, press the ring down into


the cylinder bore about two inches.
NOTE: Using a piston in this way will place
the ring square with the cylinder walls.

Fig. 35V—Removing Piston Rod Fig. 37V—Measuring Ring Gap

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-42

11. Proper clearance of the piston ring in its groove


is very important to provide proper ring action and
reduce wear. Therefore, when fitting new rings,
the clearances between the top and bottom surfaces
of the ring grooves should be measured (fig. 39V).
(See specifications.)
Installation
NOTE: Be sure to install new pistons in the
same cylinders for which they were fitted, and
used pistons in the same cylinder from which
they were removed.
Each connecting rod and bearing cap should be marked
1, 3, 5 and 7 in the left bank and 2, 4, 6 and 8 in the right
bank, beginning at the front of the engine. The numbers
on the connecting rod and bearing cap must be on the
same side when installed in the cylinder bore. If a con-
necting rod is ever transposed from one block or cylinder
to another, new bearings should be fitted and the con-
necting rod should be numbered to correspond with the
Fig. 38V—Checking Ring in Groove
new cylinder number.
NOTE: Cylinder bores must be clean before
3. Measure the space or gap between the ends of the piston installation. This may be accomplished
ring with a feeler gauge (fig. 37V). with a hot water and detergent wash or with a
4. If the gap between the ends of the ring is below light honing as necessary. After cleaning, the
specifications (see specifications), remove the ring bores should be swabbed several times with
and try another for fit. light engine oil and a clean cloth and then wiped
5. Fit each compression ring separately to the cylinder with a clean dry cloth.
in which it is going to be used.
6. If the pistons have not been cleaned and inspected 1. Lubricate connecting rod bearings and install in
as previously outlined, do so. rods and rod caps.
7. Install the oil ring spacer in oil ring groove and 2. Lightly coat pistons, rings and cylinder walls with
position gap so when piston is installed gap will be light engine oil.
in line with engine bottom. (Anti-rotation tang will 3. With bearing caps removed, install Tool J-6305 on
lock in oil slot.) Hold spacer ends butted and install connecting rod bolts.
steel rail on lower side of spacer. Position gap so CAUTION: Be sure ring gaps are properly
when piston is installed gap will be in line with positioned as previously outlined.
engine top, 45° from piston pin hole, then install
second rail on upper side of spacer. Position gap
so when piston is installed, gap will be in line with
engine top 90° from lower rail.
8. Flex the oil ring assembly in its groove to make
sure ring is free and does not bind in the groove
at any point. If binding occurs, the cause should be
determined and removed by carefully dressing with
a fine cut file. However, if the binding is caused
by a distorted ring, install a new ring.
9. Slip the outer surface of the second compression
ring into the piston ring groove and roll the ring
entirely around the groove to make sure that the
ring is free and does not bind in the groove at any
point (fig. 38V). If binding occurs, the cause should
be determined and removed by carefully dressing
with a fine cut file. However, if the binding is
caused by a distorted ring, check a new ring. Repeat
step seven with the top compression ring. Install
ring expander, then install ring and position gap
so when piston is installed gap will be in line with
engine top 45° from piston pin hole.
NOTE: Tools J-8021 and J-8032 are available
for installing rings.
10. Repeat step seven with the top compression ring
(no expander) and position ring gap 90° from second
compression ring. Fig. 39V—Measuring Ring Groove Clearance

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-43

4. Install each piston in its respective bore, using Tool


J-6305 on each assembly. The side of the piston
with the cast depression in the head should be to the
front of the cylinder block. Use Tool J-8307 to
compress the rings for installation (fig. 40V).
NOTE: Use a hammer handle and light blows
to install the piston into the bore. Hold the
ring compressor firmly against the cylinder
block until all piston rings have entered the
cylinder bore.
5. Guide the connecting rod bearing into place on the
crankshaft journals with Tool J-6305-2 Connecting
Rod Guide Set.
6. Install the bearing caps and torque to specifications.
NOTE: If bearing replacement is required refer
to "Connecting Rod Bearings".

CRANKSHAFT
The crankshaft can be replaced while the engine is
disassembled for overhaul, or without complete
disassembly.
Removal
1. With the engine removed from the vehicle and the
transmission and/or clutch housing removed from Fig. 41V—Removing Crankshaft Sprocket
the engine, mount engine in overhaul stand and
clamp securely. 10. Remove main bearing caps and lift crankshaft out
2. Remove the oil dip stick and oil dip stick tube. of cylinder block.
3. Remove the starting motor, clutch assembly (if 11. Remove rear main bearing oil seal and main bear-
equipped) and flywheel. ings from cylinder block and main bearing caps.
4. Remove the spark plugs. 12. Remove crankshaft sprocket using Tool J-5825 (fig.
5. Remove crankshaft pulley and hub or harmonic 41V).
balancer. Cleaning and Inspection
6. Remove oil pan and oil pump.
1. Wash crankshaft in solvent and dry with compressed
7. Remove crankcase front end cover, timing chain and
air.
camshaft sprocket.
8. Check the connecting rod caps for cylinder number 2. Measure dimensions of main bearing journals and
identification. If necessary mark them. crankpin with a micrometer for out-of-round, taper
9. Remove the connecting rod caps and push the pistons or undersize (see specifications).
3. Check crankshaft for run-out by supporting at the
to top of bores.
front and rear main bearing journals in "V" blocks
and check at the front and rear intermediate journals
with a dial indicator (see specifications).
4. Replace or recondition the crankshaft if out of
specifications.
Installation
1. Install the crankshaft sprocket using Tool J-5590
(fig. 42V).
2. Lubricate and install main bearings and a new rear
main bearing oil seal in cylinder block and main
bearing caps. Main bearing halves with the oil holes
are the upper halves and are installed in the cylinder
block.
NOTE: Whenever a new or reconditioned crank-
shaft is installed, new connecting rod bearings
and main bearings of the correct size should
be installed.
3. Install crankshaft in block being careful not to
damage bearing surfaces.
NOTE: Main bearing caps are marked with an
arrow for identification purposes. The caps are
installed with arrows pointing toward the front
Fig. 40V—Installing Connecting Rod and Piston Assemblies of engine.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-44

a. Install the timing chain, camshaft sprocket and


crankcase front end cover.
b. Install the oil pump, oil pan, and oil dip stick,
c. Install the harmonic balancer or crankshaft hub
and pulley.
d. Install spark plugs, starting motor and clutch
assembly.
FLYWHEEL
Removal
With transmission and/or clutch housing and clutch
removed from engine, remove the flywheel.
Installation
1. Clean the mating surfaces of flywheel and crankshaft
to make certain there are no burrs.
2. Install flywheel on crankshaft and position to align
dowel hole of crankshaft flange and flywheel (fig.
43V).
Fig. 42V—Installing Crankshaft Sprocket
NOTE: On Powerglide equipped engines, the
4. Install all main bearing caps and torque all except flywheel must be installed with the flange collar
the rear to specifications. When tightening the rear to transmission side (fig. 44V).
main bearing cap, torque bolts 10-12 ft. lbs. first, CAMSHAFT
then tap end of crankshaft rearward, with a lead
hammer, (this will locate bearing cap and bearing). Measuring Lobe Lift at Push Rod
Refer To Figure 45V
Then tap end of crankshaft forward (this will line
up upper and lower crankshaft thrust surfaces). NOTE: Procedure is similar to that used for
Proceed with final torquing of all main bearing checking valve timing. If improper valve oper-
caps to specifications. ation is indicated, measure the lift of each push
5. Measure crankshaft end play by forcing the crank- rod in consecutive order and record the
shaft to the extreme front position. Measure at the readings.
front end of rear main bearing with a feeler gauge
(see specifications) (fig. 30V).
6. Lubricate connecting rod bearings and install in
connecting rods and connecting rod caps. CONVERTER RING GEAR
7. Install the connecting rod caps and torque to BOLT AREA
specifications. DEPRESSED
8. Measure connecting rod side clearances (see speci-
fications) (fig. 33V).
9. Install the flywheel as outlined in this section.
10. Install the following as outlined in the Service
Manual:

WELDS

TRANS.
4 ENGINE
Fig. 43V-Flywheel Installation Fig. 44V—Powerglide Flywheel Installation

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-45

Remove valve rocker covers and gaskets.


Remove rocker arm nuts, balls and rocker arms.
BEARING JOURNALS
Attach Tool J-8520 to stud.
Position clamp on Tool J-8520.
Position indicator with ball socket adapter on Tool
J-8520 to push rod.
NOTE: Make sure push rod is in the lifter
socket. FUEL PUMP DRIVE DISTRIBUTOR
ECCENTRIC DRIVE GEAR
Rotate the crankshaft balancer slowly in the direc-
tion of rotation until the lifter is on the heel of the
cam lobe. At this point, the push rod will be in its
lowest position. Fig. 46V—Checking Camshaft Alignment
7. Set dial indicator on zero, then rotate the balancer
slowly, or attach an auxiliary starter switch and evidence of wear or damage. (Bearings showing the above
"bump" the engine over, until the push rod is in the should be replaced).
fully raised position. Removal
CAUTION: The primary distributor lead must Camshaft bearings can be replaced while engine is
be disconnected from the negative post on the disassembled for overhaul, or without complete disas-
coil and the ignition switch must be in the on sembly of the engine. To replace bearings without com-
position. Failure to do this will result in a plete disassembly remove the camshaft and crankshaft,
damaged grounding circuit in the ignition switch. leaving cylinder heads attached and pistons in place.
Before removing crankshaft, tape threads of connecting
8. Compare the total lift recorded from the dial indi- rod bolts to prevent damage to crankshaft. Fasten con-
cator Tool J-8520 with specifications. necting rods against sides of engine so they will not be in
9. Continue to rotate the engine until the indicator reads way while replacing camshaft bearings.
zero. This will be a check on the accuracy of the 1. With camshaft and crankshaft removed, drive cam-
original indicator reading. shaft rear plug from cylinder block.
10. If camshaft readings for all lobes are within speci-
NOTE: This procedure is based on removal of
fications, remove dial indicator assembly Tool
the bearings nearest center of the engine first.
J-8520 from cylinder head stud.
11. Install all push rods, valve rocker arms, and balls.
With this method a minimum amount of turns
are necessary to remove all bearings.
Adjust valves as outlined in the Service Manual.
12. Replace valve rocker covers and gaskets. 2. Using Tool Set J-6098, with nut (J-6098-5) then
Inspection thrust washer installed to end of threads, index
The camshaft bearing journals should be measured with pilot in front camshaft bearing .and install puller
a micrometer for an out-of-round condition. If the screw through pilot.
journals exceed .001" out-of-round, the camshaft should 3. Install Tool J-6098-1 with shoulder toward number
be replaced. three bearing, making sure a sufficient amount of
The camshaft should also be checked for alignment. threads are engaged.
The best method is by use of "V" blocks and a dial 4. Using two wrenches, hold puller screw while turning
indicator (fig. 46V). The dial indicator will indicate the nut (J-6098-5). When bearing has been pulled from
exact amount the camshaft is out of true. If it is out bore, remove Tool J-6098-1 and bearing from puller
more than .002" dial indicator reading, the camshaft screw.
should be replaced. 5. Reinstall Tool J-6098-1 on puller screw with
shoulder toward number two bearing and pull
CAMSHAFT BEARINGS bearing. When bearing has been pulled from bore,
Inspection remove Tool J-6098-1 and bearing from puller
With the camshaft removed, inspect the bearings for screw and remove puller screw and pilot from
cylinder block.
6. Index pilot in rear camshaft bearing and install
puller screw through pilot.
7. Install Tool J-6098-1 with shoulder toward number
four bearing and pull bearing. When bearing has
been pulled from bore, remove Tool J-6098-1 and
bearing from puller screw and remove puller screw
and pilot from cylinder block.
8. Assemble Tool J-6098-1 on driver handle (J-6098-4)
and remove front and rear camshaft bearings by
driving towards center of cylinder block.
Installation
Refer To Figure 47V and 48V
The front and rear camshaft bearings should be in-
stalled first. These bearings will act as guides for the
pilot and center the remaining bearings being pulled into
Fig. 45V-Measuring Camshaft Lobe Lift place.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-46

install Tool J-6098-1 on puller screw with shoulder


toward bearing.
4. Using two wrenches, hold puller screw while turning
nut (J-6098-5). When bearing has been pulled into
bore, remove Tool J-6098-1 from puller screw and
check alignment of oil hole in camshaft bearing.
Index number two camshaft bearing in bore, reinstall
Tool J-6098-1 on puller screw and pull bearing into
bore.
6. Remove Tool J-6098-1 from puller screw, remove
puller screw and pilot from cylinder block and check
alignment of oil hole in camshaft bearing.
7. Index pilot in rear camshaft bearing and install
puller screw through pilot.
8. Index number four camshaft bearing in bore, rein-
stall Tool J-6098-1 on puller screw and pull bearing
into bore.
9. Remove Tool J-6098-1 from puller screw, remove
puller screw and pilot from cylinder block and check
alignment of oil hole in camshaft bearing.
10. Install a new camshaft rear plug.
NOTE: Plug should be installed flush to 1/32"
Fig. 47V—Replacing No. 4 Camshaft Bearing deep and be parallel with rear surface of cyl-
inder block.
1. Assemble Tool J-6098-1 on driver handle (J-6098-4) CYLINDER BLOCK
and install front and rear camshaft bearings by Inspection
driving towards center of cylinder block. 1. Inspect the cylinder block for cracks in the cylinder
CAUTION: Oil holes in bearings must line up walls, water jacket valve lifter bores and main
with oil holes in cylinder blockT bearing webs.
2. Measure the cylinder walls for taper, out-of-round
2. Using Tool Set J-6098, with nut (J-6098-5) then
or excessive ridge at top of ring travel. This should
thrust washer installed to end of threads, index pilot
be done with a dial indicator. Set the gauge so that
in front camshaft bearing and install puller screw
the thrust pin must be forced in about 1/4" to enter
through pilot.
gauge in cylinder bore. Center gauge in cylinder and
3. Index number three camshaft bearing in bore, then turn dial to "O". Carefully work gauge up and down
cylinder to determine taper and turn it to different
points around cylinder wall to determine the out-of -
round condition. If cylinders were found to exceed
specifications honing or boring will be necessary
(fig. 49V).
Repairs
Cylinder Conditioning
The performance of the following operation is contin-
gent upon engine condition at time of repair.

Fig. 48V—Replacing Rear Camshaft Bearing Fig. 49V—Measuring Cylinder Bores

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-47

If the cylinder block inspection indicated that the block BASE PISTON MARKING
was suitable for continued use except for out-of-round or CYLINDER * * |S4|S5|S6|S7|
tapered cylinders, they can be conditioned by honing or DIAMETER *
•|S5|S6|S7k-EXAMPLE " A " 1 i 2|3
boring. 283 CU. IN. 1 1
Hi
If the cylinders were found to have less than .005" 020
taper or wear they can be conditioned with a hone and
3.8745"
327 CU. IN.
BASE
DIA 1 §
CN
S 3 S
o o o OS
- ' CN

q
CN
CN
q
fitted with the high limit standard size pistons. A cyl- 3.9995"
CYLINDER OVERSIZE
inder bore of less than .005" wear or taper may not 195 H.P. PISTON MARKING
entirely clean up when fitted to a high limit piston. If it 250 H.P. | * * 1 1 2 3 4
is desired to entirely clean up the bore in these cases, 2 | 3 EXAMPLE " B " EL 2 | 3
it will be necessary to rebore for an oversize piston. 350 H.P. ! 1 1
CN CO ^ U">
If more than .005" taper or wear, they should be bored 365 P.P. .030" CO CO CO CO CO
nAn
0 4 0
CN

and honed to the smallest oversize that will permit O.S. q O -q 3


.040'-'.041".042 q q q O.S.
complete resurfacing of all cylinders. 283 ONLY
CYLINDER OVERSIZE
Cylinder Boring
1. Before using any type boring bar, the top of the cyl-
Fig. 51V—Piston Selection Chart
inder block should be filed off to remove any dirt or
burrs. This is very important. Otherwise, the boring size identification is marked, in ink, on the
bar may be tilted which would result in the rebored piston top.
cylinder wall not being at right angles to the
crankshaft. 4. To determine the correct size of piston needed,
2. The piston to be fitted should be measured with a measure the cylinder bore with a telescope gauge
micrometer, measuring at the center of the piston and subtract the base cylinder bore diameter from
skirt and at right angles to the piston pin. The cyl- the measured diameter, then locate this dimension
inder should be bored to the same diameter as the on the Piston Selection Chart (fig. 51V). The number
piston and honed to give the specified clearance. shown on the chart in the box above the dimension is
NOTE: Hone cylinders as outlined under "Cyl- the marking on the piston which should be used.
inder Honing and Piston Fitting''. EXAMPLE "A":
3. The instructions furnished by the manufacturer of
the equipment being used should be carefully Cylinder bore measurement 3.8775 Worn standard
followed. bore
Cylinder Honing and Piston Selection
Base cylinder bore diameter 3.8745 283 cu. in. engine
1. When pistons are being fitted and honing is not Difference .0030
necessary cylinder bores may be cleaned with a hot Number on Chart S7 Standard piston
water and detergent wash. After cleaning, the bores (+.003") marked
should be swabbed several times with light engine S7
oil and a clean cloth and then wiped with a clean dry EXAMPLE " B " :
cloth.
2. When cylinders are to be honed follow the hone Cylinder bore measurement 3.9065 Rebored bore
manufacturer's recommendations for the use of the Base cylinder bore diameter 3.8745 283 cu. in. engine
hone and cleaning and lubrication during honing. Difference .032
3. Occasionally during the honing operation, the cyl- Number on chart 4 .030 oversize
inder bore should be thoroughly cleaned and the (+.002") marked 4
piston selected for the individual cylinder checked 5. Permanently mark the piston for the cylinder to
for correct fit. which it has been fitted and proceed to hone cylinders
When finish honing a cylinder bore to fit a piston, and fit the remaining pistons.
the hone should be moved up and down at a sufficient
speed to obtain very fine uniform surface finish CAUTION: Handle the pistons with care and do
marks in a cross-hatch pattern of approximately not attempt to force them through the cylinder
45° to 65° included angle. The finish marks should until the cylinder has been honed to correct size
be clean but not sharp, free from imbedded particles as this type piston can be distorted through
careless handling.
and torn or folded metal (fig. 50V).
NOTE: Replacement pistons are available in a 6. Thoroughly clean the cylinder bores with hot water
range of four standard sizes and four each .020", and detergent. Scrub well with a stiff bristle brush
.030" and on 283 only .040", oversize and the and rinse thoroughly with hot water. It is extremely
essential that a good cleaning operation be per-
formed. If any of the abrasive material is allowed
to remain in the cylinder bores in addition to the
bearings lubricated by the contaminated oil. The
bores should be swabbed several times with light
engine oil and a clean cloth and then wiped with a
%
'• --.--- , ;--,,..~^ -;/"•"•*? '-£?*•'?». >-v. "** ^ '"-r^ clean dry cloth. Cylinders should not be cleaned
with kerosene or gasoline. Clean the remainder of
the cylinder block to remove the excess material
Fig. 50V-CyUnder Finish Marks spread during the honing operation.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-48

V-8 ENGINES
(409 CU. IN.)
INDEX
Page Page
General Description 6-48 Inspection 6-59
Repair Procedures 6-48 Checking Clearances 6-59
Engine Assemblies 6-48 Replacement 6-60
Disassembly 6-48 With Crankshaft Removal 6-60
Cleaning and Inspection 6-50 Without Crankshaft Removal 6-60
Assembly 6-50 Connecting Rod Bearings 6-61
Cylinder Head Assemblies 6-50 Inspection and Replacement 6-61
Disassembly 6-50 Connecting Rod and Piston Assemblies 6-61
Cleaning 6-50 Removal 6-61
Inspection 6-51 Disassembly 6-62
Repairs 6-52 Cleaning and Inspection 6-62
Valve Guide Bores 6-52 Connecting Rods 6-62
Rocker Arm Studs 6-52 Pistons 6-62
Valve Seats 6-52 Piston Pins 6-62
Valves 6-53 Assembly 6-63
Assembly 6-54 Piston Rings . 6-63
Valve Stem Oil Seal 6-54 Installation 6-64
Replacement 6-54 Crankshaft 6-65
Valve Lifters (Hydraulic) 6-55 Removal 6_65
Disassembly 6-56 Cleaning and Inspection 6-65
Cleaning and Inspection 6-56 Installation 6-65
Assembly 6-56 Flywheel 6 -66
Valve Lifters (Mechanical) 6_ 57 Removal 6-66
Cleaning and Inspection 6-57 Installation 6-66
Oil Pump 6_57 Camshaft 6_66
Disassembly 6-57 Measuring Lobe Lift at Push Rod 6-66
Cleaning and Inspection 6-57 Inspection 6-67
Assembly 6-58 Camshaft Bearings 6-67
Oil Filter By-Pass Valve 6-58 Inspection 6-67
Inspection and Replacement 6-58 Removal 6-67
Oil Seal — Crankcase Front Cover 6-58 Installation 6-68
Replacement 6-58 Cylinder Block 6-68
With Cover Removal 6-58 Inspection 6-68
Without Cover Removal 6-58 Repairs 6-68
Oil Seal — Rear Main Bearing 6-58 Cylinder Conditioning 6-68
Replacement 6-58 Cylinder Boring 6-68
Main Bearings 6-59 Cylinder Honing and Piston Selection 6-69

GENERAL DESCRIPTION
The V-8, over head valve, engines covered in this Full pressure lubrication, through a full flow oil filter,
section are the 409 cu. in. engines used in the Chevrolet is furnished by a gear-type oil pump. The distributor,
passenger car vehicle. driven by a helical gear on the camshaft, drives the oil
The cylinders are numbered front to rear, 1-3-5-7 on pump. The main oil gallery feeds oil, through drilled
the left bank and 2-4-6-8 on the right bank. Firing order passages, to the camshaft and crankshaft to lubricate the
is, 1-8-4-3-6-5-7-2. Crankshaft rotation as viewed from bearings. The main oil gallery also feeds the valve
the rear is counter-clockwise. lifters which, through hollow push rods, feed the individ-
The crankshaft has five main bearings and the camshaft ually mounted rocker arms (fig. 1W).
has five bearings.

REPAIR PROCEDURES
ENGINE ASSEMBLIES
4. On engines so equipped; remove power steering
Disassembly pump.
1. With engine removed from the vehicle and trans- 5. Disconnect fuel pump-to-carburetor line and remove
mission and/or clutch housing removed from the fuel pump, then remove mounting plate and pump
engine, mount engine in overhaul stand and clamp push rod from block and discard gaskets.
securely. 6. Disconnect choke rod, fuel lines, spark advance line,
2. Remove engine ground strap, oil dip stick and oil dip and crankcase vent line; then remove carburetor and
stick tube. discard gaskets.
3. Remove Delcotron and mounting bracket as an 7. Remove distributor cap and spark plug wire as-
assembly. sembly, then remove distributor and coil.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-49

DISTRIBUTOR
SHAFT OILING

FUEL PUMP OIL FILTER A N D


PUSH ROD OILING BY-PASS VALVE

Fig. 1W— Engine Lubrication

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-50

8. Remove water pump, water outlet and thermostat 3. Clean and inspect water passages in the cylinder
and discard gaskets. block.
9. Remove intake manifold and exhaust manifolds and 4. Inspect the cylinder block for cracks in the cylinder
discard gaskets and seals. walls, water jacket valve lifter bores and main
10. Remove rocker arm nuts, rocker arms and push bearing webs.
rods, then remove valve lifters. 5. All further cleaning and inspection is outlined under
NOTE: Valve lifters rocker arms, rocker arm the part of sub-assembly being serviced.
balls and push rods should be placed in a rack Assembly
in their proper sequence so they can be in-
stalled in their same positions during build-up. NOTE: Use new gaskets and seals on engine
assembly.
11. Remove cylinder heads and discard gaskets.
12. If necessary remove screw retaining crankcase inner 1. Apply sealer to new oil gallery plugs and install
ventilator body to cylinder block and remove venti- plugs.
lator body from cylinder block. 2. Install the crankshaft, flywheel and oil filter by-pass
CAUTION: Do not damage vent body. valve, as outlined in this section.
3. Install the connecting rod and piston assemblies as
13. Remove starter, clutch housing cover plate, oil filter outlined in this section.
and oil filter by-pass valve and discard seal. 4. Install the following as outlined in the Service
14. Remove oil pan and discard gaskets and seals. Manual.
15. Remove crankshaft pulley and harmonic balancer a. Camshaft, camshaft sprocket, timing chain and
using Tool J-6978. crankcase front end cover.
16. Remove crankcase front end cover and discard b. Oil pump, oil pump shaft extension and oil pan.
gasket. c. Starting motor and oil filter.
17. Remove three camshaft sprocket to camshaft bolts. d. Fuel pump push rod, fuel pump mounting plate and
18. Remove camshaft sprocket and timing chain together. fuel pump.
Sprocket is a light press fit on camshaft for approxi- e. Harmonic balancer and pulley.
mately 1/8". If sprocket does not come off easily, f. Water pump, thermostat and water outlet.
a light blow with plastic-faced hammer on the lower g. Cylinder heads, valve lifters, push rods and
edge of the camshaft sprocket should dislodge the rocker arms.
sprocket. h. Crankcase inner ventilator body, intake manifold
19. Install two bolts, 5/16"-18 x 4" in two camshaft and exhaust manifolds,
bolt holes. Remove camshaft from engine. i. Carburetor, crankcase vent line, spark advance
CAUTION: AH camshaft journals are the same line, fuel line and choke rod.
diameter and caution must be used in removing j . Distributor, coil, distributor cap and spark plug
camshaft to avoid damage to bearings. wire assembly.
k. On engines so equipped, power steering pump.
20. Remove oil pump and extension shaft. 1. Delcotron and mounting bracket as an assembly,
21. Check the connecting rods and caps for cylinder m. Oil dip stick tube, oil dip stick and ground strap,
number identification and if necessary, mark them. n. Clutch assembly.
22. Remove connecting rod journal bearing caps and in-
stall Tool J- 6305 on studs. Push piston assemblies CYLINDER HEAD ASSEMBLIES
out of top of cylinder block. If piston rings strike
ridge at top of cylinder, remove ridge to prevent Disassembly
damaging piston ring lands. 1. With cylinder head removed, remove valve rocker
NOTE: It will be necessary to turn the crank- arm nuts, ball and rocker arms.
shaft slightly to disconnect some of the rods and 2. Using Tool J-8062, compress the valve springs and
to push them out of the cylinder. remove valve keys (fig. 2W). Release the spring
23. On engines so equipped, loosen clutch to flywheel compressor tool and remove spring caps, spring
bolts a turn at a time (to prevent distortion of clutch shields, oil seals, springs and spring dampers.
cover) until the diaphragm spring pressure is 3. Remove valves from bottom of cylinder head and
released. Remove cpver assembly and disc. place them in a rack in their proper sequence so they
24. Remove the flywheel. can be assembled in their original positions.
25. Remove main bearing caps and lift crankshaft out of
cylinder block. Remove the main bearings from the Cleaning
cylinder block and main bearing caps. 1. Clean all carbon from combustion chambers and
26. All further disassembly is covered under the part or valve ports using Tool J-8089 (fig. 3W).
sub-assembly being serviced. 2. Thoroughly clean the valve guide bores using Tool
Cleaning and Inspection J-8101 (fig. 4W).
1. Wash cylinder block thoroughly in cleaning solvent 3. Clean all carbon and sludge from push rods and
and clean all gasket surfaces. rocker arms.
2. Remove oil gallery plugs and clean all oil passages. 4. Clean valve stems and heads on a buffing wheel.
NOTE: These plugs may be removed with a 5. Clean carbon deposits from head gasket mating hole
sharp punch or they may be drilled and pried gauge in valve guide bore, measuring at the center.
out. Subtract highest reading of valve stem diameter.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-51

Fig. 2W—Compressing Valve Springs Fig. 4W—Cleaning Valve Guide Bores

Inspection and bottom. Determine the minimum and maxi-


1. Inspect the cylinder head for cracks in the exhaust mum clearances. If clearance is not within
ports, combustion chambers, or external cracks to limits (see specifications) use next oversize
the water chamber. valve and ream valve guide bore.
2. Inspect the valves for burned heads, cracked faces or 4. Check valve spring tension with Tool J-8056 spring
damaged stems. tester (fig. 5W).
3. Check fit of valve stems in their respective bores.
NOTE: Springs should be compressed to the
NOTE: Excessive valve stem to bore clearance specified height and checked against the specifi-
will cause excessive oil consumption and may cations chart. Springs should be replaced if not
cause valve breakage. Insufficient clearance will within 10 lbs. of the specified load without
result in noisy and sticky functioning of the dampers.
valve and disturb engine smoothness.
Valve stem to bore clearance may be checked
by using a micrometer and a suitable telescope
hole gauge. Using a micrometer measure the
diameter of the valve stem in three places, top
center, and bottom. Insert telescope hole gauge
in valve guide bore, measuring at the top center

Fig. 3W—Removing Carbon From Combustion Chambers Fig. 5W—Checking Valve Spring Tension

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-52

Fig. 7W—Removing Rocker Arm Stud

engine to deliver the power and performance built into it.


Another important factor is the cooling of the valve
heads. Good contact between each valve and its seat in
the head is imperative to insure that the heat in the valve
Fig. 6W—Reaming Valve Guide Bores head will be properly carried away.
Several different types of equipment are available for
Repairs reseating valve seats. The recommendations of the
manufacturer of the equipment being used should be
Valve Guide Bores carefully followed to attain proper results.
Valves with oversize stems are available (see specifi- Regardless of what type of equipment is used, however,
cations). To ream the valve guide bores for oversize it is essential that valve guide bores be free from carbon
valves use Tool set J-7910 (fig. 6W). or dirt to insure proper centering of pilot in the guide.
Rocker Arm Studs
Rocker arm. studs that have damaged threads or are
loose in cylinder heads should be replaced with new studs
available in .003" and .013" oversize. Studs may be
installed after reaming the holes as follows:
NOTE: On engines with mechanical lifters the
rocker arm studs are locked to the head and
retaining pin must be removed before stud can
be removed. After installation the retaining pin
must be removed before stud can be removed.
After installation the retaining pin must be
installed.
1. Remove old stud by placing Tool J-5802-1 over the
stud, installing -nut and flat washer and removing
stud by turning nut (fig. 7W).
2. Ream hole for oversize stud using Tool J-5715 for
.003" oversize and Tool J-6036 for .013" oversize
(fig. 8W)
CAUTION: Do not attempt to install an over-
size stud without reaming stud hole.
3. Coat press-fit area of stud with hypoid axle lubri-
cant. Install new stud, using Tool J- 6880 as a guide.
Gauge should bottom on head (fig. 9W).
Valve Seats
Reconditioning the valve seats is very important, be-
cause the seating of the valves must be perfect for the Fig. 8W—Reaming Rocker Arm Stud Hole

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-53

NOTE: This operation is done by grinding the


port side with a 30° stone to lower seat and a
60° stone to raise seat.
5. Remove expanding pilot and clean cylinder head
carefully to remove all chips and grindings from
above operations.
6. Measure valve concentricity (fig. 10W).
NOTE: Valve seats should be concentric to
within .002" total indicator reading.
Valves
Valves that are pitted can be refaced to the proper
angle, insuring correct relation between the head and
stem on a valve refacing machine. Valve stems which
show excessive wear, or valves that are warped exces-
sively should be replaced. When a valve head which is
warped excessively is refaced, a knife edge will be
ground on part or all of the valve head due to the amount
of metal that must be removed to completely reface.
Knife edges lead to breakage, burning or pre-ignition due
to heat localizing on this knife edge. If the edge of the
valve head is less than 1/32" thick after grinding, replace
the valve.
Fig. 9W-lnstalling Rocker Arm Stud
Several different types of equipment are available for
refacing valves. The recommendations of the manu-
1. Install expanding pilot in the valve guide bore and facturer of the equipment being used should be carefully
expand pilot by tightening nut on top of pilot. followed to attain proper results.
2. Place roughing stone or forming stone over pilot and 1. If necessary, dress the valve refacing machine
just clean up the valve seat. Use a stone cut to 46°. grinding wheel to make sure it is smooth and true. Set
3. Remove roughing stone or forming stone from pilot, chuck at 45° mark for grinding valves (fig. 11W).
place finishing stone, cut to 46°, over pilot and cut 2. Clamp the valve stem in the chuck of the machine.
just enough metal from the seat to provide a smooth 3. Start the grinder and move the valve head out in line
finish. with the grinder wheel by moving the lever to the
4. Narrow down the valve seats to the specified width left.
(see specifications). 4. Turn the feed screw until the valve head just contacts
wheel. Move valve back and forth across the wheel
and regulate the feed screw to provide light valve
contact.
5. Continue grinding until the valve face is true and
smooth all around the valve. If this makes the valve
head thin the valve must be replaced as the valve will
overheat and burn.
6. Remove valve from chuck and place stem in "V"
block. Feed valve squarely against grinding wheel to
grind any pit from rocker arm end of stem.

INTERFERENCE

Fig. 10W—Measuring Valve Seat Concentricity Fig. 11W—Relation of Valve and Seat Angles

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-54

NOTE: Only the extreme end of the valve stem


is hardened to resist wear. Do not grind end of
stem excessively.
After cleaning valve face and cylinder head valve
seat of grinding particles, make pencil marks about
1/4" apart across the valve face, place the valve in
cylinder head and give the valve 1/2 turn in each
direction while exerting firm pressure on head of
valve.
8. Remove valve and check face carefully. If all pencil
marks have not been removed at the point of contact Fig. 13W—Vacuum Cup
with the valve seat, it will be necessary to repeat
the refacing operation and again recheck for proper height, install a valve spring seat shim approxi-
seating. mately 1/16" thick. At no time should the spring be
9. Grind and check the remaining valves in the same shimmed to give an installed height under the mini-
manner. mum specified (fig. 14W).
Assembly
1. Insert.a valve in the proper port.
2. Set the valve spring, and damper assembly, valve
shield and valve cap in place (fig. 12W). The close
coiled end of the spring is installed against the
cylinder head.
3. Compress the spring with Tool J-8062.
4. Install oil seal in the lower groove of the stem,
making sure the seal is flat and not twisted.
5. Install the valve locks and release the compressor
tool, making sure the locks seat properly in the
upper groove of the valve stem.
NOTE: Grease may be used to hold the locks
in place while releasing the compressor tool.
6. Install the remaining valves.
7. Check each valve stem oil seal by placing a vacuum
cup or similar device over the end of the valve stem
and against the cap. Operate the vacuum cup and
make sure no air leaks past the oil seal.
A vacuum cup can be made from a small syringe
and a high voltage shield (fig. 13W). Fig. 14W—Measuring Valve Spring Installed Height
8. Measure the installed height of the valve springs,
using a narrow thin scale. Measure from the top of
the shim or the spring seat to the top of the valve NOTE: If springs and/or seals are to be
spring shield. If this is found to exceed the specified changed with the cylinder head installed, Tool
J-5892 may be used to compress the springs.
Compressed air, through the spark plug hole,
may be used to hold the valves in place.
LOCK
VALVE STEM OIL SEAL
CAP
SEAL Valve stem oil seals can be replaced with the cylinder
SHIELD-^J head installed. On some vehicles equipped with power
SPRIN brakes it may be necessary to remove the power brake
DAMPER unit.
Replacement
1. Remove the valve cover and spark plug on cylinder to
be serviced.
2. Apply compressed air to the spark plug hole to hold
the valves in place.
NOTE: A tool to apply air to the cylinder is
available through local jobbers or may be manu-
factured. In manufacturing this Tool a AC-46N
Spark Plug or its equivalent is recommended.
This will make the Tool universal for all Chev-
rolet engines. Chisel the spark plug as shown,
Fig. 12W— Valve Spring Installation then drive the porcelain out of the plug by

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-55

tapping the center electrode against a hard block. 7. Install the valve locks and release the compressor
Using a 3/8" pipe tap, cut threads in the re- tool, making sure the locks seat properly in the
maining portion of the spark plug and assemble upper groove of the valve stem.
as shown (fig. 15W).
NOTE Grease may be used to hold the locks
in place while releasing the compressor tool.
8. Check valve stem oil seals as outlined under cyl-
inder head assembly and replace valve cover and
spark plug.
VALVE LIFTERS (HYDRAULIC)
Two types of hydraulic lifters are used. Both types
of lifters operate on the same principle and are serviced
basically in the same manner. The complete lifter as-
semblies are interchangeable but parts from one lifter

Fig. 15W-Air Adapted Tool

3. Using Tool J-5892 to compress the valve spring,


remove the valve locks, valve cap, valve shield and
valve spring and damper (fig. 16W).

Fig. 16W—Compressing Valve Spring

Remove the valve stem oil seal.


To replace, set the valve spring and damper, valve
shield and valve cap in place. The close coiled end
of the spring is installed against the cylinder head. Fig. 17W-Hydraulic Valve Lifters
6. Compress the spring with Tool J- 5892 and install oil
seal in the lower groove of the stem, making sure the 1. Lifter Body 5. Check Ball Retainer
seal is flat and not twisted. 2. Push Rod Seat 6. Push Rod Seat Retainer
3. Metering Valve (Lifter A) 7. Plunger
NOTE: A light coat of oil on the seal will help Inertia Valve (Lifter B) 8. Check Ball Spring
prevent twisting. 4. Check Ball 9. Plunger Spring

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-56

are not interchangeable with another. Both lifters are


easily identified by the outside configuration of the lifter
body. For purposes of identification we refer to them as
lifter " A " and lifter " B " (fig. 17W).
Disassembly
1. Hold the plunger down with a push rod, and using the
blade of a small screw driver, remove the push rod
seat retainer.
2. Remove the push rod seat and metering valve (lifter
"A") or the push rod seat and inertia valve assembly
(lifter "B").
3. Remove the plunger, ball check valve assembly and
the plunger spring.
4. Remove the ball check valve and spring by prying the
ball retainer loose from the plunger with the blade of
a small screw driver (fig. 18W).

1 Fig. 19W-lnsralling Ball Check Valve

f ^p. r
- 4. Fill the assembly with SAE 10 oil, then insert the
m end of a 1/8" drift pin into the plunger and press
down solid. At this point oil holes in the lifter body
and plunger assembly will be aligned (fig. 20W).
1 " '$
m m 1
/I /
hi
y
Fig. 18W-Removing Ball Check Valve

Cleaning and Inspection


Thoroughly clean all parts in cleaning solvent, and
inspect them carefully. If any parts are damaged or worn
the entire lifter assembly should be replaced.
NOTE: Inertia valve and retainer (lifter "B")
should not be removed from the push rod seat.
To check the valve, shake the push rod seat and
inertia valve assembly and the valve should
move.
Assembly
1. Place the check ball on small hole in bottom of the
plunger.
2. Insert check ball spring on seat in ball retainer and
place retainer over ball so spring rests on the ball.
Carefully press the retainer into position in plunger
with the blade of a small screw driver (fig. 19W).
3. Place the plunger spring over the ball retainer and
slide the lifter body over the spring and plunger,
being careful to line up the oil feed holes in the lifter
body and plunger. Fig. 20W—Assembling the Hydraulic Lifters

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-57

CAUTION: Do not attempt to force or pump the


plunger.
5. Insert a 1/16" drift pin through both oil holes to hold
the plunger down against the lifter spring tension
(fig. 20W).
NOTE: On lifter " B " , the drift pin must not
extend inside the plunger.
6. Remove the 1/8" drift pin, refill assembly with
SAE 10 oil.
7. Install the metering valve and push rod seat (lifter
"A") or the push rod seat and inertia valve assembly
(lifter "B").
8. Install the push rod seat retainer, press down on the
push rod seat and remove the 1/16" drift pin from
the oil holes. The lifter is now completely as-
sembled, filled with oil and ready for installation.
NOTE: Before installing any new lifters, coat
the bottom of the lifter with Moly Kote or its
equivalent.
Fig. 22W-OII Pump (Exploded View)
VALVE LIFTERS (MECHANICAL)
Cleaning and Inspection 1. Shaft Extension 7. Pressure Regulator Spring
2. Pump Body 8. Pin (Valve Retaining)
The mechanical valve lifter (fig. 21W) should never be 3. Drive Gear and Shaft 9. Screws
disassembled. Wash lifter assembly in cleaning solvent 4. Idler Gear 10. Pin (Pipe Retaining)
and dry with compressed air. Blow out oil holes in lifter 5. Pump Cover 11. Pick-Up Screen and Pipe
body and push rod seat with compressed air. Inspect 6. Pressure Regulator Valve
push rod seat retainer. Inspect lifter for scuffed or
worn lifter body or push rod seat. If the lifter body wall OIL PUMP
is scuffed or worn inspect the cylinder block. If the The oil pump consists of two gears and a pressure
bottom of the lifter is scuffed or worn inspect the cam- regulator (relief) valve enclosed in a two-piece housing.
shaft lobe, if the push rod seat is scuffed or worn inspect The oil pump is driven by the distributor shaft which is
the push rod. All damaged or worn lifters should be driven by a helix gear on the camshaft (fig. 22W).
replaced. A baffle is incorporated on the pick-up screen to
NOTE: Before installing a new lifter, coat eliminate pressure loss due to sudden or surging stops.
the bottom of the lifter with Molykote or its Disassembly
equivalent. 1. With the oil pump removed, remove the pump shaft
extension, the pump cover attaching screws and the
pump cover.
NOTE: Mark gear teeth so they may be reas-
sembled with the same teeth indexing.
2. Remove idler gear and the drive gear and shaft
from the pump body.
3. Remove the pressure regulator valve retaining pin,
pressure regulator valve and related parts from the
pump cover.
4. If the pick-up screen and pipe assembly need re-
placing, mount the pump cover in a soft-jawed vise
and using Tool J-8369, extract pipe from pump
cover.
CAUTION: Do not disturb the pick-up screen
on the pipe. This is serviced as an assembly.
Cleaning and Inspection
1. Wash all parts in cleaning solvent and dry with
compressed air.
2. Inspect the pump body and cover for cracks or
excessive wear.
3. Inspect pump gears for damage or excessive wear.
4. Check the drive gear shaft for looseness in the pump
body.
5. Inspect inside of pump cover for wear that would
Fig. 21W-Mechanical Valve Lifters permit oil to leak past the ends of the gears.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-58

6. Inspect the pick-up screen and pipe assembly for


damage to screen, pipe or relief grommet.
7. Check the pressure regulator valve for fit in the
pump cover.
NOTE: The pump gears to body are a selective
fit. If the pump gears or body are damaged or
worn replacement of the entire oil pump as-
sembly is necessary.
Assembly
1. If the pick-up screen and pipe assembly was re-
moved, mount the pump cover in a soft-jawed vise,
apply sealer to end of pipe, and using Tool J-8369.
tap the pipe in place with a plastic hammer. Tap the
retaining pin in place and stake pin.
CAUTION: Be careful of twisting, shearing or
collapsing pipe, while installing in pump cover.
2. Install the pressure regulator valve and related parts
in the-pump cover.
3. Install the drive gear and shaft in the pump body.
4. Install the idler gear in the pump body with the
smooth side of gear towards pump cover opening.
5. Install the pump cover and torque attaching screws to
specifications.
6. Install pump shaft extension. Fig. 24W—Installing Oil Seal (Cover Removed)

OIL FILTER BY-PASS VALVE with a large screw driver, being careful not to
damage the seal surface on the crankshaft.
Inspection and Replacement 2. Install new seal so that open end of seal is toward the
With the oil filter removed, check the spring and fibre inside of cover and drive it into position with Tool
valve for operation. Inspect for a cracked or broken J-8340 (fig. 25W).
valve. If replacement is necessary, remove valve and
seal, clean valve chamber in cylinder block and install
a new valve with a new seal. Torque bolts to specifica-
tions (fig. 23W).

Fig. 25W-lnstalling Oil Seal (Cover Installed)

OIL SEAL-REAR MAIN BEARING


Fig. 23W-OII Filter By-Pass Valve Replacement
The rear main bearing oil seal can be replaced (both
halves) without removal of the crankshaft (fig. 26W).
OIL SEAL-CRANKCASE FRONT COVER
NOTE: Always replace the upper and lower
Replacement seal as a unit. Install with the lip facing toward
With Cover Removal the front of the engine.
1. With cover removed, pry old seal out of cover from 1. With the oil pan and oil pump removed, remove the
the front with a large screw driver. rear main bearing cap.
2. Install new seal so that open end of the seal is toward 2. Remove oil seal from the groove by prying from the
the inside of cover and drive it into position with bottom with a small screw driver (fig. 27W).
Tool J-995 (fig. 24W). 3. Lubricate the lip of a new seal with engine oil. Keep
CAUTION: Support cover at sealing area. (Tool oil off the parting line surface as this is treated with
J-971 may be used as support.) glue. Insert seal in cap and roll it into place with
finger and thumb, using light pressure so seal tangs
Without Cover Removal at parting line; do not cut bead on back of seal.
1. With crankshaft pulley and hub or harmonic balancer 4. To remove the upper half of the seal, use a small
removed, pry old seal out of cover from the front hammer to tap a brass pin punch on one end of seal

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-59

glue Gradually push with a hammer handle, while


turning crankshaft, until seal is rolled into place.
(Similar to installing a main bearing.) Be careful
that seal tangs at parting line do not cut bead on
back of seal.
6. Install the rear main bearing cap (with new seal) and
torque to specifications.
MAIN BEARINGS
Main bearings are of the precision insert type and do
not utilize shims for adjustment. If clearances are found
to be excessive a new bearing, both upper and lower
halves, will be required. Bearings are available in
standard size and .002" undersize for use with new and
used standard size crankshafts, and in .010", .020" and
.030" undersize for use with reconditioned crankshafts.
In production, the use of undersize main bearings is
limited to .001" undersize bearing halves as required to
obtain specified clearance between the crankshaft journal
and case bore. The use of .001 undersize bearing halves
Fig. 26W—Rear Main Bearing Oil Seal in production does not affect the service procedure
outlined.
NOTE: If, for any reason, main bearing caps
are replaced, shimming may be necessary.
Laminated shims for each cap are available for
service. Shim requirement will be determined
by bearing clearance.
Inspection
In general, the lower half of the bearing shows a
greater wear and the most distress from fatigue. If upon
inspection the lower half is suitable for use, it can
safely be assumed that the upper half is also satisfactory.
If the lower half shows evidence of wear or damage, both
upper and lower halves should be replaced. Never re-
place one half without replacing the other half.
Fig. 27W-Removing Oil Seal (Lower Half)
Checking Clearance
until it protrudes far enough to be removed with To obtain the most accurate results with Plastigage,
pliers (fig. 28W). (or its equivalent) a wax-like plastic material which will
NOTE: Always wipe crankshaft surface clean compress evenly between the bearing and journal sur-
faces without damaging either surface, certain precau-
before installing a new seal. tions should be observed. If the engine is out of the
5. Lubricate the lip of a new seal with engine oil. Keep vehicle and upside down, the crankshaft will rest on the
oil off the parting line surface as this is treated with upper bearings and the total clearance can be measured
between the lower bearing and journal. If the engine is to
remain in the vehicle, the crankshaft should be supported
both front and rear (balancer and flywheel) to remove the
clearance from the upper bearing. The total clearance
can then be measured between the lower bearing and
journal.
NOTE: To assure the proper seating of the
crankshaft, the rear main bearing oil seal should
be removed and all bearing cap bolts should be
at their specified torque. In addition, prepara-
tory to checking fit of bearings, the surface of
the surface of the crankshaft journal and bearing
should be wiped clean of oil.
1. With the oil pan and oil pump removed, and starting
with the rear main bearing, remove bearing cap and
wipe oil from journal and bearing cap.
2. Place a piece of gauging plastic the full width of the
bearing (parallel to the crankshaft) on the journal
Fig. 28W-Removing Oil Seal (Upper Half) (fig. 29W).

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-60

the flattened gauging plastic tapers toward the


middle or ends, there is a difference in clear-
ance indicating a taper, low spot or other ir-
regularity of the bearing or journal. Be sure to
measure the journal with a micrometer if the x"
flattened gauging plastic indicates more than
.001" difference.
6. If the bearing clearance is within specifications, the
bearing insert is satisfactory. If the clearance is
not within specifications, replace the insert. Always
replace both upper and lower insert as a unit.
NOTE: If a new bearing cap is being installed
and clearance is less than .001", inspect for
burrs or nicks; if none are found then install
shims as required.
7. A .002" undersize bearing may produce the proper
clearance. If not, it will be necessary to regrind the
crankshaft journal for use with the next undersize
bearing.
Fig. 29W—Gauging Plastic on Journal
8. Proceed to the next bearing. After all bearings have
been checked rotate the crankshaft to see that there
is no excessive drag.
CAUTION: Do not rotate the crankshaft while 9. Measure crankshaft end play (see specifications) by
the gauging plastic is between the bearing and forcing the crankshaft to the extreme front position.
iournal. Measure at the front end of the rear main bearing
3. Install the bearing cap and evenly torque the re- with a feeler gauge (fig. 31W).
taining bolts to specifications. 10. Install a new rear main bearing oil seal in the cyl-
4. Remove bearing cap. The flattened gauging plastic inder block and main bearing cap.
will be found adhering to either the bearing shell or Replacement
journal. On the edge of gauging plastic envelope
there is a graduated scale which is correlated in NOTE: Main bearings may be replaced with or
thousandths of an inch. without removing the crankshaft.
5. Without removing the gauging plastic measure its
compressed width (at the widest point) with the With Crankshaft Removal
graduations on the gauging plastic envelope (fig. 1. Remove and inspect the crankshaft.
30W). 2. Remove the main bearings from the cylinder block
NOTE: Normally, main bearing journals wear and main bearing caps.
evenly and are not out-of-round. However, if a 3. Coat bearing surfaces of new, correct size, main
bearing is being fitted to an out-of-round jour- bearings with oil and install in the cylinder block and
nal, be sure to fit to the maximum diameter of main bearing caps.
the journal. If the bearing is fitted to the mini- 4. Install the crankshaft.
mum diameter and the journal is out-of-round
.001", interference between the bearing and Without Crankshaft Removal
journal will result in rapid bearing failure. If 1. With oil pan, oil pump and spark plugs removed.

Fig. 30W—Measuring Gauging Plastic Fig. 31W-Measuring Crankshaft End Play

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-61

2. Remove cap on main bearing requiring replacement


and remove bearing from cap.
3. Install a main bearing removing and installing tool in
oil hole in crankshaft journal.
NOTE: If such a tool is not available, a cotter
pin may be bent as required to do the job.
4. Rotate the crankshaft clockwise as viewed from the
front of engine. This will roll upper bearing out of
block.
5. Oil new selected size upper bearing and insert plain
(unnotched) end between crankshaft and indented or
notched side of block. Rotate the bearing into place
and remove tool from oil hole in crankshaft journal.
6. Oil new lower bearing and install in bearing cap.
7. Torque main bearing cap to specifications.
CONNECTING ROD BEARINGS
Connecting rod bearings are of the precision insert Fig. 32W—Gauging Plastic on Crankpin
type and do not utilize shims for adjustment. DO NOT
FILE RODS OR ROD CAPS. If clearances are found to
be excessive a new bearing will be required. Bearings
are available in standard size and .001" and .002" under-
size for use with new and used standard size crankshafts,
and in .010" and .020" undersize for use with recondi-
tioned crankshafts.
Inspection and Replacement
1. With oil pan and oil pump removed, remove the con-
necting rod cap and bearing.
2. Inspect the bearing for evidence of wear or damage.
(Bearings showing the above should not be rein-
stalled.)
3. Wipe the bearings and crankpin clean of oil.
4. Measure the crankpin for out-of-round or taper
with a micrometer. If not within specifications re-
place or recondition the crankshaft. If within speci-
fications and a new bearing is to be installed,
measure the maximum diameter of the crankpin to
determine new bearing size required.
5. If within specifications measure new or used bearing
clearances with Plastigage or its equivalent.
NOTE: If a bearing is being fitted to an out-of -
round crankpin, be sure to fit to the maximum
diameter of the crankpin. If the bearing is fitted Fig. 33W—Measuring Gauging Plastic
to the minimum diameter and the crankpin is
out-of-round .001", interference between the 8. When all connecting rod bearings have been installed
bearing and crankpin will result in rapid bearing tap each rod lightly (parallel to the crankpin) to make
failure. sure they have clearance.
a. Place a piece of gauging plastic the full width of 9. Measure all connecting rod side clearances (see
specifications) between the connecting rods (fig.
the crankpin (parallel to the crankshaft) (fig. 34W).
32W).
b. Install the bearing in the connecting rod and cap. CONNECTING ROD AND PISTON ASSEMBLIES
c. Install the bearing cap and evenly torque to Removal
specifications. 1. With oil pan, oil pump and cylinder head removed,
CAUTION: Do not turn the crankshaft with the use a ridge reamer to remove any ridge and/or
gauging plastic installed. deposits from the upper end of the cylinder bore.
d. Remove the bearing cap and using the scale on the NOTE: Before ridge and/or deposits are r e -
gauging plastic envelope, measure the gauging moved, turn crankshaft until piston is at the
plastic width at the widest point (fig. 33W). bottom of stroke and place a cloth on top of
6. If the clearance exceeds specifications select a new, piston to collect the cuttings. After ridge and/or
correct size, bearing and remeasure the clearance. deposits are removed, turn crankshaft until
7. Coat the bearing surface with oil, install the rod cap piston is at top of stroke and remove cloth and
and torque to specifications. cuttings.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-62

SUPPORT
PILOT

Fig. 36W—Removing Piston Pin

Fig. 34W—Measuring Connecting Rod Side Clearance 2. Remove piston rings by expanding them and sliding
them off the pistons. Tool J-21989 is available for
Inspect connecting rods and connecting rod caps for this purpose.
cylinder identification. If necessary mark them. 3. Place connecting rod and piston assembly in an
Remove connecting rod cap and install Tool J-5239 arbor press with piston on support (J-6994-5) and
on studs. Push connecting rod and piston assembly using remover (J-6994-3), press piston pin out of
out of top of cylinder block (fig. 35W). connecting rod and piston (fig. 36W).
4. Remove assembly from arbor press and remove
NOTE: It will be necessary to turn the crank-
Tools J-6994-5, J-6994-3 and piston pin, connecting
shaft slightly to disconnect some of the con-
rod and piston.
necting rod and piston assemblies and push
them out of the cylinder. Cleaning and Inspection

Disassembly Connecting Rods


1. Remove connecting rod bearings from connecting Wash connecting rods in cleaning solvent and dry with
rods and caps. compressed air.
Check for twisted or bent rods and inspect for nicks
NOTE: If connecting rod bearings are being or cracks. Replace connecting rods that are damaged.
reused, place them in a rack so they may be
reinstalled in their original rod and cap. Pistons
Clean varnish from piston skirts and pins with a
cleaning solvent. DO NOT WIRE BRUSH ANY PART
OF THE PISTON. Clean the ring grooves with a groove
cleaner and make sure oil ring holes and slots are clean.
Inspect the piston for cracked ring lands, skirts or
pin bosses, wavy worn ring lands, scuffed or damaged
skirts, eroded areas at top of the piston. Replace pistons
that are damaged or show signs of excessive wear.
Inspect the grooves for nicks or burrs that might
cause the rings to hang up.
Piston Pins
The piston pin clearance is designed to maintain
adequate clearance under all engine operating conditions.
Because of this, the piston and piston pin are a matched
set and not serviced separately.
Inspect piston pin bores and piston pins for wear.
Piston pin bores and piston pins must be free of varnish
or scuffing when being measured. The piston pin should
be measured with a micrometer and the piston pin bore
should be measured with a dial bore gauge or an inside
micrometer. If clearance is in excess of specifications
and the .001" wear limit, the piston and piston pin as-
Fig. 35W—Removing Connecting Rod and Piston Assemblies sembly should be replaced.

CHEVROLET CHASSIS OVERHAUL AAANUAL


ENGINE MECHANICAL 6-63

Assembly
Chevrolet piston rings are furnished in standard sizes
1. Lubricate piston pin holes in piston and connecting as well as .020", .030" and .040" oversizes.
rod to facilitate installation of pin. 1. Select rings comparable in size to the piston being
2. Position connecting rod in its respective piston so used.
that flange or heavy side of rod at the bearing end 2. Slip the compression ring in the cylinder bore; then
will be towards front of piston (cast depression in using the head of a piston, press the ring down
top of piston head) on 1, 3, 5 and 7 pistons, and the into the cylinder bore about two inches.
rod flange to the rear of the piston on 2, 4, 6 and 8
pistons. NOTE: Using a piston in this way will place
3. Place support (J-6994-5) with spring and pilot the ring square with the cylinder walls.
(J-6994-2) in place on an arbor press. 3. Measure the space or gap between the ends of the
4. Place piston on support, indexing pilot through piston ring with a feller gauge (fig. 39W).
and rod. 4. If the gap between the ends of the ring is below
5. Place installer (J-6994-3) on piston pin, start piston specifications (See Specifications), remove the ring
pin into piston and press on installer until pilot and try another for fit.
bottoms in support. 5. Fit each compression ring separately to the cylinder
6. Remove installer from connecting rod and piston in which it is going to be used.
assembly and check piston for freedom of movement 6. If the pistons have not been cleaned and inspected as
on piston pin. previously outlined, do so.
7. Install the oil ring spacer in oil ring groove and
Piston Rings position gap so when piston is installed gap will
All compression rings are marked in the upper side
of the ring. When installing compression rings, make
sure the marked side is toward the top of the piston.
The top ring is chromed for maximum life.
The oil control rings used are of the three piece type,
consisting of two segments (rails) and a spacer.

REMOVER AND
INSTALLER

PISTON PIN

Fig. 38W—Measuring Ring Cap

PILOT

SPRING

SUPPORT

Fig. 37W-Piston Pin and Tool Layout Fig. 39W—Checking Ring in Groove

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-64

be in-line with engine bottom. (Anti-rotation tang Installation


will lock in oil slot.) Hold spacer ends butted
and install steel rail on lower side of spacer. NOTE: Be sure to install new pistons in the
Position gap so when piston is installed gap will be same cylinders for which they were fitted, and
in line with engine top, 45° from piston pin hole, used pistons in the same cylinder from which
then install second rail on upper side of spacer. they were removed. Each connecting rod and
Position gap so when piston is installed, gap will bearing cap should be marked 1, 3, 5 and 7 in
be in line with engine top 90° from lower rail. the left bank and 2, 4, 6 and 8 in the right bank,
beginning at the front of the engine. The num-
8. Flex the oil ring assembly in its groove to make bers on the connecting rod and bearing cap
sure ring is free and does not bind in the groove at must be on the same side when installed in the
any point. If binding occurs, the cause should be cylinder bore. If a connecting rod is ever
determined and removed by carefully dressing with transposed from one block or cylinder to an-
a fine cut file. However, if the binding is caused by other, new bearings should be fitted and the
a distorted ring, install a new ring. connecting rod should be numbered to correspond
with the new cylinder number.
9. Slip the outer surface of the second compression
ring into the piston ring groove and roll the ring NOTE: Cylinder bores must be clean before
entirely around the groove to make sure that the piston installation. This may be accomplished
ring is free and does not bind in the groove at any with a hot water and detergent wash or with a
point (fig. 39W). If binding occurs, the cause should light honing as necessary. After cleaning, the
be determined and removed by carefully dressing bores should be swabbed several times with light
with a fine cut file. However, if the binding is caused engine oil and a clean cloth and then wiped with
by a distorted ring, check a new ring. Repeat step a clean dry cloth.
seven with the top compression ring. Install ring
expander, then install ring and position gap so 1. Lubricate connecting rod bearings and install in rods
and rod caps.
when piston is installed gap will be in line with
2. Lightly coat pistons, rings and cylinder walls with
engine top 45° from piston pin hole. light engine oil.
NOTE: Tool J-21989 is available for installing 3. With bearing caps removed, install Tool J-5239 on
rings. connecting rod bolts.
10. Repeat step seven with the top compression ring CAUTION: Be sure ring gaps are properly
(no expander) and position ring gap 90° from second positioned as previously outlined.
compression ring. 4. Install each piston in its respective bore, using
11. Proper clearance of the piston ring in its piston ring Tool J-5239 on each assembly. The side of the
groove is very important to provide proper ring piston with the cast depression in the head should be
action and reduce wear. Therefore, when fitting new to the front of the cylinder block. Use Tool J-8307
rings, the clearances between the top and bottom upside down to compress the rings for installation
surfaces of the ring grooves should be measured (fig. 41W).
(fig. 40W). (See specifications.) NOTE: Use a hammer handle and light blows
to install the piston into the bore. Hold the ring

Fig. 40W—Measuring Ring Groove Clearance Fig. 41W—Installing Connecting Rod and Piston Assemblies

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-65

compressor firmly against the cylinder block Cleaning and Inspection


until all piston rings have entered the cylinder 1. Wash crankshaft in solvent and dry with compressed
bore. air.
Guide the connecting rod bearing into place on the 2. Measure dimensions of main bearing journals and
crankshaft journals with the J-5239-2 Connecting crankpin with a micrometer for out-of-round, taper
Rod Guide Set. or under size (see specifications).
.Install the bearing caps and torque to specifications 3. Check crankshaft for run-out by supporting at the
NOTE: If bearing replacement is required refer front and rear main bearings journals in "V" blocks
and check at the front and rear intermediate journals
to "Connecting Rod Bearings/ 7
with a dial indicator (see specifications).
CRANKSHAFT 4. Replace or recondition the crankshaft if out of
The crankshaft can be replaced while the engine specifications.
is disassembled for overhaul, or without complete Installation
disassembly. 1. Install the crankshaft sprocket using Tool J-5590
Removal (fig. 43W).
1. With the engine removed from the vehicle and the 2. Lubricate and install main bearings and a n6w rear
transmission and/or clutch housing removed from main bearing oil seal in cylinder block and main
the engine, mount engine in overhaul stand and bearing caps. Main bearing halves with the oil holes
clamp securely. are the upper halves and are installed in the cylinder
2. Remove the oil dip stick and oil dip stick tube. block.
3. Remove the starting motor, clutch assembly (if
equipped) and flywheel. NOTE: Whenever a new or reconditioned crank-
4. Remove the spark plugs. shaft is installed, new connecting rod bearings
5. Remove crankshaft pulley and harmonic balancer. and main bearings of the correct size should
6. Remove oil pan and oil pump. be installed.
7. Remove crankcase front end cover, timing chain and 3. Install crankshaft in block being careful not to
camshaft sprocket. damage bearing surfaces.
8. Check the connecting rod caps for cylinder number
identification. If necessary mark them. NOTE: Main bearing caps are marked with
9. Remove the connecting rod caps and push the pistons and arrow for identification purposes. The caps
to top of bores. are installed with arrows pointing toward the
10. Remove main bearing caps and lift crankshaft out of front of engine.
cylinder block.
4. Install all main bearing caps and torque all except
11. Remove rear main bearing oil seal and main bear- the rear to specifications. When tightening the rear
ings from cylinder block and main bearing caps. main bearing cap, torque bolts 10-12 ft. lbs. first,
12. Remove crankshaft sprocket using Tool J-5825 then tap end of crankshaft rearward, with a lead
(fig. 42W). hammer, (this will locate bearing cap and bearing).
Then tap end of crankshaft forward (this will line up
upper and lower crankshaft thrust surfaces). Pro-
ceed with final torquing of all main bearing caps
to specifications.
5. Measure crankshaft end play by forcing the crank-
shaft to the extreme front position. Measure at

Fig. 42W—Removing Crankshaft- Sprocket Fig. 43W-lnsralling Crankshaft Sprocket

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-66

the front end of rear main bearing with a feeler


gauge (see specifications) (fig. 31W).
6. Lubricate connecting rod bearings and install in CONVERTER RING GEAR
connecting rods and connecting rod caps. BOLT AREA
7. Install the c o n n e c t i n g rod caps and torque to DEPRESSED
specifications.
8. Measure connnecting rod side clearances (see speci-
fications) (fig. 34W).
9. Install the flywheel as outlined in this, section.
10. Install the following as outlined in the Service
Manual:
a. Install the timing chain, camshaft sprocket and
crankcase front end cover.
b. Install the oil pump, oil pan and oil dip stick tube
and oil dip stick.
c. Install the harmonic balancer and pulley.
d. Install spark plugs, starting motor and clutch
assembly.

FLYWHEEL
Removal
WELDS
With transmission and/or clutch housing and clutch r e -
moved from engine, remove the flywheel.
Installation
1. Clean the mating surfaces of flywheel and crankshaft
to make certain there are no burrs.
2. Install flywheel on crankshaft and position to align ENGINE TRANS.
dowl hole of crankshaft flange and flywheel (fig. 44W). 4
NOTE: On Power glide equipped engines, the
flywheel must be installed with the flange collar
to transmission side (fig. 45W). Fig. 45W—Powerglide Flywheel Installation
CAMSHAFT
1. Remove valve rocker covers and gaskets.
Measuring Lobe Lift at Push Rod
2. Remove rocker nuts, balls, and rocker arms.
Refer to Figure 46W 3. Attach Tool J-8520 to stud.
4. Position clamp on Tool J-8520.
NOTE: Procedure is similar to that used for 5. Position indicator with ball socket adapter on Tool
checking valve timing. If improper valve oper-
J-8520 to push rod.
ation is indicated, measure the lift of each push
rod in consecutive order and r e c o r d the NOTE: Make sure push rod is in the lifter
readings. socket.
6. Rotate the crankshaft balancer slowly in the direc-
tion of rotation until the lifter is on the heel of the

Fig. 44W-Flywheel Installation Fig. 46W-Measuring Camshaft Lobe Lift

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-67

cam lobe. At this point, the push rod will be in its


lowest position.
7. Set dial indicator on zero, then rotate the balancer
slowly, or attach an auxiliary starter switch and
"bump" the engine over, until the push rod is in the
fully raised positon.
CAUTION: The primary distributor lead must
be disconnected from the negative post on the
coil and the ignition switch must be in the on
position. Failure to do this will result in a
damaged grounding circuit in the ignition switch.
8. Compare the total lift recorded from the dial in-
dicator Tool J-8520 with specifications.
9. Continue to rotate the engine until the indicator
reads zero. This will be a check on the accuracy of
the original indicator reading.
10. If camshaft readings for all lobes are within specifi-
cations, remove dial indicator assembly Tool J-8520 Fig. 48W—Installing No. 4 Camshaft Bearing
from cylinder head stud.
11. Install all push rods, valve rocker arms, and balls. 1. With camshaft and crankshaft removed, drive cam-
Adjust valves as outlined in the Service Manual. shaft rear plug from cylinder block.
12. Replace valve rocker covers and gaskets.
NOTE: This procedure is based on removal of
Inspection the bearings nearest center of the engine first.
The camshaft bearing journals should be measured With this method a minimum amount of turns
with a micrometer for an out-of-round condition. If the are necessary to remove all bearings.
journals exceed .001" out-of-round, the camshaft should
be replaced. 2. Using Tool Set J-6098, with nut (J-6098-5) then
The camshaft should also be checked for alignment. thrust washer installed to end of threads, index
The best method is by use of " V " blocks and a dial pilot in front camshaft bearing and install puller
indicator, (fig. 47W) The dial indicator will indicate the screw through pilot.
exact amount the camshaft is out of true. If it is out 3. Install Tool J-6098-1 with shoulder toward number
more than .002" dial indicator reading, the camshaft three bearing, making sure a sufficient amount of
should be replaced. threads are engaged.

FUEL PUMP DRIVE DISTRIBUTOR


ECCENTRIC DRIVE GEAR

Fig. 47W—Checking Camshaft Alignment

CAMSHAFT BEARINGS (Fig. 48W and Fig. 49W)


Inspection
With the camshaft removed, inspect the bearings for
evidence of wear or damage. (Bearings showing the above
should be replaced).
Removal
Camshaft bearings can be replaced while engine is
disassembled for overhaul, or without complete dis-
assembly of the engine. To replace bearings without
complete disassembly remove the camshaft and crank-
shaft, leaving cylinder heads attached and pistons in
place. Before removing crankshaft, tape threads of
connecting rod bolts to prevent damage to crankshaft.
Fasten connecting rods against sides of engine so they
will not be way while replacing camshaft bearings. Fig. 49W—Installing Rear Camshaft Bearing

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-68

4. Using two wrenches, hold puller screw while turning 5. Index number two camshaft bearing in bore, reinstall
nut (J-6098-5). When bearing has been pulled from Tool J-6098-1 on puller screw and pull bearing into
bore, remove Tool J-6098-1 and bearing from puller bore.
screw. 6. Remove Tool J-6098-1 from puller screw, remove
5. Reinstall Tool J-6098-1 on puller screw with puller screw and pilot from cylinder block and check
shoulder toward number two bearing and pull bear- alignment of oil hole in camshaft bearing.
ing. When bearing has been pulled from bore, r e - 7. Index pilot in rear camshaft bearing and install
move Tool J-6098-1 and bearing from puller screw puller screw through pilot.
and remove puller screw and pilot from cylinder 8. Index number four camshaft bearing in bore, rein-
block. stall Tool J-6098-1 on puller screw and pull bear-
6. Index pilot in rear camshaft bearing and install ing into bore.
puller screw through pilot. 9. Remove Tool J-6098-1 from puller screw, remove
7. Install Tool J-6098-1 with shoulder toward number puller screw and pilot from cylinder block and
four bearing and pull bearing. When bearing has check alignment of oil hole in camshaft bearing.
been pulled from bore, remove Tool J-6098-1 and 10. Install a new camshaft rear plug.
bearing from puller screw and remove puller screw NOTE: Plug should be installed flush to 1/32"
and pilot from cylinder block. deep and be parallel with rear surface of cylin-
8. Assemble Tool J-6098-1 on driver handle (J-6098-4) der block.
and remove front and rear camshaft bearings by
driving towards center of cylinder block.
CYLINDER BLOCK
Installation Inspection
Refer to Figure 48W and 49W 1. Inspect the cylinder block for cracks in the cylinder
walls, water jacket valve lifter bores and main
The front and rear camshaft bearings should be in- bearing webs.
stalled first. These bearings will act as guides for the
2. Measure the cylinder walls for taper, out-of-round
pilot and center the remaining bearings being pulled
into place. or excessive ridge at top of ring travel. This should
be done with a dial indicator. Set the gauge so that
1. Assembly Tool J-6098-1 on driver handle (J-6098-4) the thrust pin must be forced in about 1/4" to enter
and install front and rear camshaft bearings by gauge in cylinder bore. Center gauge in cylinder and
driving towards center of cylinder block. turn dial to "O". Carefully work gauge up and
down cylinder to determine taper and turn it to
CAUTION: Oil holes in bearings must line up different points around cylinder wall to determine
with oil holes in cylinder block. the out-of-round condition. If cylinders were found
2. Using Tool set J-6098, with nut (J-6098-5) then to exceed specifications honing or boring will be
thrust washer installed to end of threads, index necessary (fig. 50W).
pilot in front camshaft bearing and install puller Repairs
screw through pilot. Cylinder Conditioning
3. Index number three camshaft bearing in bore, then The performance of the following operation is con-
install Tool J-6098-1 on puller screw with shoulder tingent upon engine condition at time of repair.
toward bearing. If the cylinders were found to have less than .005"
4. Using two wrenches, hold puller screw while turning taper or wear they can be conditioned with a hone and
nut (J-6098-5). When bearing has been pulled into fitted with the high limit standard size pistons. A cylin-
bore, remove Tool J-6098-1 from puller screw and der bore of less than .005" wear or taper may not
check alignment of oil hole in camshaft bearing. entirely clean up when fitted to a high limit piston.
If it is desired to entirely clean up the bore in these
cases, it will be necessary to rebore for an oversize
piston. If more than .005" taper or wear, they should
be bored and honed to the smallest oversize that will
permit complete resurfacing of all cylinders.
Cylinder Boring
1. Before using any type boring bar, the top of the
cylinder block should be filed oof to remove any
dirt or burrs. This is very important. Otherwise,
the boring bar may be tilted which would result in
the rebored cylinder wall not being at right angles
to the crankshaft.
2. The piston to be fitted should be measured with a
micrometer, measuring at the center of the piston
skirt and at right angles to the piston pin. The
cylinder should be bored to the same diameter as
the piston and honed to give the specified clearance.
NOTE: Hone cylinders as out lined under < 'Cyl-
Fig. 50W—Measuring Cylinder Bores inder Honing and Piston Fitting".

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-69

3.. The instructions furnished by the manufacturer of the BASE PISTON MARKING
equipment being used should be carefully followed. CYL. DIA. 4 31 2C" lS4js5lS6|S7J ^ E X A M P L E ' 'A"
Cylinder Honing and Piston Selection * |S4|S5|S6|S7|^ LL| 2 | 3 | «]
1. When pistons are being fitted and honing is not * 340 H P. 02
1 l
CN
necessary cylinder bores may be cleaned with a BASE 5 S S S 0' CN CN
DIA. P o q q O.S q
hot water and detergent wash. After cleaning, the * * 400 H P. q
CYLINDER OVERSIZE
bores should be swabbed several times with light
engine oil and a clean cloth and then wiped with a PISTON MARKING
clean dry cloth. * * |1 |2 3|4 EXAMPLE " B " | 1 | 2 | 3 | 4 | 5 | 6]

2. When cylinders are to be honed follow the hone Hla |3|4 V 11 2 3 )4 |


manufacturer's recommendations for the use of the 1 I 1 i I

.03H
.030 04 061 3 " g> CO CO
hone and cleaning and lubrication during honing. O.S.
S ° 5 3 O.S. g
CO
o
3. Occasionally during the honing operation, the cylin- o O.S. o q 8 q
der bore should be thoroughly cleaned and the piston CYLINDER OVERSIZE
selected for the individual cylinder checked for
correct fit. Fiq. 52W—Piston Selection Chart
When finish honing a cylinder bore to fit a piston,
the hone should be moved up and down at a sufficient
speed to obtain very fine uniform surface finish
marks in a cross-hatch pattern of approximately EXAMPLE "B":
45° to 65° included angle. The finish marks should
be clean but not sharp, free from imbedded particles Cylinder bore measurement 4.3440 Rebored bore
and torn or folded metal (fig. 51W).
Base cylinder bore diameter 4.3120 409 cu. in. engine
Difference .032
Number on chart .030 oversize
(+.002") marked 4

5. Permanently mark the piston for the cylinder to


which it has been fitted and proceed to hone cylinders
and fit the remaining pistons.
Fig. 51VV—Cylinder Finish Marks

NOTE: Replacement pistons are available in a CAUTION: Handle the pistons with care and
range of four standard sizes and four each do not attempt to force them through the cylinder
(.020", .030" and .040") oversize and the size until the cylinder has been bored to correct
identification is marked, in ink, on the piston size as this type piston can be distorted through
top. careless handling.
4. To determine the correct size of piston needed,
measure the cylinder bore with a telescope gauge and 6. Thoroughly clean the cylinder bores with hot water
subtract the base cylinder bore diameter from the and detergent. Scrub well with a stiff bristle brush
measured diameter, then locate this dimension on and rinse thoroughly with hot water. It is extremely
the Piston Selection Chart (fig. 52W). The number essential that a good cleaning operation be per-
shown on the chart in the box above the dimension is formed. If any of the abrasive material is allowed
the marking on the piston which should be used. to remain in the cylinder bores, it will rapidly wear
the new rings and cylinder bores in addition to the
EXAMPLE "A": bearings lubricated by the contaminated oil. The
Cylinder bore measurement 4.3150 Worn standard bores should be swabbed several times with light
bore engine oil and a clean cloth and then wiped with a
Base cylinder bore diameter 4.3120 409 cu. in. engine clean dry cloth. Cylinders should not be cleaned
Difference .0030 with kerosene or gasoline. Clean the remainder of
Number on Chart S7 Standard piston the cylinder block to remove the excess material
(+.003") marked S7 spread during the honing operation.

CHEVROLET CHASSIS OVERHAUL MANUAL


ENGINE MECHANICAL 6-70

SPECIAL TOOLS

Fig. IT—Special Tools

1. J-4536 Engine Lift Kit 14. J-5802 Rocker Arm Stud Remover
2. J-8062 Valve Spring Compressor 15. J-8089 Carbon Removing Brush
3. J-1264 (0-200 Ft. Lb.) Torque Wrench 16. J-7316 Belt Tension Gauge
J-8058 (0- 50 Ft. Lb.) 17. J-8001 Indicator Set (Universal)
J-5853 (0-100 In. Lb.) 18. J-8520 Indicator Set (Camshaft Lobe)
4. J-6994 Piston Pin Assembly Tool 19. J-0966 Crankcase Cover Centering Gauge
5. J-9510 Piston Pin Assembly Tool 20. J-21742 Crankcase Cover Centering Gauge
6. J-6098 Cam Bearing Tool 21. J-5590 Crankshaft Sprocket or
7. J-8037 Piston Ring Compressor Gear Installer
8. J-6305 Connecting Rod Guide Set 22. J-5595 Crankcase Cover Seal Installer
9. J-8020 (3 9/16") Piston Ring Expander 23. J-8340 Crankcase Cover Seal Installer
J-8021 (3 7/8") 24. J-6978 Harmonic Balancer Puller
J-8032 (4") 25. J-8792 Harmonic Balancer Installer
J-21989 (4 5/16") 26. J-8105 Crankshaft Gear Puller
10. J-8101 Valve Guide Cleaner 27. J-5825 Crankshaft Sprocket Puller
11. J-5830 (11/32") Valve Guide Reamer Set 28. J-9534 Distributor Lower Bushing Remover
J-7049 (3/8") 29. J-9535 Distributor Lower Bushing Installer
12. J-5715 (.003") Rocker Arm Stud Reamer 30. J-0971 Camshaft Gear Support
J-6036 (.013") 31. J-5860 Cylinder Head Bolt Wrench
13. J-6880 Rocker Arm Stud Installer 32. J-8087 Indicator Set (Cylinder Bore)
33. J-8369 O i l Pick-Up Pipe Replacer

CHEVROLET CHASSIS OVERHAUL MANUAL


SECTION 6K
WATER PUMP
INDEX
Page
Disassembly 6-1
Inspection 6-2
Assembly 6-2
Special Tools 6-5

I
Fig. 1—Water Pump, Cross-Section (4 and 6 Cyl.) Fig. 2—Water Pump, Cross-Section (8 Cyl. Typical)

REPAIR PROCEDURES
WATER PUMP 5. Support impeller on seal surface, using Tool J-5855
in an arbor press, and using a 1/2" x 1" pin, press
Disassembly
shaft out of impeller (fig. 5). Discard seal.
1. Remove bolts and fan and pulley.
2. On V-8 models, remove back plate screws, plate and
gasket.
3. Support fan hub in an arbor press and press pump
shaft out of hub. A 1/2" dia. x 2" rod will allow the
shaft to be pushed through the hub. See Figure 3.
4. Support pump in an arbor press as shown (fig. 4).
Press shaft and impeller assembly out of pump, ap-
plying pressure on the outer race of the shaft bearing
only.

CAUTION: Shaft and bearing assembly must not


be pushed out of housing by applying force on
shaft, or bearings will be damaged. Use a 7/8"
deep socket or piece of tubing 1/8" P.P. Shaft
and bearing assembly should be pressed out of
rear of pump only. Fig. 3—Removing Fan Hub

CHEVROLET CHASSIS OVERHAUL MANUAL


WATER PUMP 6K-2

w
tl
'^^ J^HiiHpiiil
i
Fig. 6-— In-Line Pump Disassembled
Fig. 4—Removing Shaft and Bearing Assembly

Assembly
Inspection 1. Install pump shaft and bearing assembly into pump
1. Wash all parts except pump shaft bearing in cleaning body bearing bore, applying pressure to outer race
solvent. Figures 6 and 7 show the water pumps until it is flush with front of pump body (fig. 8).
disassembled. CAUTION: Apply pressure to outer race only.
NOTE: Pump shaft bearing is a permanently 2. Lightly coat O.D. of new seal with a sealing com-
sealed and lubricated bearing and should not be pound and press into place with Tool J-5590, applying
washed in cleaning solvent. pressure to the seal outer flange. The seal should
2. Inspect shaft and bearing assembly for roughness or bottom with the outer flange against the pump body
excessive end play. Remove any rust or scale from (fig. 9).
shaft with fine emery cloth. The bearing should be 3. Press on fan hub. Check fan hub location using cor-
wrapped in cloth while this operation is performed to rect fan hub locating gauge listed in chart below and
prevent emery dust from entering bearing. shown in Figures 10 and 11.
3. Inspect seat for thrust washer on impeller for pit
marks or scoring. If seat for t h r u s t washer is Tool Usage
scored or pitted the impeller should be replaced. J-9583 4, 6 cyl. Chevy II;
6 cyl. Chevrolet
J-21505 6 cyl. Chevelle
J-9648 (Step) 283, 327 cu. in. V-8 all
J-9608 and 7/32" Drill 409 cu. in. V-8

Fig. 5—Removing Seal Fig. 7—V-8 Pump Disassembled

CHEVROLET CHASSIS OVERHAUL MANUAL


WATER PUMP 6K-3

Fig. 10—Installing Fan Hub (In-Line Engines)

Fig. 8—Installing Shaft and Bearing Assembly


4. Support pump on front (hub end) of shaft and press on
impeller. Press to obtain .010" to .035" clearance
between impeller vanes and pump body. On eight cyl-
inder models; it will be necessary to put a bend about
1/2" from end of feeler gauge to enable clearance
checking (figs. 12 and 13).

5. On V-8 models, install pump back plate and gasket


with a light coat of gasket sealer and install screws,
then tighten all six diagonally.

Fig. 9—Installing Seal (Typical) Fig. 11— Installing Fan Hub V-8 Engines

CHEVROLET CHASSIS OVERHAUL MANUAL


WATER PUMP 6K-4

Fig. 13—Installing Impeller (V-8)

Fig. 12—Installing Impeller (In-Line)

CHEVROLET CHASSIS OVERHAUL MANUAL


WATER PUMP 6K-5

SPECIAL TOOLS

Fig. 14—Cooling System Special Tools

J-9583 Fan Hub Locating Gauge 4 Cyl., 6 Cyl. Chevy I I ; 6 Cyl. Chevrolet 2. J-5855 Generator Bearing Remover and Installer
J-21505 Fan Hub Locating Gauge 6 Cyl. Chevelle 3. J-5590 Transmission Front Bearing Installer
J-9648 Fan Hub Locating Gauge 8 Cyl. (327)
J-9608 Fan Hub Locating Gauge 8 Cyl. (283)

CHEVROLET CHASSIS OVERHAUL MANUAL


SECTION 6M
CARBURETORS
CONTENTS OF SECTION 2

Page
Rochester BV ^ Carter WCFB 6M_35
Rochester 2GV 6M_? Carter AFB 6M-45
Rochester 4GC 6M-13 Holley 4150 6M_55
Rochester 4GC "Low Silhouette" 6M-22 Special Tools . . 6M-62
YF
6M-30

ROCHESTER BV
INDEX
Page Page

General Description 6M-1 Adjust Float 6M-5


Repair Procedures 6M-2 Assemble Bowl Cover to Bowl 6M-5
Disassembly 6M-2 Adjust Choke Rod (Fast Idle) 6M-6
Cleaning and Inspection 6M-2 Adjust Choke Unloader 6M-6
Assembly and Adjustments 6M-3 Adjust Choke Vacuum Break 6M-6
Assemble Bowl and Throttle Body 6M-3 Adjust Idle Vent 6M-6
Assemble Bowl Cover 6M-5

GENERAL DESCRIPTION

The Rochester BV Carburetor (fig. 1) is used on all acts as a choke valve break during engine warm up.
L-6 e n g i n e s in the Chevrolet, Chevelle and Chevy II. The spark advance is partial vacuum on synchromesh
equipped vehicles and full vacuum on Powerglide equipped
This carburetor, used in conjunction with a temper- vehicles. On Powerglide equipped vehicles, the spark
ature sensing choke coil (mounted in a cast depression on advance also operates the transmission vacuum modu-
the exhaust manifold), provides excellent choke valve r e - lator and if carburetors are switched, the transmission
sponse. A vacuum diaphragm, mounted on the carburetor, shift pattern would be affected.

IDLE VENT VACUUM


BREAK
DIAPHRAGM

\ IDLE MIXTURE
SCREW

IDLE SPEED
SCREW

Fig. 1—Rochester BV Carburetor

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER BV 6 M - 2

REPAIR PROCEDURES
Disassembly 17. Remove idle adjusting n e e d l e and spring from
1. Disconnect choke d i a p h r a g m vacuum h o s e at throttle body.
diaphragm. Cleaning and Inspection
2. Remove fast idle cam, then disconnect fast idle rod 1. Wash all metal parts thoroughly in carburetor sol-
at choke lever. vent and dry with compressed air.
3. Remove fuel line fitting, gasket, bronze fuel filter
CAUTION: Vacuum d i a p h r a g m and pump
and spring from bowl cover,
plunger should not be immersed in cleaning sol-
4. Remove four bowl cover screws.
vent. Clean the plunger in clean gasoline - clean
5. Lift cover straight up to prevent damage to floats.
the diaphragm unit by wiping with a rag only.
6. Place bowl cover up-ended on flat surface and r e -
move float hinge pin, floats and float needle (fig. 2). 2. Check all parts and passages for carbon deposits.
7. Using screw driver of proper width, remove float 3. Blow out all drilled passages with compressed air
needle seat and fibre gasket. and check to make sure they are clean.
8. Remove main metering jet and power valve assembly CAUTION: Do not pass drills or wires through
from main well support. calibrated jets or p a s s a g e s as this may
NOTE: Use care when removing power valve enlarge orifice and seriously affect carburetor
not to lose small spring and ball. calibration.
4. Inspect pump plunger. If the rubber or its expanding
9. Remove main well support attaching screw and r e - spring are damaged, the plunger assembly should be
move support. Lift straight up to prevent damage to replaced. Shake the plunger to determine if by-pass
main well support tube. ball check is free.
10. Lift power piston and spring from bowl cover. To check pump system: Pour 1/2 inch of gasoline into
11. Lift bowl cover gasket from bowl cover. carburetor bowl. Take pump plunger from can of gasoline
12. Remove choke shaft lever screw (diaphragm side), or kerosene and slide into pump cylinder. Place the dis-
remove two diaphragm bracket screws and remove charge check ball into body. Raise plunger and press
diaphragm. lightly on shaft to expel air from the pump passage. Using
13. Holding accelerator pump plunger all the way down, a small clean brass rod, hold the discharge ball down
remove hairpin retainer from pump link and remove firmly on its seat. Again raise plunger and press down-
pump link from throttle lever and pump plunger. ward. No fuel should be emitted from either the intake or
Pump plunger may now be lifted from bowl. Place discharge passage. If any fuel does emit from either
plunger in gasoline or kerosene to prevent rubber passage, the presence of dirt or a damaged check ball are
from drying out. indicated. Clean the passage again and repeat the test.
14. Lift pump spring from pump well. If leakage is still present, replace the check valve.
15. With small needlenose pliers, remove pump dis- 5. Check floats for dents and wear on lip and hinge pin.
charge guide (fig. 3). Pump discharge spring and ball Also check cover for wear in hinge pin holes.
check will fall from bowl when turned upside down.
16. With bowl upside down, remove 2 throttle body at-
taching screws and remove throttle body assembly.

Fjg. 2—Removing Float Fig. 3—Removing Pump Discharge Guide

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER BV 6M-3

18 20

y <?\\ 10 11 12

Fig. 4—Rochester BV—Exploded View

1. Vacuum Diaphragm 7. Bowl Cover 13. Bowl Cover Gasket 18. Pump Connecting Rod
2. Choke Shaft and Lever 8. Choke Rod 14. Pump Discharge Ball Check 19. Throttle Body Gasket
3. Choke Valve 9. Choke Lever 15. Accelerator Pump 20. Idle Mixture Needle
4. Float 10. Main Well Support 16. Pump Return Spring 21. Throttle Body
5. Needle and Seat 11. Main Metering Jet 17. Bowl 22. Fast Idle Cam
6. Power Piston and Spring 12. Power Valve

Check float needle. If wear is noted on float needle, body. As a temporary idle adjustment, back needle
install new float needle assembly c o n s i s t i n g of out 1-1/2 turns.
matched and tested needle and seat and new fibre
gasket.
Check power piston for burrs or other damage.
Piston must move freely in cover bore.
Check throttle arm for looseness on the shaft and for
excessive wear at throttle rod connection.
Check throttle shaft for excessive looseness in
throttle body.
NOTE: Any damage or e x c e s s i v e wear in
throttle arm or shaft necessitates replacement
of the throttle body assembly. This is due to the
close tolerance of throttle valve fit required and
the fact that the idle d i s c h a r g e and spark
advance holes are drilled in relation to a proper
fitting valve.
10. Check the choke valve for freedom of operation in
cover.
11. Check bronze fuel filter for chips or cracks.
12. Check fast idle cam for corrosion. If present, r e -
move with a wire brush.
Assembly and Adjustments
Assemble Bowl and Throttle Body
1. Install idle needle and spring finger-tight in throttle Fig. 5—Installing Pump Discharge Ball

CHEVROLET CHASSIS OVERHAUL /MANUAL


ROCHESTER BV 6 M - 4

Fig. 8—Float Drop Adjustment


Fig. 6-—Float Level Adjustment

2. Using a new throttle body gasket, attach bowl to


throttle body. Tighten screws evenly and securely.
3. Place pump return spring into pump well and center
it by depressing with finger.
4. Install pump plunger and connect pump link to
throttle lever and pump rod. Install hairpin retainers
at both upper and lower ends.
5. Drop large steel ball into pump discharge cavity of
bowl and place bronze color spring on top of ball
(fig. 5).
6. Index end of pump discharge guide into bronze color
spring and press down until guide is flush with bowl
surface.

Fig. 7—Float Alignment Fig. 9—Ghoke Rod (Fast Idle) Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER BV 6M-5

Assemble Bowl Cover


1. Place new bowl cover gasket on bowl cover.
2. Place power piston spring and power piston in bowl
cover cavity and attach main well support to bowl
cover.
3. Install main metering jet and tighten securely.
4. Hold power piston stem down and install power ball,
spring and plug and tighten securely.
5. Install spring and bronze fuel filter with opening
away from spring and attach fuel line fitting with
gasket.
6. Install vacuum diaphragm, two bracket screws and
choke valve lever.
7. Install float needle seat using new fibre washer and
install float needle.
8. Attach float with hinge pin.
NOTE: Float tang must face cover.

Adjust Float
1. Invert cover a s s e m b l y and measure float level
(fig. 6) using Tool J-21216. Bend f l o a t arms to
adjust.
2. Hold cover sideways and check float centering using
same gauge. Floats should not t o u c h gauge legs Fig. 11—Choke Vacuum Break Adjustment
(fig. 7).
3. Hold cover in upright position and check float drop
measurement between gasket and lower edge of float
(fig. 8). Adjust by bending stop tang.
Assemble Bowl Cover to Bowl
1. Carefully place cover assembly on bowl, making cer-
tain the main channel male centering protrusion in
the cover is properly aligned with the female channel
in the bowl.
2. Make certain bowl cover sits flat on bowl, then in-
stall attaching screws and tighten securely.
3. Connect choke vacuum diaphragm hose securely.
4. Connect choke rod at choke lever, then connect and
install fast idle cam.

Fig. 10—Choke Uploader Adjustment Fig. 12—Idle Vent Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER BV 6M-6

Adjust Choke Rod (Fast Idle) (Fig. 9) Adjust Choke Vacuum Break (Fig. 11)
1. Hold diaphragm lever against diaphragm to bottom
1. Place end of idle adjusting screw on the next to diaphragm in housing.
highest step of the fast idle cam. Using Tool J-9580, 2. Measure clearance between lower edge of choke
see if specified gauge slides easily between lower valve and wall of air horn using Tool J-21616. Clear-
edge of choke valve and bore of carburetor. ance should be .122" to .142" on Powerglide vehicles
2. If necessary, bend choke rod using Tool J-4552 until and .154" to .173" on synchromesh transmission
required clearance is obtained. vehicles.
3. If necessary to adjust bend diaphragm link.
Adjust Choke Unloader (Fig. 10)
Adjust Idle Vent (Fig. 12)
1. Place throttle in wide open position. 1. Adjust idle speed screw until it just touches low step
2. Using a l l / 3 2 n drill, see if drill slides freely be- of fast idle cam.
tween l o w e r edge of choke valve and bore of 2. Turn idle speed screw two a d d i t i o n a l turns in
carburetor. (clockwise).
3. Place idle speed screw on the second highest step of
3. If necessary, bend tang of throttle lever with Tool the fast idle cam and adjust idle vent until it just
J-4552 to obtain necessary clearance. starts to open.

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 2GV 6 M - 7

ROCHESTER 2GV
INDEX
Page Page
General Description 6M-7 Assemble Bowl Cover 6M-10
Repair Procedures 6M-8 Adjust Float 6M_10
Disassembly 6M-8 Assemble Bowl Cover to Bowl 6M-11
Bowl Cover 6M-8 Adjust Accelerator Pump Rod 6M-11
Bowl and Throttle Body 6M-8 Adjust Idle Vent 6M-12
Cleaning and Inspection 6M-8 Adjust Choke Rod (Fast Idle) 6M-12
Assembly and Adjustment 6M-10 Adjust Choke Unloader 6M-12
Assemble Bowl and Throttle Body 6M-10 Adjust Choke Vacuum Break 6M-12

GENERAL DESCRIPTION

The Rochester 2GV Carburetor (fig. 13) is used on all


Chevrolet, Chevelle and Chevy n 283 cu. in. engines. IDLE AIR BLEEDS IDLE RESTRICTION

This carburetor, used in c o n j u n c t i o n with a tem-


perature sensing coil (mounted on the intake manifold
IDLE mT, gi* \\ ^
/.I
over the exhaust crossover passage), provides excellent
choke valve response. Lib ^ * >
IDLE AIR
COMPENSATOR
IDLE TUBE- T1 T l_Dtj]||l
TWM BI-METAL

II 1
^ STRIP
fipvyii • IIIU
Carburetors on vehicles equipped with air conditioning
contain a hot idle compensator (fig. 14). The hot idle
MAIN METERING •—
JCTC 11
v-sSin'll
-\NSK>'^B I
lift: AIR PASSAGE

compensator, a thermostatic controlled air bleed which MAIN WELL ^jE=ll^y - |o£1 1 / C C l D L E DISCHARGE
H0LES
supplies additional air to the idle mixture, is used as an IDLE H H
aid to prevent stalling during prolonged hot idle periods. ADJUSTMENT NEEDLES >

The hot idle compensator consists of a bi-metal strip, a IDLE NEEDLE HOLE
THROTTLE
VALVE
\ffig
\ B WMm
OFF-IDLE
1
/
valve and a mounting bracket and is mounted in the cavity
at the rear of the carburetor bowl.

' Fig. 14—Hot Idle Compensator

IDLE VENT
ACCELERATOR / CHOKE VACUUM x^ INLET FUEL
PUMP LEVER _ / Jj^ m^
BREAK DIAPHRAGM \ \ £ ^ *> FILTER

^ • B P I \ S P A R K ADVANCE
LEVER ^ H ^ H ^ ^ • ^ H ^ - AND MODULATOR
iwW ^ B B L _ _ _ ^ THROTTLE W Q I \* VACUUM PORT
* LEVER
H H P IDLE MIXTURE
mw
*^ SCREW

Fig. 13—Rochester 2GV Carburetor

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 2GV 6 M - 8

REPAIR PROCEDURES
Disassembly
13. If choke shaft or valve need replacement, remove two
Disassemble Bowl Cover choke valve screws, then remove choke valve, and
1. Remove pump rod retaining clip (throttle lever end) slide shaft from cover.
then remove rod.
2. Remove fast idle cam, rotate rod to align tang with Disasemble Bowl and Throttle Body
groove at choke kick lever end, then remove cam and 1. Remove pump plunger return spring from pump well,
rod. and baffle plate from panel.
3. Disconnect c h o k e vacuum d i a p h r a g m hose at 2. Remove main metering jets and power valve.
diaphragm. 3. Remove three screws on top of cluster, then remove
4. Remove fuel filter inlet nut, filter, spring and two cluster and gasket and main well inserts.
gaskets. 4. Using a pair of long nose pliers, remove the pump
5. Remove idle vent and bracket. discharge spring retainer. Then the spring and check
6. Remove 8 bowl cover screws and lift cover from ball may also be removed.
bowl (fig. 15). 5. Upend carburetor and remove three large bowl to
7. Place the bowl cover top-down on bench and remove throttle body attaching screws. Throttle body and
float hinge pin, float and float needle. gasket may now be removed.
8. Remove float needle seat and gasket with wide blade 6. Remove idle adjusting needles and springs from
screw driver. throttle body.
9. Removing power p i s t o n by depressing shaft and
allowing spring to snap, thus forcing piston from
casting. Cleaning and Inspection
10. Remove retainer on pump plunger shaft, remove 1. Thoroughly clean carburetor castings and metal
plunger assembly from pump arm. Place plunger in parts in cleaning solvent.
gasoline or kerosene to prevent rubber from drying
out. The pump lever and shaft may be removed by CAUTION: Vacuum d i a p h r a g m and pump
loosening set screw on inner arm and removing outer plunger should not be immersed in cleaning sol-
lever and shaft. vent. Clean the plunger in clean gasoline - clean
the diaphragm unit by wiping with a rag only.
NOTE: The pump plunger may be further dis- 2. Blow all passages in castings dry with compressed
assembled by c o m p r e s s i n g the spring and air.
removing the retainer.
CAUTION: Do not pass drills or wires through
11. Remove the cover gasket. calibrated jets or p a s s a g e s as this may
12. Remove choke lever screw, disengage lever from enlarge orifice and seriously affect carburetor
choke shaft and let it hang from diaphragm rod, then calibration.
remove diaphragm mounting screv/s and remove the
assembly.
Inspect all parts for wear. If wear is noted, defec-
tive parts must be replaced. Note especially the
following:
a. Inspect float needle and seat for wear. If wear is
noted the assembly must be replaced.
b. Inspect float lip for wear and float for dents. In-
spect floats for leaks by shaking.
c. Inspect throttle and choke shaft bores in throttle
body and cover castings for wear or out of round.
d. Inspect idle adjusting needles for burrs or ridges.
Such a condition requires replacement.
e. Inspect fast idle cam. If wear is noted on steps of
fast idle cam, it should be replaced as it may up-
set engine idle speed during the choking period.
f. Inspect pump plunger rubber. Replace plunger if
rubber is damaged.
g. Inspect gaskets to see if they appear hard or
brittle or if the edges are torn or distorted. If
any such condition is noted they must be replaced.
h. Inspect filter for dirt or lint. Clean and if it
is distorted or remains plugged, replace.
i. Inspect cluster assembly. If for any reason parts
have become loose or damaged in the cluster
casting, it must be replaced.
Fig. 15—Bowl Cover Screw Location

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 2GV 6 M - 9

8 9

10 11 — fJV 12 13 14 - 15 16 17 18 19 20

Fig. 16—Bowl Cover—Exploded View

1. Choke Valve 6. Bowl Cover 11. Pump Inner Lever 16. Filter Spring
2. Choke Shaft 7. Vacuum Diaphragm 12. Accelerator Pump 17. Inlet Fuel Filter
3. Choke Kick Lever 8. Diaphragm Link 13. Float 18. Gasket—Filter
4. Vent Shield 9. Choke Lever 14. Needle and Seat Assembly 19. Gasket—Inlet Nut
5. Vent Valve 10. Pump Outer Lever 15. Float Hinge Pin 20. Inlet Nut

10
ouwsw \

11

Fig. 17—Bowl and Throttle Body—Exploded View

1. Cluster Assembly 4. Power Valve Assembly 8. Throttle Body to Bowl Gasket 11. Accelerator Pump Spring
2. Gasket 5. Main Jets 9. Throttle Body Assembly 12. Fast Idle Cam
3. Splash Shield-Main 6. Bowl Cover Gasket 10. Pump Discharge Check 13. Idle Mixture Screws
Well 7. Bowl Assembly Assembly 14. Choke Rod

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 2GV 6 M - 1 0

4. Install main well inserts, gasket and cluster as-


sembly, tighten screws evenly and securely. Make
certain center screw is fitted with fibre gasket.
5. Install main metering jets, power valve gasket and
power valve. Figure 18 shows the bowl and throttle
body at this stage of assembly.
6. Install pump return spring, pressing with finger to
center it in pump well. Install baffle plate.

Assemble Bowl Cover


1. Install choke shaft and choke valve if they were
removed.
2. Install vacuum diaphragm with bracket screws, then
install choke lever on end of choke shaft and retain
with screw.
3. Install vent valve and shield.
4. Install fuel inlet filter spring, filter, gaskets and
inlet nut.
5. Install pump lever assembly.
NOTE: Lubricate pump shaft bearing surface
with lubriplate before installation.
Fig. 18—Bowl Assembly Parts Location
6. Install float needle seat and gasket, using wide blade
Assembly and Adjustments
screw driver.
Assemble Bowl and Throttle Body 7. Install power piston in vacuum cavity; piston should
1. Screw idle adjusting needles and springs into throttle travel freely in cavity. Lightly stake retainer in
body until finger tight. Back out screw 1-1/2 turns place.
as a temporary idle adjustment. 8. Attach accelerator pump shaft with retainer, with
shaft end pointing inward.
CAUTION: Do not force needle against seat or 9. Install cover gasket.
damage will result. 10. Attach needle to float, carefully position float and
2. Upend bowl, place new throttle body gasket in po- insert float hinge pin. Figure 19 shows the bowl
sition and a t t a c h throttle body to bowl. Tighten cover assembled.
screws evenly and securely.
3. Drop pump discharge check ball into discharge hole.
Ball is 3/16" diameter steel. Install spring and Adjust Float
retainer. 1. Invert the cover on a flat surface. Place float gauge
(Tool J-21607) over float and measure float level
(fig. 20).
2. Bend float hinge arm as required until the highest
part of the float just clears the gauge step.
3. Hold bowl in an upright position and check float drop
measurement from the gasket to the bottom of the
float (fig. 21). Bend the tang at the end of the float
hinge arm to obtain the correct drop, recheck both
settings after this adjustment.

Fig. 19—Bowl Cover Assembly Parts Location Fig. 20—Float Level Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 2GV 6M-11

ATMOSPHERIC
VENT VALVE
GAUGE

Fig. 23—Idle Vent Adjustment

cam at the other end, rotate the rod and install cam
on bowl.
NOTE: The rod offset end goes toward fast idle
cam.
Fig. 21—Floaf Drop Adjustment 5. Connect vacuum hose at flange.
Adjust Accelerator Pump Rod (Fig. 22)
Assemble Bowl Cover to Bowl
1. Place cover on bowl, making certain that accelerator 1. Back off idle screw until throttle valves are com-
pump plunger is positioned and will move freely. pletely closed.
Raise cover and lower straight down to insure proper 2. Holding throttle valves closed, check the distance
installation. from the top of the pump housing on the bowl cover
to top of pump rod.
2. Install and t i g h t e n 8 cover screws evenly and
securely. 3. Leg of gauge marked "pump" should just touch top
3. Install pump rod and retainer. of pump rod.
4. Install fast idle rod in choke kick lever, then fast idle 4. The accelerator pump rod may be carefully bent to
obtain the correct adjustment.

PUMP AND
, VENT VALVE ATMOSPHERIC VENT VALVE
I CHECKING POINTS
= • = * - • — VALVE
^ SEAT

I L PUMP AND
VENT LEVER

IDLE
SPEED
SCREW

SCREW O N
SECOND STEP

Fig. 22—Accelerator Pump Rod Adjustment Fig. 24—Choke Rod (Fast Idle) Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 2GV 6 M - 1 2

Adjust Idle Vent (Fig. 23) 2. If necessary, bend tang of choke rod kick lever to
adjust relationship.
NOTE: Always make p u m p rod adjustment
before checking and adjusting idle vent valve.
Adjust Choke Unloader (Fig. 25)
1. Place float gauge in Chain Gauge Set J-21607 on top 1. Hold throttle lever in wide open position so unloader
of pump housing on bowl cover. tang pushes against tang on fast idle cam.
2. Slowly open throttle valves to a point where the 2. Using Tool J-21607, measure distance between upper
atmospheric valve just closes on its seat. edge of choke valve and bore of carburetor.
3. Holding the throttle valves in this position, leg of 3. If necessary to adjust, bend tang of throttle lever to
gauge marked "vent" should just touch top of pump obtain needed clearance.
rod.
4. Bend the tang on the pump lever with bending Tool Adjust Choke Vacuum Break (Fig. 26)
J-5197 to adjust. 1. Hold diaphragm arm in against diaphragm to bottom
against housing.
Adjust Choke Rod (Fatf Idle) (Fig. 24) 2. Measure clearance between upper edge of choke
1. Place end of idle adjusting s c r e w on the next to valve and wall of bowl cover using Tool J-21607.
highest step of the fast idle cam. Using a 1/16" drill, Clearance should be .080 to .105 on Powerglide vehi-
see if drill just slides easily between upper edge of cles and .108 to .133 on synchromesh transmission
choke valve and bore of carburetor at the center. vehicles.
3. If necessary to adjust bend diaphragm link.

BEND UNLOADER
TANG TO ADJUST!

Fig. 25—Choke Unloader Adjustment Fig. 26—Choke Vacuum Break Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC 6 M - 1 3

ROCHESTER 4GC
INDEX

Page Page
General Description 6M-13 Assemble Bowl Cover to Bowl 6M-19
Repair Procedures 6M-13 Assemble Choke Housing 6M-19
Disassembly 6M-13 Adjust Accelerator Pump Rod 6M-19
Bowl Cover 6M-13 Adjust Idle Vent 6M-20
Choke 6M-14 Adjust Intermediate Choke Rod 6M-20
Bowl and Throttle Body 6M-14 Assemble and Adjust Choke Cover 6M-20
Cleaning and Inspection 6M-16 Adjust Choke Rod (Fast Idle) 6M-20
Assembly and Adjustments 6M-17 Adjust Choke Unloader 6M-21
Assemble Bowl and Throttle Body 6M-17 Adjust Secondary Throttle Lockout. . . . 6M-21
Assemble Bowl Cover 6M-18 Adjust Secondary Throttle Contour 6M-21
Adjust Float 6M-19

GENERAL DESCRIPTION
The Rochester 4GC Carburetor (fig. 27) is mixed pro- Carburetors on vehicles equipped with air conditioning
duction on 327 cu. in. engines in Chevrolet, Chevelle and contain a hot idle compensator (fig. 28). The hot idle
Chevy II vehicles. compensator, a thermostatic controlled air bleed which
supplies additional air to the idle mixture, is used as an
aid to prevent stalling during prolonged hot idle periods.
SHIELD The hot idle compensator consists of a bi-metal strip, a
valve and a mounting bracket and is mounted between the
venturi on the secondary side of the carburetor bowl.

AIR CLEANER
MOUNTING STUD H<DLE
IDLE AIR VALVE
fM' FILTER NUT
INTERMEDIATE
• CHOKE ROD
hi
u /
/
/
>VALVE HOLDER
^Bl-METAL STRIP

PRIMARY / '
SIDE \ / / \ ^MOUNTING BRACKET
/ GASKET

MIXTURE |
SCREWSJ
PRIMARY^^H 1 ^ ^ ^ ^ SIDE
THROTTLE VALVE
^ ^

Fig. 27—Rochester 4GC Carburetor Fig. 28—Hot Idle Compensator

REPAIR PROCEDURES
Disassembly 7. Invert the bowl cover and remove the hinge pin and
spring from the primary float, then lift the float and
Disassemble Bowl Cover
needle from the air horn. Mark float assembly
1. Disconnect intermediate choke rod at upper end. "primary" to prevent unnecessary bending during
2. Remove gasoline inlet fitting and inlet screen. assembly.
3. Unhook the spring clip from the upp,er end of the 8. Remove the primary float needle seat using a wide
pump rod, and remove rod and clip from pump lever. blade screw driver. Remove seat g a s k e t and
4. Remove the small retainer screw holding the trip strainer.
lever to the choke shaft, then remove the trip lever.
5. Remove the 13 bowl cover to carburetor body at- NOTE: The float needle and seat are factory
taching screws. matched and must be installed in mated pairs.
6. Carefully lift the bowl cover straight up until the Never mix float needle and seats during cleaning
float is clear of the c a r b u r e t o r body (fig. 29). or replacement.

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC 6M-14

NOTE: Do not mix metering jets. Primary


main metering jets are different from secondary
side.
3. Remove the three attaching screws and lock washers
from venturi cluster on secondary side, and care-
fully remove cluster and gasket.
4. Remove both main metering jets from secondary side
of carburetor body. Keep separate from primary
jets.
Remove the pump return spring from the pump
well.

Fig. 29—Bowl Cover Removal


9. Remove the hinge pin and spring, float, needle seat,
gasket and strainer from secondary side of bowl
cover. Remove bowl cover gasket.
10. Remove the power piston by depressing the stem and
allowing it to snap into position.
11. Remove the horseshoe type retainer from the pump
plunger shaft.
12. Remove pump plunger by sliding the shaft through
the rubber seal. Place plunger in gasoline to pre-
vent rubber from drying out. Remove the rubber seal
from the top side of the bowl cover casting.
13. Remove the two choke valve retaining screws and
slide the choke valve from the shaft. Discard r e -
taining screws.
Disassemble Choke
1. Remove the three choke cover attaching screws and
retainers, then remove choke cover, gasket, and coil
assembly from carburetor (fig. 31).
2. Carefully lift the baffle plate from the choke housing.
3. Remove the choke housing attaching screws and re-
move choke housing and "O" ring seal from bowl.
4. Remove choke piston lever retaining screw and r e -
move choke shaft.
5. Rotate choke piston lever counter-clockwise to free
choke piston from housing, and remove piston and
lever assembly.

Disassemble Bowl and Throttle Body


1. Remove the three attaching screws and lock washers Fig. 30-—Bowl Cover—Exploded View
from venturi cluster on the primary side, and care- 1. Bowl Cover 12. Float Valve Gasket
fully remove cluster and gasket. 2. Choke Valve 13. Float Valve
3. Pump Plunger Rubber 14. Float Valve Needle
NOTE: The primary venturi cluster (fig. 32) Seal 15. Power Valve Piston
contains the pump discharge nozzles and idle 4. Pump Shaft and Lever 16. Pump Spring Clip
tube in addition to main well tubes, and must 5. Choke Trip Lever 17. Pump Spring Washer
always be installed on primary side. The venturi 6. Choke Counterweight 18. Pump Duration Spring
clusters are serviced as an assembly. 7. Inlet Filter Spring 19. Pump Plunger
8. Inlet Filter 20. Float Tension Spring
9. Inlet Gaskets 21. Float Hinge Pin
2. Remove both main metering jets from primary 10. Inlet Fitting 22. Primary Float
(pump) side of carburetor body (fig. 33), then remove 11. Bowl Cover 23. Secondary Float
power valve and gasket. Gasket 24. Choke Valve Shaft

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC 6 M - 1 5

Fig. 31-— Bowl and Choke—Exploded View

1. Secondary Cluster 9. Discharge Spring Guide 17. Float Bowl 24. Baffle Plate
2. Secondary Cluster Gasket 10. Discharge Spring 18. Auxiliary Throttle Valves 25. Choke Piston and Pin
3. Primary Cluster 11. Discharge Ball 19. Throttle Flange Gasket 26. Choke Piston Lever
4. Primary Cluster Gasket 12. Power Valve 20. Choke Coil Cover Retainer 27. Choke Housing Screw
5. Pump Return Spring 13. Idle Compensator 21. Choke Coil Cover 28. Choke Housing
6. Retaining Ring 14. Power Valve Gasket 22. Choke Coil Spring 29. Choke Housing " O " Ring
7. Screen 15. Primary Main Metering Jets 23. Choke Cover Gasket 30. Choke Shaft
8. Check Ball 16. Secondary Main Metering Jets

5. Remove retaining ring, pump inlet screen and check


ball from bottom of bowl (fig. 33)
^ SECONDARY CLUSTER

Mr

INLET STRAINER

Fig. 32—Primary Venturi Cluster Fig. 33—Bowl Assembly Parts Location

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC 6 M - 1 6

PUMP DISCHARGE SPRING GUIDE


of the carburetion operation, primarily during
wide open throttle.
PUMP
BORE The idle mixture needle screws may be removed for
cleaning or replacement. The idle speed screw and
spring can be replaced if necessary.
NOTE: The throttle f l a n g e and levers are
serviced as a unit. No further disassembly of
throttle flange should be attempted as it may be
impossible to again reassemble throttle valves
/ correctly in relation to vacuum and idle dis-
charge orifices.
Cleaning and Inspection
1. Thoroughly clean carburetor castings and metal
parts in clean cleaning solvent.
CAUTION: Pump p l u n g e r should not be im-
mersed in cleaning solvent. Clean the plunger in
'AUXILIARY clean gasoline. Do not i m m e r s e auxiliary
THROTTLE
VALVES
throttle valves in cleaning solvent. Clean with
WARM WATER and brush only.
2. Blow all passages in castings dry with compressed
Fig. 34—Removing Pump Discharge Guide air (fig. 37).
CAUTION: Do not use drills or wire to clean
6. Using needlenose pliers remove <<T" shaped pump out jets or passages as this may enlarge orifices
discharge spring guide, then remove the small spring and seriously affect carburetor calibration.
and steel ball (fig. 34).
7. Invert carburetor body and remove four throttle 3. Carefully inspect parts for wear and replace those
flange to carburetor body attaching screws. Then which are worn. Check the following specific points:
remove throttle flange, and gasket from carburetor a. Inspect choke piston and choke piston housing for
body.
8. Remove the secondary auxiliary throttle valve as-
sembly from the carburetor body (fig. 35).
NOTE: Do not attempt any further disassembly
of the auxiliary throttle valve assembly (fig. 36).
The spring tension is exactly calibrated and any
change will completely upset the secondary side

AUXILIARY
THROTTLE VALVES

BODY SPRING

Fig. 35—Auxilliary Throttle Valves Fig. 36—Throttle Body Assembly

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC 6 M - 1 7

carbon. If n e c e s s a r y to clean choke piston press downward. No fuel should be emitted from
housing, remove Welch plug in the top of housing. either the intake or discharge passage. If any fuel
Plug can be removed by piercing center with a does emit from either passage, the presence of
small instrument and prying outward. Care should dirt or a damaged check ball are indicated. Clean
be exercised so that damage will not result to the the passage again and repeat the test. If leakage
casting when removing this plug. Before installing is still present, replace the check valve,
new plug, carbon present in piston cylinder slots i. Inspect the upper and lower surfaces of the car-
should be removed and the Welch plug seat should buretor body to see that the small sealing beads
be carefully cleaned. are not damaged. Damaged beading may result in
b. Remove carbon from bores of throttle flange with loss of air or fuel.
sandpaper; never use emery cloth. j . Inspect holes in the pump rocker arm, fast idle
c. Inspect float needles and seats for wear; if worn, cam and throttle shaft lever. If holes are worn
both needle and seat must be replaced. excessively or out of round to the extent of im-
d. Inspect float pins for excessive wear. proper operation of the carburetor, the worn
e. Inspect floats for dents and excessive wear on lip parts should be replaced.
or at hinge pin holes. Check for fluid inside floats k. Inspect the steps on the fast idle cam for ex-
by shaking. Replace float if any of above are cessive wear. If excessive wear is n o t e d , it
present. should be replaced to assure proper warmup and
f. Inspect throttle shafts for excessive wear (loose- choking periods.
ness or rattle in body flange casting) replace 1. Check all filters for lint or dirt. Clean or replace
flange assembly if worn excessively. as necessary.
g. Inspect idle mixture adjusting screws for burrs. m. Check venturi clusters for loose or worn parts.
Replace if burred. If damage or looseness exists, replace cluster
h. Inspect pump plunger assembly. If rubber is not assembly.
in good condition, replace plunger as a complete Assembly and Adjustments
assembly. Assemble Bowl and Throttle Body
To check pump system: Pour 1/2 inch of 1. Install the auxiliary throttle valve assembly (with the
gasoline into carburetor bowl. Take pump plunger calibrated spring operating pin) down into the base of
from can of gasoline or kerosene and slide into the carburetor body (fig. 38).
pump cylinder. Place the discharge check ball
2. Position the throttle flange gasket on the carburetor
into body. Raise plunger and press lightly on shaft
body so that all holes are properly aligned.
to expel air from the pump passage. Using a 3. Place the throttle flange on the carburetor body and
small clean brass rod, hold the discharge ball install four attaching screws (fig. 39), then tighten
down firmly on its seat. Again raise plunger and the 3/8" x 24 center screw and 12 x 28 outer screws
securely.
4. Install the idle mixture screws and springs as they
were removed from the throttle flange. Back off
screws 1-1/2 turns for initial adjustment.

POWER PISTON

VALVE
SHAFT

AUXILIARY THROTTLE
VALVE BODY

Fig. 37—Passage Identification Fig. 38—Auxilliary Throttle Valves Installed

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC 6 M - 1 8

secondary venturi does not carry the idle tubes or


pump discharge nozzles.)
11. Install the primary venturi cluster and gasket using
three attaching screws and lock washers.

Assemble Bowl Cover

1. Install choke valve shaft carefully, then slide the


choke valve through shaft so the letters "R.P.' on
the valve are facing up with the valve closed.
2. Start the two small brass choke valve to shaft at-
taching screws. Do not tighten.
3. Position the choke counterweight over the choke
shaft.
4. Position the choke trip lever over the end of choke
shaft. Be sure the small tab of the trip lever is
above the choke counterweight tang and keyed to the
choke shaft before tightening the retaining screw.
5. To provide correct fit of the choke valve in bowl
cover, push lightly on the end of the choke shaft to
obtain a minimum clearance of .020" Chain Gauge
Set J-8879 b e t w e e n the trip l e v e r and choke
Fig. 39—Throttle Body Screw Location counterweight.
6. While holding the choke shaft in this position, tighten
5. Place the carburetor upright and install steel pump choke valve retaining screws. Check for free opera-
outlet ball, spring and "T" shaped guide (fig. 40). tion of choke valve in bowl cover.
NOTE: The steel o u t l e t ball is 3/16" in 7. Install gasoline inlet screen and fitting.
diameter. 8. Install the power piston into bowl cover and stake
very lightly to hold piston in place.
6. Install the pump return spring in the pump plunger 9. Assemble rubber seal on pump plunger shaft.
cylinder. 10. Index pump plunger with rubber seal in the bowl
NOTE: The spring must be all the way down cover by inserting the small end through from the
^nd seated. bottom. The lips of the seal must be sealed on both
sides of the bowl cover.
7. Install the pump inlet ball, screen, and retaining 11. Install the upper end of pump rod (with spring
ring. retaining clip) on the pump lever.
8. Install the two primary main metering jets and the 12. Install needle seat gasket.
power valve. 13. Install needle seat with wide bladed screw driver.
9. Install the two secondary main metering jets. Repeat operation for other needle and seat.
10. Install the secondary venturi cluster and gasket with
three attaching screws and lock washers. (The

STEEL BALL

EQUALIZER

Fig. 40—-Installing Pump Discharge Ball Fig. 41-—Float Level Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC 6 M - 1 9

8 9

jr
\ \
1 ir
IO^\2 13

^^V^ 1

\—®>

Fig. 44—Bowl Cover Screw Tightening Sequence


Fig. 42—Float Assemblies
CAUTION: Needle seats must be installed on Assemble Bowl Cover to Bowl
the same sides from which they were removed 1. Carefully guide bowl cover assembly on carburetor
to match their respective float needle. body, indexing pump plunger into well and closely
14. Install both float and needle arid spring assemblies observing alignment of floats and power piston shaft.
on the bowl cover, retaining in place with the hinge 2. Align bowl cover and gasket to holes in body and
pin. start the 13 bowl cover attaching screws (fig. 44).
3. Tighten evenly and securely the three inner attaching
Adjust Float (Figs. 41,42 and 43) screws, then tighten the remaining outside screws in
1. Invert the cover on a flat surface. Place Tool the same manner.
(J-8879-1 for primary float and J-8879-2 for sec- Assemble Choke Housing
ondary float) over floats on bowl cover gasket, so 1. Install the choke shaft and piston assembly by sliding
that it rests against the curvature of the bore of the the shaft through its bore. Then carefully fit the
bowl cover. piston in the bore of the housing, and install lever at-
2. Bend float arms horizontally until each float is cen- taching screw (fig. 45).
tered between tool legs. 2. Rotate the choke shaft clockwise to check for free
3. Bend float arms at rear of assembly until floats just movement of the shaft and the piston.
touch the tool at the notch. 3. Assemble the choke housing and gasket to the bowl
4. Hold the bowl cover in an upright position and meas- and tighten with two countersunk head screws.
ure the distance from the bowl cover to the bottom of 4. Connect intermediate choke rod to choke valve shaft
the float, with the float hanging free. Bend float tang lever.
at end of the float hinge arm to obtain the correct Adjust Accelerator Pump Rod (Fig. 46)
drop. 1. Back off idle screw to allow primary valves to close.

Fig. 43—Float Drop Adjustment Fig. 45—Choke Housing Assembly

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC 6 M - 2 0

GAUGE
J-7169
PUMP GAUGE
POSITION

GAUGE
J-7169
VENT
POSITION

Fig. 48—Idle Vent Adjustment


Fig. 46—Accelerator Pump Rod Adjustment

2. To check and adjust pump lever rod, place gauge on Adjust Intermediate Choke Rod (Fig. 49)
Chain Gauge Set J-8879 on bowl cover and insert 1. Hold the choke valve closed and push lightly on the
pump plunger rod in hole marked "Pump". Pump end of the choke piston to remove all lash in the
lever rod should enter pump lever freely. linkage, and then check to see if choke piston is flush
3. If necessary, bend rod with Tool J-4552 at upper with end of sleeve.
angle of pump rod. 2. Bend intermediate choke rod, if necessary, to cor-
Adjust Idle Vent (Figs. 47 and 48) rectly position the choke piston with Tool J-1137.
1. To check and adjust Atmospheric Valve, place gauge
on Chain Gauge Set J-8879 on bowl cover with side
Assemble and Adjust Choke Cover
marked "Vent/ 7 and insert pump plunger rod in hole.
With tool in this position, Atmospheric Valve should 1. Place baffle plate in position in choke housing.
be just closed as shown in inset. 2. Install thermostat cover and coil assembly, gasket
and retaining screws (with retainers). Leave housing
2. If necessary, bend arm with Tool J-4552 at tang on cover retaining s c r e w s loose enough to permit
pump lever. rotating of cover.
3. Assemble pump rod to pump lever and secure with 3. Rotate cover counter-clockwise until coil engages
clip. tang.
NOTE: On vehicles equipped with synchromesh 4. Set the cover at the specified mark. Tighten coil
transmission install pump rod in inner hole in cover retaining screws.
upper lever.
Adjust Choke Rod (Fast Idle) (Fig. 50)
1. Turn idle speed screw in until it just contacts the
second step of the fast idle cam.
2. Be certain that choke trip lever is in contact with
choke counterweight lever.
3. Holding the screw on the second step and against the
shoulder of the high step, check clearance with a

CHOKE VALVE CLOSED

BEND ROD TO ADJUST

END OF CHOKE PISTON


FLUSH WITH END OF
SLEEVE

Fig. 47-Checking Idle Vent Fig. 49—Intermediate Choke Rod Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC 6M-21

•£= CHOKE TRIP AND


J . COUNTERWEIGHT
•• LEVER MUST BE
* IN CONTACT

Fig. 52—Secondary Throttle Lockout Adjustment

Bend tang on the fast idle cam with Tool J-5197 to


correct adjustment.

Adjust Secondary Throttle Lockout (Fig. 52)


Fig. 50—Choke Rod (Fast Idle) Adjustment
1. With the choke valve closed so that secondary lockout
tang is in the fast idle cam slot, check clearance be-
1/16" drill between top edge of choke valve and tween fast idle cam and tang. The clearance should
dividing wall in the bowl cover. be .015".
4. Bend choke rod at lower angle if necessary to adjust. 2. Bend tang horizontally, using Tool J-4552.

Adjust Secondary Throttle Contour (Fig. 53)


Adjust Choke Unloader (Fig. 51) 1. With choke valve held wide open and the fast idle cam
1. With choke trip lever contacting choke counterweight and secondary lockout lever positioned as shown
lever, hold throttle valve in the wide open position. there should be a clearance of .015" (Tool J-8879)
2. Using Tool J-8879 check clearance between top of between the cam and the tang.
choke valve and the dividing wall of the bowl cover. 2. Bend tang vertically to adjust, using Tool J-6058-A.

f; r

BEND CHOKE VALVE


TANG WIDE OPEN

Fig. 51—Choke Unloader Adjustment Fig. 53—Secondary Throttle Contour Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC " L O W SILHOUETTE" 6 M - 2 2

ROCHESTER 4GC "LOW SILHOUETTE'


INDEX
Page Page
General Description 6M-22 Assemble Bowl Cover to Bowl 6M-27
Repair Procedures 6M-23 Assemble Choke Housing 6M-27
Disassembly 6M-23 Adjust Accelerator Pump Rod 6M-28
Bowl Cover 6M-23 Adjust Idle Vent 6M-28
Choke 6M-23 Adjust Intermediate Choke Rod 6M-28
Bowl and Throttle Body 6M-24 Assemble and Adjust Choke Cover 6M-28
Cleaning and Inspection 6M-25 Adjust Choke Rod (Fast Idle) 6M-28
Assembly and Adjustments 6M-25 Adjust Choke Unloader 6M-29
Assemble Bowl and Throttle Body 6M-25 Adjust Secondary Throttle Opening 6M-29
Assemble Bowl Cover 6M-26 Adjust Secondary Throttle Lockout 6M-29
Adjust Float 6M-26

GENERAL DESCRIPTION
The Rochester 4GC "Low Silhouette" Carburetor (fig.
ACCELERATOR CHOKE C O U N T E R W E I G H T LEVER
PUMP LEVER TR|p
54), used on the hydraulic lifter 409 cu. in. engine in the
Chevrolet, has a vacuum assisted primary float, a sec-
VENT VALVE LFEVER ondary float balance spring, a shallow fuel bowl assembly
ACTUATING T A N G SECONDARY
and a hot idle compensator. This carburetor; used in
VENT VALVE ACTUATING
LEVER
conjunction with an external, bowl type, fuel filter and a
metered fuel by-pass line; maintains a continued flow of
fuel in the lines thus eliminating possible vapor lock
conditions.
The hot idle compensator (fig. 55), a thermostatic con-
trolled air bleed which supplies additional air to the idle
mixture, is used as an aid to prevent stalling during
prolonged hot idle periods. The hot idle compensator
consists of a bi-metal strip, a valve and a mounting
bracket and is mounted between the venturi on the sec-
ondary side of the carburetor bowl.
ACCELERATOR
PUMP ROD
AIR CLEANER
SECONDARY MOUNTING STUD H(DLE
E ROD IDLE AIR VALVE
ACTUATING
ROD

SECONDARY
THROTTLE LEVER IDLE S C R E W
FAST IDLE C A M

THROTTLE LEVER
h /
/
/
>VALVE HOLDER
^-Bl-METAL STRIP

PRIMARY /
SIDE [ ^ / \ \ ^ ^MOUNTING BRACKET
CHOKE SHAFT ACCELERATOR PUMP SHAFT / / GASKET
LEVER
VENT VALVE
INTERMEDIATE GUARD
CHOKE ROD
PRIMARY/^^H
THROTTLE VALVE ^ ^
-
• ^^(rSECONDARY

Fig. 55—Hot Idle Compensator

FUEL
INLET NUT

IDLE
INTERMEDIATE VACUUM SPARK MIXTURE
CHOKE LEVER ADVANCE HOLE SCREWS

Fig. 54—Rochester 4GC (Low Silhouette)

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC "LOW SILHOUETTE" 6M-23

REPAIR PROCEDURES
Disassembly some g a s o l i n e to keep the rubber from
Disassemble Bow/ Cover hardening.
1. Remove fuel inlet nut, screen and gasket. 12. Use a large, wide-blade screw driver and remove
2. Remove intermediate choke rod hairpin clips then needle seats, gaskets and screens. Secondary float
remove rod. spring need not be removed.
3. Disconnect accelerator pump rod hairpin clips first
then remove rod. NOTE: If needle and seats are to be re-used it
4. Remove choke rod hairpin clips and remove choke is particularly important that the mating parts
rod. be kept in original order.
5. Remove idle vent shield and vent assembly by r e - 13. This is as far as is ordinarily necessary to dis-
moving attaching screw. assemble the bowl cover for cleaning. If it is
6. Remove 13 cover attaching screws (fig. 56) and break necessary to remove choke valve or shaft:
cover loose using finger pressure only. Do not pry • Remove choke shaft trip lever screw and remove
the cover loose. trip and kick levers from choke shaft.
7. Lift the bowl cover assembly straight up from the • File off the staked ends of choke valve screws and
bowl section to avoid damage to float assemblies. remove screws.
8. Invert the cover on bench then remove float hinge • Remove valve then slide shaft out of bowl cover.
pins, floats and needles. Remove needles from floats; • Install new parts using new choke valve screws.
they are attached with small wire clips. Support the shaft and stake the screw ends after
NOTE: Keep parts from primary side sepa- installation.
rated from secondary parts.
9. Remove and discard bowl cover gasket. Disassemble Choke (Fig. 58)
10. If necessary, remove vacuum power piston from bowl 1. Remove choke coil cover screws and retainers, and
cover by depressing plunger and allowing it to snap remove cover. Do not remove thermostatic coil from
back several times. It may be necessary to remove shaft in cover, as they are matched and come as
burrs around power piston bore caused by staking. a complete assembly.
Remove piston spring. Be careful not to damage 2. Remove cover gasket and choke baffle plate.
vacuum assist spring and cup retainer on power 3. Remove choke piston lever screw and slide choke
piston stem. piston out of its cylinder.
11, Disconnect accelerator pump from pump lever, then
remove pump plunger and boot (as an assembly)
downward out of bowl cover.
NOTE: If accelerator pump plunger is to be
re-used (see Inspection Procedures), place it in

Fig. 56-—Bowl Cover Screw Location Fig. 57—Bowl. Cover - Exploded View

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC "LOW SILHOUETTE" 6M-24

. „.. Choke Piston Lever Baffle Screws


Horseshoe Clip j /
Intermediate Choke Rod f Screw / Gasket

ntermediate / I 1 \

Shaft Lever j \ piston p in


Choke Housing ^ Thermostat Coil
And Cover

Fig. 58—-Choke Assembly - Exploded View

4. Disconnect choke piston from choke piston lever by


tapping piston and allowing piston pin to fall into
cupped hand.
5. Remove choke housing from bowl by removing two
inner attaching screws.
6. Remove intermediate choke shaft lever from choke
housing. Remove and discard choke housing gasket.

Disassemble Bowl and Throttle Body Fig. 60—Throttle Body Screw Location
1. Remove accelerator pump spring.
2. Remove pump inlet screen retainer.
3. Remove power valve and gasket with large screw 6. Remove primary and secondary main metering jets
driver. using a large screw driver.
4. Remove primary and secondary venturi clusters by 7. Remove <<T" shaped pump discharge check valve r e -
removing 3 attaching screws and lock washers from tainer from primary side with needlenosed pliers.
each. Remove gaskets from clusters. Baffles in Remove copper spring. Invert bowl and catch pump
main wells under primary cluster may be removed. discharge check ball, inlet check ball and pump inlet
Do not attempt to remove idler tubes or nozzles from screen.
venturi cluster.
5. Remove hot idle compensator and gasket from sec- Screw Screw
ondary side by removing two small self-tapping (3 Req'd) (2 Required)
screws. Discard gasket. Do not bend or distort bi- Lock Washer
metal strip. Idle compensator cannot be repaired or Hot Idle
Primary
recalibrated in the field. If defective, it must be Compensator
Venturi
replaced. Cluster
Secondary
Venturi
Power Valve Cluster
VENTURI HOT IDLE
CLUSTER COMPENSATOR
Gasket Secondary Jets
METERING \ , 11 fl Spring
ESS? Steel Check Ball
Accelerator
Pump Spring

Accelerator
Pump
VALVE T J H | ^ Baffle
Check Ball
Required.)

Gasket
Auxiliary Throttle
4yfltf|3| Valve Assembly
1WW^ ^
1 ^^j^3[p^>''\METERING
ACCELERATOR
PUMP SPRING ^g/pk
PRIMARY SIDE SECONDARY SIDE

Fig. 59—Bowl Assembly Parts Location Fig. 61—Bowl Assembly - Exploded View

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC "LOW SILHOUETTE" 6M-25

8. Invert carburetor on work bench. 7. Examine float needles and seats. If a needle appears
9. Remove idle mixture screws and springs. grooved, replace entire set with a factory matched
10. Remove idle air by-pass screw and spring. needle, seat, and gasket.
11. Remove large screw and lock washer from counter - 8. Inspect idle mixture adjusting screws for burrs,
bore in center of throttle body. ridges, or grooves. If wear is evident, replace
12. Remove three small attaching screws and lock screws.
washers. Screw in short passage is protected by 9. Inspect floats for dents or leaks. If floats have any
asbestos pad. liquid in them, replace float. Inspect hinge pin bores
13. Break throttle body loose from bowl with finger for burrs or wear. Check hinge pins for straightness.
pressure only. Do not attempt to pry bowl loose. 10. Clean strainer screens of dirt and lint. If distorted
14. Remove and discard throttle body-to-bowl gasket. or plugged, these screens should be replaced.
15. Remove auxiliary throttle assembly by sliding it out 11. Inspect auxiliary valve assembly. Shaft must be
of bowl. straight and must not bind.
12. Carefully check body assembly and valve assembly
Cleaning and Inspection
for wear at throttle valves and bores, and between
1. Thoroughly clean all metal parts of carburetor in shafts and their bores. Check for loose valve on their
cleaning solvent, with exceptions noted below, and shafts.
dry with compressed air.
Assembly and Adjustments
CAUTION: Do not wash a c c e l e r a t o r pump
plunger assembly, pump boot, rubber vent valve, Assemble Bowl and Throttle Body
or choke thermostatic coil housing in cleaning 1. Install idle speed screw and spring. Initial adjust-
solution. Wash these parts in clean solvent only. ment should be 3 complete turns from fully seated
position.
2. Clean and blow out all passages with compressed air. 2. Install idle mixture screws and springs. Tighten
Remove any gum d e p o s i t s which may have ac- screws carefully so as not to groove needles or en-
cumulated within carburetor parts. Clean carbon out large seats. Back out each screw 2 turns from lightly
of throttle body heat passage. seated position for initial mixture adjustment.
3. Make sure all calibrated restrictions, such as idle 3. With bowl upright, drop large steel pump outlet check
ports, air bleeds, or vents are clean, but do not pass ball and copper spring into bore under primary
drills through these passages. Use compressed air venturi cluster location. Install "T" retainer in slot
only. in bore, compressing spring.
4. Check all shafts and their corresponding bores for 4. Position smaller aluminum check ball on its seat in
wear. Check each piston in its respective cylinder. bottom of pump well.
Check for worn or damaged jets and worn holes in 5. Place pump spring in pump bore and compress into
the ends of the various levers. position with finger pressure.
5. Inspect accelerator pump plunger rubber, replacing 6. Install idle compensator and new gasket, using two
plunger as an assembly if rubber is creased or small self-tapping screws.
cracked. 7. Install baffles in primary main wells, if removed,
6. Inspect rubber vent valve and replace if it is with projections toward primary bores. Place new
cracked, swollen, or damaged. gaskets on primary and secondary venturi clusters
and install clusters in bowl, using 3 screws and lock
washers,
8. Invert bowl assembly.
9. Install auxiliary valve assembly in bowl with spring
cavity opening facing down.
10. Place new throttle body-to-bowl gasket on bottom
surface of bowl.
NOTE: Gasket is not reversible. Largest pro-
jecting tab must be placed on primary side of
bowl, surrounding vacuum passage to power
piston.
11. Place throttle body assembly on bowl and start 3
cross head attaching s c r e w s and lock washers
through gasket into bowl.
12. Install and tighten l a r g e center screw and lock
washer.
13. Tighten 3-outer screws uniformly.
14. Install primary and secondary main metering jets in
bowl. Primary jets have smaller holes than second-
ary jets and are installed in pump side of carburetor
bowl.
15. Install power valve and gasket.
16. Install small pump inlet screen and retainer in bot-
Fig. 62—Throttle Body Assembly tom of fuel bowl next to pump well.

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC "LOW SILHOUETTE" 6 M - 2 6

Floats Should Be Centered In Gage

Fig. 65—Float Level Adjustment


Fig. 63—Primary Float Alignment
10. Secure needles to floats with clips and install float
Assemble Bowl Cover
assemblies using hinge pins.
NOTE: Balance spring must be installed so as
1. Place small amount of lubricant on pump shaft and to assist closing the needle. Spring must be
install boot. between float tang and needle seat.
2. Lubricate pump arm shaft and install.
3. Install accelerator pump shaft in pump arm and r e - Adjust Floats
tain with clip. NOTE: All float adjustments should be made
4. Install pump arm shaft clip. with bowl cover gasket in place.
5. Install vent valve assembly with guard, using small 1. Using J-21608 check primary and secondary float
screw. alignment (figs. 63 and 64). If adjustment is neces-
NOTE: Be careful not to distort idle vent valve sary, bend float arms horizontally as required. Slide
with tang on pump lever. Tang should be posi- float assembly from side to side on hinge pin to make
tioned underneath spring metal strip. sure floats do not touch gauge.
6. Invert bowl cover. 2. Adjust primary and secondary float level as follows
7. Install power p i s t o n and spring. Do not damage (figs. 65 and 66):
vacuum assist spring and cup retainer. • With the bowl cover inverted and gasket in place,
8. Install primary and secondary needle seats, gaskets, check the height of each float at heel. Measure
and screens. from gasket to float heel.
9. Install new bowl cover gasket. • If necessary to adjust, bend float arm at center
with Tool J-7182-2. Use caution to prevent bend-
ing power piston stem.
• With bowl cover still inverted and gasket in place,
Floats Should Be Centered In Gage

Gasket

Fig. 64—Secondary Float Alignment Fig. 66—Bending Float Arm

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC "LOW SILHOUETTE" 6 M - 2 7

Bending Tool
J-7182-2

Vacuum
Assist Cup

Fig. 67—Float Drop Adjustment Primary Float Tang

check height of float toe at dimple. Measure from


gasket to dimple on toe of float. Fig. 69—Bending Primary Float Tang
• If necessary to adjust, bend float arm as r e -
quired. If toe adjustment is required, recheck NOTE: Be careful not to hold bowl cover in
heel adjustment. such a manner as to press against floats with
Adjust float drop as follows (fig. 67): hand when installing.
• Hold bowl cover so floats are hanging down.
Install 13 bowl cover screws and lock washers;
NOTE: To check primary float drop, power tighten inner 3 screws first. Install identification
piston must be fully extended. tag under corner screw above choke cam.
• Bounce floats lightly, then measure distance from Place choke rod and choke counterweight lever on
gasket to center of dimple on toe of float. choke shaft, with collar inward and tang pointing out-
• If adjustment is necessary, bend tang at rear of ward and toward secondary side of carburetor.
float arm. Install choke trip lever with letters " R P " facing out-
Adjust vacuum assist spring as follows (figs. 68 and ward and with lever projecting above tang on choke
69): lever. Install retaining screw.
• Hold bowl cover so floats are hanging down. 5. Install pump rod and spring clip.
• Hold power piston in full up position by placing
thumb nail at brass portion of power piston. Assemble Choke Housing
• Bounce floats lightly, then measure distance from 1. Place new choke housing gasket on choke housing.
gasket to center of dimple on toe of float.
• If adjustment is necessary, bend slotted tang at
center of float arms using Tool J-7182-2.

Assemble Bowl Cover to Bowl


1. Holding bowl cover assembly in upright position,
carefully lower into bowl.

PRIMARY FLOAT

GASKET

Fig. 68—Vacuum Assist Spring Adjustment Fig. 70—Accelerator Pump Rod Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC "LOW SILHOUETTE" 6 M - 2 8

VALVE
STARTS
MOVEMENT

PISTON END
FLUSH WITH BORE

Fig. 71—Idle Vent Adjustment Fig. 72—Intermediate Choke Rod Adjustment

2. Install intermediate c h o k e shaft lever in choke Assemble and Adjust Choke Cover
housing from side toward carburetor. 1. Install choke baffle plate.
3. Install choke housing with self-locking attaching 2. Install choke cover and gasket. Rotate counter-
screws. clockwise until cover choke valve is just closed and
4. Install choke piston on lever with piston pin. index marks align and tighten 3 cover retaining
5. Install piston assembly into housing with tang facing screws.
outward. Slide piston into vacuum cylinder. Adjust Choke Rod (Fast Idle) (Fig. 73)
6. Place piston lever over intermediate choke lever
1. Position fast idle screw on second step of fast idle
shaft, and retain with screw while holding lever cam, with screw resting against shoulder of highest
toward choke housing. step.
7. Install intermediate choke rod in choke shaft lever. 2. Hold choke valve closed so that choke trip lever is
Grooved end of rod goes into choke shaft lever. Re- in contact with choke counterweight lever.
tain with clip.
Adjust Accelerator Pump Rod (Fig. 70)
1. Back out idle speed screw until throttle valve is in
the fully closed position.
2. Measure the distance from the top of the bowl cover
to the bottom of the pump rod.
3. If adjustment is necessary, bend pump rod at upper
angle.
Adjust Idle Vent Valve (Fig. 71)
1. Turn idle speed screw in until measurement from top
of bowl cover to bottom of pump rod (measure as
outlined for Accelerator Pump Rod Adjustment) is
29/32. At this point the idle vent valve should just
close.
2. If necessary, bend actuating tang up or down using
Tool J-5197.
Adjust Intermediate Choke Rod (Fig. 72) IDLE SCREW
2ND STEP
1. Hold choke valve closed, push lightly on end of choke
CAM
piston to remove all lash in linkage. Then check to
see if choke piston is flush with choke piston bore.
2. Bend intermediate choke rod if necessary to cor-
rectly position choke piston.
NOTE: Choke mechanism must be absolutely
free in any position. Mechanism is free if choke
will fall open from its own weight. Fig. 73—Choke Rod (Fast Idle) Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


ROCHESTER 4GC "LOW SILHOUETTE" 6 M - 2 9

3. With fast idle screw and cam in this position, care-


fully bend choke rod to obtain specified clearance
between top edge of choke valve and dividing wall in
bowl cover. Use Bending Tool, J-1137.

Adjust Choke Unloader (Fig. 74)


1. With choke trip lever in contact with choke counter-
weight, move throttle to full open position.
2. Hold in this position and carefully bend tang of fast
idle cam to obtain specified clearance between top
edge of choke valve and dividing wall in cover. Use
Bending Tool, J-5197 on fast idle cam tang.
Adjust Secondary Throttle Opening
1. With carburetor inverted, move choke to fully opened
position.
2. Rotate primary throttle to fully open position.
3. Check opening of secondary throttle valves. They
should reach wide open position at the same time as
primary valve.
4. Check wide open stops on primary and secondary
throttle shafts, and bend tangs with heavy pliers as
required to obtain wide open positions. Tangs should
contact stops at same instant.
Fig. 75—Secondary Throttle Lockout Adjustment
Adjust Secondary Throttle Lockout
1. Position fast idle cam and secondary lockout lever 4. Open choke valve and open secondary throttle slightly
with choke valve partially closed, Figure to position lockout lever over fast idle cam (fig. 76).
2. Check clearance between upper edge of lever and
5. Measure clearance between lever and cam in this
cam with .015" Wire Gage, J-21608 (fig. 75).
position with .015" Wire Gage, J-21608, and bend
3. Use Tool J-6058 to bend secondary lockout lever to
with Tool J-6058 to obtain specified clearance.
obtain proper clearance.

Fig. 74—Choke Unloader Adjustment Fig. 76—Secondary Throttle Contour Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER YF 6 M - 3 0

CARTER YF
INDEX

Page Page
General Description 6M-30 Assemble and Adjust Metering Rod 6M-33
Repair Procedures 6M-30 Assemble Bowl Cover 6M-34
Disassembly 6M-30 Adjust Float 6M-34
Cleaning and Inspection 6M-31 Assemble Bowl Cover to Bowl 6M-34
Assembly and Adjustments 6M-32 Adjust Idle Vent 6M-34
Assemble Bowl and Throttle Body 6M-32 Adjust Choke Rod (Fast Idle) 6M-34

GENERAL DESCRIPTION
The Carter YF Carburetor (fig. 77) with hand choke, is accelerator pump and metering rod are controlled
used on L-4 engines in the Chevy II vehicle. This car- manually and automatically through a vacuum diaphragm
buretor has the conventional float and the conventional pump unit. This carburetor also incorporates an idle
low speed, high speed and accelerator pump circuits. The vent.

Fig. 77—Carter YF Carburetor

REPAIR PROCEDURES
Disassembly 8. Loosen throttle shaft pump arm lock screw and r e -
1. Remove clip at each end of fast idle rod and remove move arm and pump connector link.
rod. 9. Remove diaphragm housing screws and lift out entire
2. Remove inlet filter nut, filter, spring and gaskets pump, metering rod, and idle vent assembly (fig. 78).
from bowl cover. 10. Remove metering rod from metering rod arm, then
3. Remove 6 bowl cover screws (3 from body to cover compress upper pump spring(s); remove retainer,
then 3 from cover to body) and lift cover straight up spring(s), metering rod arm, and pump lifter link as-
from body (to prevent float damage). sembly. If necessary, remove idle vent screw as-
4. Place cover up-ended on a flat surface and remove sembly from lifter link.
float hinge pin, float, and float needle. 11. Compress lower spring; remove the spring retainer
5. Remove float needle seat using a wide screw driver. and lower pump spring.
6. Check the fuel bowl for evidence of dirt, grit, or 12. Remove pump housing screws from housing and dia-
metal particles in the fuel or in bottom of bowl, then phragm, then remove diaphragm shaft retaining ring
hold finger over pump discharge passage (to retain and slide diaphragm assembly out of housing.
discharge needle) and operate the pump manually a 13. Remove main metering jet and low speed (idle) jet
few times to check operation of diaphragm; check (fig. 79). (Do not remove any pressed-in parts.)
ball and needle, and passage restriction. 14. Remove idle mixture screw and 2 remaining body-
7. Empty the gas and remove pump discharge needle by flange attaching screws and remove body and gasket
up-ending carburetor bowl. from throttle flange.

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER YF 6M-31

Fig. 79—Metering Rod and Idle Jet Location

NOTE: Damage or excessive wear in throttle


shaft bores necessitates replacement of the
throttle flange to maintain position of drilled
passages to throttle plate.

Fig. 78—Pump and Metering Rod Assembly

Ordinarily, the carburetor flange and bowl cover


are disassembled as far as is necessary during an
overhaul procedure. The valve and shaft should not
be removed unless shaft is binding, valve is dam-
aged or s h a f t spring needs replacing. If either
condition exists, disassemble as follows:
15. File staked ends of choke valve screws flush with
shaft to prevent damage to shaft threads, then r e -
move screws and choke valve and slide choke shaft
from housing.
16. To remove choke cam lever pry off retainer ring,
then slide lever and spring from mounting boss.
17. File staked ends of throttle valve screws flush with
throttle shaft; remove screws and throttle plate, then
slide shaft out of flange and remove fast idle arm.

Cleaning and Inspection


1. Wash all metal parts in cleaning solvent and dry with
compressed air.
2. Check all passages for clogging and blow clean with
compressed air.
CAUTION: Do not use wire or other pointed
instruments to clean drilled passages or cali-
brated openings.
3. Inspect pump diaphragm for tears or holes and dia-
phragm housing for free intake check ball and clean
passages.
4. Check floats for leaks, dents, wear at lip and hinge
pin.
5. Check float needle and seat for wear and replace if
necessary.
6. Check fuel filter for chips, cracks or clogging.
7. Check throttle flange for surface squareness and for
slop in shaft bores. Fig. 80—Fast Idle Arm Installation

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER YF 6M.-32

8. Check choke valve and shaft for binding in bowl cover


when assembled.
Assembly and Adjustments
Assemble Bowl and Throttle Body
1. If disassembled, install fast idle arm over boss on
throttle flange and slide shaft into flange (fig. 80).
2. Install throttle valve with lettering toward manifold
side of flange and part number opposite idle port.
3. Install throttle valve screws; support the shaft at the
screwhead and stake the other end of the screws.

Fig. 82—Pump Connector Link Installation

4. Install idle adjustment screw and spring lightly to its


s e a t and back out 1-1/2 t u r n s as an initial
adjustment.
5. Assemble throttle flange to body casting using a new
gasket.
6. Install low speed jet assembly and main metering jet.
7. Assemble diaphragm and shaft into pump housing and
install retaining ring on shaft, then install lower
pump spring and retainer (fig. 81).
8. Assemble pump lifter link, then metering rod arm,
upper spring(s) and spring retainer onto pump shaft.
9. If idle vent screw assembly was replaced, install new
assembly onto pump lifter link.
10. Align diaphragm with holes in housing, then install
screws (4) through housing and thread into diaphragm
2 or 3 threads.
11. Install diaphragm assembly in place in carburetor
body and tighten screws securely.

12

Fig. 81—Pump and Metering Rod—Exploded View

1. Seal 7. Upper Spring


2. Lifter Link 8. Retainer
3. Metering Rod 9. Lower Spring
4. Metering Rod Arm 10. Screws
5. Idle Vent Assembly 11. Pump Housing
6. Retainer 12. Diaphragm Assembly Fig. 83—Metering Rod Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER YF 6 M - 3 3

Fig. 86—Idle Vent Adjustment


Fig. 84—Float Level Adjustment (fig. 83). Metering rod arm should rest parallel on
pump lifter link and metering rod eye should just
12. Install pump connector link in throttle shaft pump slide over metering rod arm pin.
arm, then install arm over throttle shaft, guiding
connector link end into pump lifter link, and tighten
lock screw (fig. 82). CHOKE VALVE
CLOSED
NOTE: Linkage must not bind in any throttle
position. If binding occurs, loosen lock screw,
adjust slightly and retighten screw.
13. Install pump discharge needle.
Assemble and Adjust Metering Rod
1. Place metering end through metering jet against bot-
tom in casting and, with throttle valve closed, press
down on upper pump spring until pump bottoms out

FAST IDLE
LEVER TANG

Fig. 85—Float Drop Adjustment Fig. 87—Choke Rod (Fast Idle) Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER YF 6 M - 3 4

2. Adjust by bending metering rod arm. Assemble Bowl Cover to Bowl


1. Install bowl cover assembly and 6 attaching screws
Assemble Bowl Cover (one long screw installed through flange and body into
1. Install needle seat and gasket assembly, needle, float cover).
and float hinge pin with stop shoulder on hinge pin 2. Install fast idle connector rod and clips.
on side opposite carburetor bore.
2. Install bowl cover gasket. Adjust Idle Vent (Fig.86)
3. Install fuel filter spring, filter and inlet nut using 1. Back idle speed screw out until free of fast idle cam
new gaskets. (choke open). This assures closed throttle valve.
2. Check clearance between cover and vent valve using
Adjust Float Tool J-21215 (.030'%
1. Invert bowl cover and measure float level (the dis- 3. If necessary, adjust using screw driver.
tance between float and cover at free end of float)
(fig. 84). Adjust by bending lip of float (not float arm) Adjust Choke Rod (Fast ldle)(Fig. 87)
that rests on needle. 1. With choke valve in wide open position, the tang on
2. Hold cover in upright position (allowing float to hang fast idle lever should just contact stop boss on car-
down) and measure float drop from cover to float at buretor body.
end opposite hinge (fig. 85), using Tool J-21215. 2. If necessary to adjust, bend rod at offset to correct
Adjust by bending stop tab on float arm. this relationship.

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER WCFB 6M-35

CARTER WCFB
INDEX
Page Page
General Description 6M-35 Adjust Floats 6M-40
Repair Procedures 6M-35 Assemble Bowl Cover Lower Components 6M-41
Disassembly 6M-35 Assemble Bowl Cover Upper Components 6M-41
Bowl Cover Upper Components 6M-35 Adjust Accelerator Pump Rod 6M-42
Bowl Cover Lower Components 6M-35 Adjust Metering Rod 6M-42
.Bowl 6M-36 Adjust Choke Rod (Fast Idle) 6M-43
Choke 6M-38 Adjust Idle Vent 6M-43
Throttle Body 6M-39 Adjust Intermediate Choke Rod 6M-43
Cleaning and Inspection 6M-39 Assemble and Adjust Choke Cover . . . . . . . . . . 6M-44
Assembly and Adjustments 6M-39 Adjust Choke Unloader 6M-44
Assemble Throttle Body 6M-39 Adjust Secondary Throttle Lever 6M-44
Assemble Choke Housing 6M-40 Adjust Auxiliary Valve Lockout 6M-44
Assemble Bowl 6M-40

GENERAL DESCRIPTION
The Carter WCFB Carburetor (fig. 88) is used in mixed
production on 327 cu. in. engines in the Chevrolet
vehicles.
Functionally, the Carter Model WCFB carburetor is
two dual carburetors contained in one assembly and is
built from four basic castings: choke housing, bowl
cover, carburetor body, and throttle flange. The section
containing the metering rods, accelerating pump and
choke is termed the primary side of the carburetor, and
the other section is termed the secondary side. It has
five conventional systems as have been used in previous
carburetors: float system, low speed system, high speed
system, pump system, and Climatic Control system
(choke).

Fig. 88—Carter WCFB Carburetor

REPAIR PROCEDURES
Disassembly 7. Lift metering rod arm from metering rod well. Push
connecting link out of pump shaft and remove arm
Disassemble Bowl Cover Upper Components
and link.
1. Do not remove fuel in bowl. Remove inlet nut and 8. Rotate each metering rod one-half turn and remove
gasket. Lift filter out of filter inlet well in primary from hanger. Use care to prevent losing the two
side of carburetor. metering rod disks.
NOTE: Under normal service the carburetor
NOTE: Tap filter nut l i g h t l y with hammer bowl cover may be cleaned without further dis-
before loosening with wrench. assembly. If complete disassembly is necessary
2. Remove choke connector rod and intermediate choke perform operation 9.
rod at both ends. 9. Remove two choke valve screws and choke valve, and
3. Remove retainer securing throttle rod to lever on remove shaft.
pump countershaft and disconnect rod.
4. Remove metering rod dust cover and gasket by r e - Disassemble Bowl Cover Lower Components
moving two screws. 1. Remove 16 bowl cover attaching screws. Lift bowl
5. Remove vapor vent arm attaching screw and arm. cover straight up to prevent damaging floats, vacuum
6. Loosen, but do not remove screws securing pump op- piston, or pump plunger assembly (fig. 90). To avoid
erating arm and metering rod arm to countershaft bending floats, be sure bowl cover gasket is not
and pull countershaft out of bowl cover. sticking to bowl.

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER WCFB 6M-36

Fig. 89—Bowl Cover Upper Components—Exploded View

1. Bowl Cover 5. Pump Counter Shaft 9. Metering Rods 14. Inlet Fitting Nut
2. Metering Rod Arm Assembly 10. Dust Cover Gasket 15. Filter Gaskets
3. Vent Arm 6. Choke Shaft Lever ] 1. Dust Cover 16. Filter
4. Pump Operating Arm 7. Vent Arm Screw 12. Choke Valve 17. Filter Spring
and Link 8. Metering Rod Disks 13. Choke Valve Screw 18. Choke Valve She

2. Place bowl cover upside down on a clean work bench. essary bending of floats during assembly adjustments
Remove two float hinge pins and lift out secondary due to misplaced floats.
and primary floats. Mark and group floats to identify 3. Remove secondary float needle, seat and gasket.
as primary and secondary. This eliminates unnec- Group needle and seat to p r e v e n t mismatch at
assembly.
4. Remove and group primary float needle seat and
gasket.
5. Lift pump plunger assembly out of bowl cover and
remove return spring from carburetor body. Place
pump plunger in gasoline or kerosene to prevent
leather from drying out.
6. Rotate vacuum piston 90-degrees to disconnect from
vacuum piston link and remove link.
7. Remove bowl cover gasket.
Disassemble Bowl
1. Remove pump plunger assembly and lower pump
spring.
2. Remove vacuum piston spring.
3. Check the fuel in the bowl for contamination by dirt,
water, gum or other foreign matter, then drain fuel
from bowl.
NOTE: A magnet swept around bottom of bowl
Fig. 90—Bowl Cover Removal while fuel is still present will pick up iron oxide

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER WCFB 6 M - 3 7

Fig. 91—-Bowl Cover Lower Components—Exploded View


1. Carburetor Body 7. Needle Seat Gasket 11. Needle Seat Gasket 16. Pump Plunger Assembly
2. Float Hinge Pins 8. Bowl Cover 12. Primary Float Needle Seat 17. Pump Plunger Return Spring
3. Secondary Float 9. Vacuum Piston Link 13. Primary Float Needle 18. Primary Float
4. Bowl Cover Gasket 10. Bowl Cover Attaching 14. Vacuum Piston
5. Secondary Float Needle Screw (16) 15. Vacuum Piston Spring
6. Secondary Float Needle Seat

Fig. 92-Bowl-Exploded View


1. Secondary Jets 6. Pump Discharge Needle 11. Carburetor Body 15. Auxiliary Throttle Valves
2. Pump Jet Cluster Attaching Screw 7. Vacuum Piston Spring 12. Screw 16. Carburetor Body Gasket
3. Pump Jet Cluster 8. Pump Plunger Assembly 13. Auxiliary Throttle Valve Cam 17. Throttle Flange
4. Cluster Gasket 9. Pump Plunger Return Spring 14. Auxiliary Throttle Valve Shaft 18. Throttle Flange Attaching
5. Metering Rod Jets 10. Pump Inlet Ball Retainer and Weight Assembly Screw

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER WCFB 6M-38

dust or metal particles which have a tendency to NOTE: The low speed jets are installed at
cause leakage at needle seats. slight a n g l e . The anti-percolator plugs and
bushings, and main d i s c h a r g e nozzles are
4. Remove pump jet cluster attaching screw, then r e - pressed in place and should not be removed.
move cluster and gasket.
5. Invert carburetor and remove small (brass) pump 9. Remove six throttle flange a t t a c h i n g screws and
discharge needle. separate the throttle flange and carburetor body.
6. Remove pump inlet ball retainer and check ball from 10. Remove gasket from carburetor body.
bottom of pump cylinder well by prying the retainer 11. If necessary to remove auxiliary throttle valves, file
sideways with a 5/16-inch six point socket. staked ends of screws, remove screws and valves
7. Remove 2 primary metering rod jets (located on and pull out shaft.
pump side of carburetor). Disassemble Choke
8. Remove two secondary main jets. 1. Remove 3 choke cover retainer screws.
NOTE: Primary metering rod jets have dif- 2. Remove choke cover retainer, cover, cover gasket
ferent openings than the secondary main jets. and baffle plate.
Never mix these jets. 3. Remove 3 choke housing mounting screws. Remove

Fig. 93-Throttle Body and Choke-Exploded View

\. Choke Connector Rod 10. Secondary Throttle Valves 18. Bearing Washer 26. Retainer Ring
2. Primary Throrfle Shaft 11. Primary Throttle Valves 19. Secondary Throttle Shaft 27. Choke Coil Cover
3. Pump Connector Rod 12. Idle Mixture Screws and 20. Spring Retainer 28. Choke Cover Gasket
4. Fast Idie Cam Retaining Springs 21. Bearing Washer 29. Baffle Plate
Screw 13. Throttle Flange 22. Bearing Washer 30. Choke Piston Lever Screw
5. Fast Idle Cam Assy. 14. Primary Throttle Shaft Dog 23. Pr?mary-to-Secondary 31. Choke Piston and Piston
6. Lower Choke Lever and Arm Connector Link Lever
7. Bearing Washer 15. Spacer 24. Secondary Throttle Return 32. Choke Housing
8. Bushing 16. Shaft Screw Spring 33. Choke Housing " O " Ring
9. Auxiliary Valve Lockout 17. Spring Retainer 25. Choke Coil Cover Screws 34. Choke Shaft
Lever

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER WCFB 6M-39

"O" ring seal from v a c u u m opening of housing


mounting boss.
4. Remove choke piston lever screw and disassemble
piston and 2 levers.
RETURN
Disassemble Throttle Body SPRING
(WIND IV2
1. Remove two idle mixture screws and springs. TURNS)
2. Remove throttle lever adjusting screw, washer and
spring.
NOTE: Under normal service the carburetor
flange may be cleaned without further disas-
sembly, if complete disassembly is necessary,
perform the remaining operations.
3. Remove fast idle cam retaining screw, fast idle cam
assembly and lockout arm. Fig. 94—Secondary Throttle Lever and Spring Installation
4. Remove primary to secondary connector rod pin,
springs and washers, then remove rod. NOTE: Removal of the welch plug to clean the
5. Remove primary throttle shaft screw and washer. choke piston housing should be done only if the
6. Remove primary throttle levers. choke p i s t o n does not move f r e e l y in its
7. Unhook secondary throttle return spring. cylinder.
8. File off staked ends of throttle valve attaching 7. Inspect float needles and seals for burrs and ridges.
screws and remove screws and throttle valves from If present, replace both the needle and seat; never
the bores. replace either alone.
9. Remove primary and secondary throttle shafts. 8. Inspect metering rods and jets. If either are bent,
burred, or distorted, replace both rod and jet.
Cleaning and Inspection
9. Inspect edges of primary and secondary throttle
The most frequent causes of carburetor mal-function valves for gouges and other deformations. If these
are gum, dirt, carbon, and water. For this reaspn, care- or any other conditions exist which would prevent full
fully clean and inspect all parts and castings while the seating, replace the faulty valve.
carburetor is being serviced. 10. Check pump plunger return spring and vacuum piston
1. a. Wash all parts in carburetor cleaning solution spring for weakness and distortion.
except coil housing assembly and pump plunger, 11. Inspect all mating surfaces of choke housing, bowl
b. Choke coil housing assembly should be cleaned in cover, carburetor body, and throttle flange for burrs,
gasoline. gouges, or other surface irregularities. All surfaces
2. Inspect holes in all operating levers and castings for must be smooth to prevent leaks.
excessive wear. Assembly and Adjustments
3. Inspect bearing surfaces of all shafts for excessive
wear, Assemble Throttle Body
1. Install the primary and secondary throttle shafts with
NOTE: If excessive wear is noted to the extent secondary throttle return spring on secondary shaft
of improper operation of the carburetor, the and using a piece of hooked wire, wind spring 1-1/2
worn parts should be replaced. turns clockwise and hook spring onto secondary
4. Inspect floats for bad dents and/or possible leaks. throttle lever (fig. 94).
5. Inspect pump plunger leather for cracks or creases.
To check pump system: Pour 1/2 inch of gasoline
into carburetor bowl. Take pump plunger from can IDLE ADJUSTING
of gasoline or kerosene and slide into pump cylinder. SCREWS AND
Place the discharge check ball into body. Raise O 1 SPRINGS
plunger and press lightly on shaft to expel air from
the pump passage. Using a small clean brass rod, SECONDARY
hold the discharge ball down firmly on its seat. Again THROTTLE
raise plunger and press downward. No fuel should be VALVES
emitted from either the intake or discharge passage.
If any fuel does emit from either passage, the
presence of dirt or a damaged check ball are indi-
cated. Clean the passage again and repeat the test.
If leakage is still present, replace the check valve. SECONDARY THROTTLE | p PRIMARY THROTTLE
SHAFT E i SHAFT
6. If choke piston sticks in cylinder, remove welch plug
in bottom of housing for inspection of cylinder and
air slots. If carbon or dirt is present, remove carbon
from cylinder with sandpaper (DO NOT USE EMERY
CLOTH) and clean slots. Carefully install new welch
plug. Be certain welch plug seat is carefully cleaned
before installing new plug. Fig. 95-Position of Throttle Valves

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER WCFB 6 M - 4 0

2. Position primary t h r o t t l e valve (fig. 95) with the


stamped number facing the manifold side and toward
the center of the throttle flange. Slant the shaft and LOWER CHOKE
LEVER
valves toward the center of the flange until the
throttle valves seat fully and install new throttle RETAINING
valve screws. SCREW
3. Place secondary throttle valves with the number
facing the manifold side and toward the center of the
throttle flange. Complete installation as in Step 2
above.
4. Install two idle mixture screws and springs (fig. 95)
finger tight, then back out one (1) turn as a tem-
porary adjustment. Do not overtighten screws as this
can deform seating surfaces.
FAST
5. Install throttle shaft dog s p a c e r and screw on IDLE CAM
primary throttle shaft. Adjust parts relationship as
illustrated (fig. 96). AUXILIARY VALVE
LOCKOUT LEVER
6. Using a bearing washer (fig. 96) on each side of the
secondary throttle lever and inner throttle shaft arm,
install connector rod (fig. 96). Secure rod with two
spring retainers. Fig. 97—-Assembly of Fast Idle Cam and Lower Choke Lever
7. Assemble the fast idle cam and lower choke lever
and auxiliary lockout lever on retaining screw (fig. Assemble Bowl
97). Make certain tang of lower choke lever is in- 1. If auxiliary throttle valves have been disassembled,
stalled under spring of fast idle cam as illustrated. insert auxiliary throttle valve shaft through bowl and
8. Position secondary lockout lever against boss of install auxiliary throttle valves.
throttle flange and secure with retaining screw in 2. Place NEW body to flange gasket on carburetor body.
fast idle cam assembly. Check that levers and cam 3. Install throttle flange on carburetor body with six at-
operate freely after installation. taching screws and lock washers.
9. Install choke rod in fast idle cam and secure with 4. Install primary metering rod jets.
spring retainer.
10. Install throttle lever adjusting screw, spring and NOTE: The primary metering rod jets have the
washer. large holes and must be installed in the primary
side of the carburetor. This is the pump cyl-
Assemble Choke Housing inder side of the carburetor body.
1. Install choke piston on lever and position assembly
in choke housing. 5. Install secondary main jets.
2. Install choke shaft and lever assembly in housing and 6. Install steel pump inlet ball check and retainer.
attach to choke piston lever assembly with attaching 7. Install brass pump discharge check needle. Be sure
screw. needle is installed point down.
3. Mount choke housing on throttle flange with mounting 8. Install pump discharge cluster gasket, cluster as-
screws being careful to keep v a c u u m passage sembly and attaching screw.
" O " ring seal in place. 9. Install vacuum piston spring in vacuum piston bore.
NOTE: The vacuum piston spring affects both
economy and performance. If vacuum piston
spring appears to be damaged or distorted, it
should be replaced. If any doubt exists, use a
new spring for comparison.
10. Install lower pump spring in pump cylinder.

Adjust Floats
1. Place bowl cover upside down on bench and install
primary and secondary float needles and seats, using
new seat gaskets.
CAUTION: Do not interchange p r i m a r y and
secondary needles or seats. Also, if it was
deemed necessary to replace any needle or seat
during inspection, be sure to replace both the
float needle and seat as a pair.
2. Without installing bowl cover gasket, temporarily at-
tach both the p r i m a r y and secondary floats for
adjustment. Be sure to reinstall floats on side from
which they were removed to prevent unnecessary
Fig. 96—Primary Throttle Shaft Installation bending.

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER WCFB 6M-41

GAUGE J-7665
PRIMARY

Fig. 99—Float Drop Adjustment

GAUGE J-7665 2. Insert pump shaft through bowl cover and retain in
SECONDARY position with link and pump arm assembly.
3. Reinstall the primary and secondary float assemblies
(with float tension spring on secondary side).
CAUTION: Be certain, the float and needle as-
semblies are assembled to match the correct
needle seat.
4. Carefully position the bowl cover assembly on the
carburetor body being sure the vacuum piston and
pump plunger are aligned so they enter their respec-
tive bores.
5. Install 16 bowl cover attaching screws. Determine
proper location of different length screws (fig. 100).
Tighten all screws evenly, working from the inner
Fig. 98—Float Lateral and Vertical Adjustment
located screws to the screws located around the
outer edge of the carburetor.
Three separate adjustments must be made on both
Assemble Bowl Cover Upper Components
the primary and secondary floats; lateral, vertical,
and float drop. 1. Install metering rods as follows: Use metering rod
Lateral a d j u s t m e n t (fig. 98): Position 1/4" float
gauge in Chain Gauge Set J-7665 directly under the
center of secondary float with notched portion of
gauge fitted over edge of casting as illustrated. Sides
of float should just clear vertical uprights of gauge;
otherwise bend float arms as required. Repeat this
adjustment on the primary float using 1/8" float
gauge.
Vertical adjustment (fig. 98): With float gauges posi-
tioned as in the above, tops of floats should just clear
the horizontal bar of gauges, otherwise bend arms of
floats as required. Proper distance between top of
floats and bowl cover is 1/4-inch on secondary floats
and 1/8-inch on primary floats.
Drop measurement must be made with bowl cover
gasket removed.
Float drop adjustment (fig. 99). With bowl cover held
in upright position and measuring from the lowest
point of the floats, the distance between the bottom of
the floats and the bottom of the bowl cover should be
2 inches for primary and secondary floats. Bend
float tangs as required to achieve this distance. Tool
is in Chain Gauge Set J-7665.
8. Remove floats and install a new bowl cover gasket.
Assemble Bowl Cover Lower Componenfs
1. Install vacuum piston link and vacuum piston with lip
on link toward air horn. Fig. 100—Bowl Cover Screw Location

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER WCFB 6M-42

to position metering rod disks over holes in bowl


cover with countersunk side down. Catch metering
rod spring loop with lower end of rod before rod is
inserted, then twist "eye" of rod onto vacuum piston
link assembly.
2. Place metering rod arm in place.
3. Install pump countershaft by sliding shaft through
pump operating arm and metering rod arm.
CAUTION: Be certain metering rod operating
arm is positioned in slot in vacuum piston link.
4. Tighten pump arm screw.
5. Install vapor vent arm and attaching screw.
6. Install throttle connector rod, into throttle lever METERING "
while holding lever in closed position and retain with ROD HANGER
spring and retainer.
7. Install throttle connector rod in pump countershaft
lever and retain with clip.
8. If bowl cover has been completely disassembled per-
form Steps 9, 10 and 11.
9. Install choke shaft through bowl cover,
10. Place choke valve in position on choke shaft with the
"C" (in circle) on valve visible from the top of the
carburetor. Center choke valve and install screws.
Use new screws.
NOTE: Make sure that neither valve nor shaft
binds in any position and that valve drops free by
its own weight.
11. Install choke operating lever on shaft. Tighten screw
only enough to permit lever to be moved.
12. Install choke connector rod in choke operating lever
Fig. 102—Metering Rod Adjustment
and choke lower lever, and retain lower end of rod
with pin spring. 3. Visually check the relationship between the top flat
13. Install filter, inlet fitting, gaskets, and filter spring of the pump arm and the gauge. Properly adjusted,
in primary side. these surfaces should be parallel.
Adjust Accelerator Pump Rod (Fig. 101)
4. If necessary, correct adjustment by bending pump
1. Back out idle speed adjustment screw. rod with Bending Tool J-5496.
2. Hold float drop adjustment tool from Chain Gauge Adjust Metering Rod (Fig. 102)
Set J-7665 on dust cover boss. 1. Back out throttle lever adjusting screw to allow
throttle valves to seat fully and loosen screw in
metering rod arm.

Fig. 101— Accelerator Pump Rod Adjustment Fig. 103—Choke Rod (Fast Idle) Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER WCFB 6 M - 4 3

Fig. 104—'Idle Vent Adjustment


Fig. 106—Choke Unloader Adjustment
2. Press down metering rod arm until rods bottom. out throttle lever stop screw to allow throttle valves
3. While holding metering rods down and with throttle to seat in bores of carburetor.
valves seated, rotate metering rod arm upward until 2. Insert 1/16" gauge on chain gauge on Chain Gauge
arm lightly contacts hanger. Lock arm in this posi- Set J-7665 between lower edge of vapor vent and well
tion by tightening set screw. in dust cover.
4. Using a new cover gasket, install dust cover. 3. Properly adjusted, the clearance should be 1/16".
Remove dust cover and bend v a p o r vent arm if
Adjust Choke Rod (Fast Idle) (Fig. 103)
adjustment is necessary.
1. Loosen choke lever clamp screw on choke shaft.
2. Insert .020 wire gauge from Tool J-7665 between lip Adjust Intermediate Choke Rod (Fig. 105)
of fast idle cam and boss of throttle flange. 1. Open choke valve and insert .026" wire gauge, Tool
3. Holding choke valve tightly closed, pull choke shaft J-7665, between bottom of slot in piston and top of
lever upward as illustrated to eliminate all slack slot in choke piston housing. Close choke piston
from linkage and tighten screw in choke lever clamp. against this gauge (using a rubber band doubled will
4. Throttle valve clearance during fast idle is de- keep tension of piston against wire gauge leaving one
termined by the normal idle position of the idle speed hand free for adjustment while gauging choke valve
screw on fast idle cam. and check clearance between top of choke valve and
web of air horn casting).
Adjust Idle Vent (Fig. 104)
2. If adjustment is required, bend intermediate choke
1. With dust cover and dust cover gasket installed, back rod using Bending Tool J-4552.
3. Remove gauges and rubber band from choke piston
lever.
SLOT

BEARING
WASHER

Fig. 105—Intermediate Choke Rod Adjustment Fig. 107—Secondary Throttle Lever Clearance

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER WCFB 6M-44

Fig. 109—Auxiliary Valve Lockout Adjustment


Fig. 108—-Secondary Throttle Lever Adjustment
2. To adjust, bend connector rod at upper angle with
Assemble and Adjust Choke Cover Tool J-5496.
1. Install choke baffle plate, gasket and thermostatic 3. To adjust secondary valves use 5-1/2° gauge, Tool
coil housing assembly, retainer ring and screws. Set J-7665. Hold gauge flat against throttle flange
(Leave screws loose.) and slide 5-1/2° angle of gauge beside secondary
2. Turn housing clockwise to specified setting and throttle valve.
tighten retaining screws securely. 4. Bend tang on secondary throttle dog (shoe) if neces-
sary, using Tool J-1137.
Adjust Choke Unloader (Fig. 106) 5. Flip throttle several times to make sure throttle
1. Move the throttle linkage until the throttle valves are valves are closed.
wide open. 6. With throttle valves tightly closed there should be
2. Holding the linkage in this position, the distance be- .017-.022 inch clearance between positive closing
tween inboard edge of the choke valve and the center shoes on primary and secondary throttle levers use
wall of the bowl cover should be 3/16". Measure with .020" wire gauge in Tool Set J-7665.
3/16" gauge on Tool J-7665. 7. To adjust, bend shoe on primary lever.
3. Bend unloader tang as required with Tool J-1137 to
Adjust Auxilary Valve Lockout (Fig. 109)
achieve this adjustment.
NOTE: This adjustment should be made after
Adjust Secondary Throttle Lever (Figs. 107 and 108) completing Fast Idle and Secondary Throttle
Lever Adjustments.
NOTE: With carburetor upside down, throttle
valve position can be observed. Primary valves 1. When choke valve is closed tang on auxiliary valve
should reach the wide-open position and sec- lockout lever should engage in auxiliary valve cam.
ondary valves must open to within 4° to 7° of 2. When choke is fully opened it should disengage lock-
wide open position. out lever from auxiliary valve cam so auxiliary valve
can operate freely.
1. Operate throttle linkage until full wide open position 3. If necessary to adjust, bend tang on auxiliary lockout
is obtained. Observe valves as noted above. lever.

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER AFB 6M-45

CARTER AFB
INDEX
Page Page
General Description 6M-45 Assemble Bowl Cover to Body 6M-50
Repair Procedures 6M-45 Adjust Accelerator Pump Rod 6M-51
Disassembly 6M-45 Adjust Intermediate Choke Rod. 6M-52
Bowl Cover 6M-45 Assemble and Adjust Choke Cover 6M-52
Body 6M-46 Adjust Choke Rod (Fast Idle) 6M-53
Cleaning and Inspection 6M-47 Adjust Choke Unloader 6M-53
Assembly and Adjustments 6M-49 Adjust Closing Shoe 6M-53
Assemble Body 6M-49 Adjust Secondary Throttle Opening 6M-53
Assemble Bowl Cover 6M-49 Adjust Secondary Throttle Lockout 6M-54
Adjust Floats 6M-50

GENERAL DESCRIPTION
The Carter AFB (Aluminum Four Barrel) Carburetor
7 8
(fig. 110) is used on the high performance 327 cu. in.
engines in Chevrolet and Chevelle and Chevy II vehicles.
This carburetor is also used on the high performance 409
cu. in. engine in Chevrolet vehicles.
On 327 cu. in. engines using the Carter AFB Car-
buretor a hot idle compensator (a ther mo static controlled
air bleed which supplys additional air to the idle mixture)
is used as an aid to prevent stalling during prolonged hot
idle periods. The hot idle compensator consists of a bi-
metal strip, a valve and a mounting b r a c k e t , and is
mounted between the venturi on the secondary side of the
carburetor body.

1. Pump Lever
2. Primary Throttle Shaft Lever
3. Secondary Throttle Lockout Lever
4. Secondary Throttle Shaft
5. Fast Idle Cam
6. Fast Idle Rod
7. Choke Shaft Outer Lever
8. Choke Shaft Kick Lever
9. Choke Valve
10. Piston Cover Plate
11. Fuel Inlet Fitting
12. Choke Clean Air Pickup Tube
13. Choke Valve Actuating Link
14. Choke Actuating Shaft Clamp Lever
15. Secondary Throttle Shaft Dog Lever
16. Secondary Throttle Trip Lever
17. Primary Throttle Shaft Lever
18. Choke Coil and Housing Cover 15 16 17 18 15 16 17
19. Intermediate Chojce Rod 409 V-8 327 V-8
(TYPICAL) (TYPICAL)

Fig. 110—Carter AFB Carburetors

REPAIR PROCEDURES
(409) Remove hairpin clip from upper end of fast
Disassembly
idle rod and disconnect rod. Replace clip on rods for
Disassemble Bowl Cover safe keeping.
1. Remove retainer from upper end of pump rod and (327) Remove screw from end of choke shaft and r e -
disconnect pump rod from arm. move outer lever and washer. Then remove inner
2. (327) Remove hairpin clip from upper end of inter- lever and fast idle rod from carburetor as an
mediate choke rod and disconnect rod. assembly.

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER AFB 6 M - 4 6

Ordinarily the carburetor bowl covers are disas-


sembled as far as is necessary during an overhaul
procedure. The choke valve and shaft (or shafts)
should not be removed unless shaft is binding or
valve is damaged. If either condition exists, disas-
semble as follows:
8. (327) File choke valve screws (staked ends) level
with shaft to avoid damaging threads in shaft; then
remove the screws and choke valve. Slide shaft from
cover.
(409) Remove link from choke valve end and rotate
to remove from control shaft. Proceed as above to
remove choke valve and shaft. To remove choke
control shaft, remove link lever screw and slide
shaft from cover.
Disassemble Body
1. Remove accelerator pump lower spring and the fuel
bowl splash shields.
2. Check the fuel in the bowl for contamination by dirt,
gum or other foreign matter, then empty fuel from
bowl.
NOTE: A magnet swept around the bottom of
the bowl while fuel is still present will pick up
iron oxide dust or metal particles which have a
tendency to cause leakage at needle seats.
3. Remove choke housing retainer, cover, cover gasket,
and baffle plate.
4. Remove choke housing mounting screws and housing.
Remove "O" ring seal from v a c u u m opening of
Fig. I l l — B o w l Cover Screw Location housing mounting boss.
5. Remove choke piston lever screw and remove piston
(409) Loosen choke control shaft clamp lever and two levers.
screw and remove lever and intermediate choke rod 6. Remove pump nozzle attaching screws, pump nozzle
from carburetor as an assembly. and gasket. Remove pump discharge needle.
Remove screws holding two power piston and meter- 7. Remove v e n t u r i cluster a t t a c h i n g screws and
ing rod cover plates to bowl cover and remove cover, clusters. (On 327 carburetor also remove idle com-
power piston, metering rod and power piston springs. pensator over secondary clusters.)
Remove fuel inlet fitting and gasket. Remove bowl NOTE: Each venturi cluster assembly is dif-
cover screws (fig. I l l ) and carefully lift cover from ferent and can be assembled to body in one
Body Section to avoid damaging floats or pump location only.
plunger (fig. 112).
Remove float lever pins and floats. Remove float NOTE: Primary venturi gaskets are different
needles, seats and gaskets. Keep float system parts from secondary.
separate so they may be reinstalled with minimum 8. Lift secondary auxiliary valves from carburetor
adjustment. body.
Remove pump plunger lever screw and lever. Re- 9. Remove idle mixture screws and springs.
move " S " link and plunger. Remove cover gasket'.
10. Remove all four metering jets.
NOTE: Primary metering jets are larger be-
cause metering rods are used in them.
11. Remove pump intake check ball and seat assembly.
For normal cleaning and inspection, it is not nec-
essary to disassemble the carburetor body any
further. However, if throttle valves or linkage are
worn or damaged, complete disassembly as follows:
12. Remove fast idle cam screw and cam.
13. Remove primary to secondary connecting link. Re-
move primary and secondary throttle dog lever
screws and remove levers, and springs.
14. File off staked ends of throttle valve attaching
screws and remove screws and throttle valves from
Fig. 112—Bowl Cover Removal bores. Slide throttle shafts from carburetor body.

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER AFB 6 M - 4 7

409"

"327"

Fig. V13-Bowl Cover-Exploded View

1. Bowl Cover Assembly 9. Pump Lever Pivot Screw 17. Float Needle Seat 24. Choke Valve Actuating
2. Screw 10. Screw 18. Float Needle Shaft Lever (409 only)
3. Piston Cover Plate 11. Choke Shaft Outer Lever 19. Float Hinge 25. Choke Valve Actuating
4. Power Piston 12. Washer (Spacer) 20. Float Shaft (409 only)
5. Spring 13. Choke Shaft Kick Lever 21. Choke Valve 26. Kick Lever (409 only)
6. Metering Rod 14. Fuel Inlet Fitting 22. Choke Valve Shaft 27. Choke Actuating Shaft
7. Pump Link 15. Cover Gasket 23. Choke Valve Actuating Clamp Lever
8. Pump Lever 16. Pump Plunger Assembly Link (409 only)

Cleaning and Inspection coil housing assembly should be cleaned in gasoline.


1. Wash all parts in carburetor cleaning solution ex- 2. Inspect holes in all operating levers and castings for
cept coil housing assembly and pump plunger. Choke excessive wear.

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER AFB 6M-48

21
20

15
18
\
19
\
\
fi
f
-* Acs/
.0 22 23

24

1 N
..-. ^ * 31 r^ I

Fig. 114—Body and Choke—Exploded View


1. Secondary Throttle Shaft 13. Idle Speed Screw Assembly 25. Washer 35. Secondary Metering Jet
2. Clip 14. Carburetor Body 26. Primary Throttle 36. Pump Discharge
3. Fast Idle Rod 15. Idle Mixture Screws Shaft Arm Nozzle Gasket
4. Secondary Throttle Valve 16. Choke Piston Outer Lever 27. Throttle Shaft Spring 37. Pump Discharge Nozzle
5. Primary Throttle Valves 17. " O " Ring Seal Pick-Up Lever 38. Auxiliary Valves
6. Primary Throttle Shaft 18. Choke Housing 28. Secondary Throttle Trip Lever 39. Primary Venturi Cluster Gasket
7. Primary Throttle Shaft Spring 19. Choke Piston 29. Spring 40. Primary Venturi Cluster
8. Fast Idle Screw Plate 20. Choke Baffle Plate 30. Washer 41. Secondary Venturi
9. Fast Idle Screw Plate 21. Gasket 31. Secondary Throttle Shaft Cluster Gasket
10. Screw 22. Choke Coil and Dog Lever 42. Secondary Venturi Cluster
11. Fast Idle Cam Housing Cover 32. Spring 43. Idle Compensator
12. Secondary Throttle 23. Retainer Ring 33. Primary Metering Jet 44. Pump Inlet Ball and
Lockout Lever 24. Choke Piston Inner Lever 34. Fuel Splash Shield Check Valve

3. Inspect bearing surfaces of all shafts for excessive emitted from either the intake or discharge passage.
wear. If any fuel does emit from either passage, the
NOTE: If excessive wear is noted to the extent presence of dirt or a damaged check ball are indi-
cated. Clean the passage again and repeat the test.
of improper operation of the carburetor, the
If leakage is still present, replace the check valve.
worn parts should be replaced.
If choke piston sticks in cylinder^ remove welch plug
4. Inspect floats for bad dents and/or possible leaks. in bottom of housing for inspection of cylinder and
5. Inspect pump plunger leather for cracks or creases. air slots. If carbon or dirt is present, remove carbon
To check pump system: Pour 1/2 inch of gasoline from cylinder with sandpaper (DO NOT USE EMERY
into carburetor bowl. Take pump plunger from can of CLOTH) and clean slots. Carefully install new welch
gasoline or kerosene and slide into pump cylinder. plug. Be certain welch plug seat is carefully cleaned
Place the discharge check ball into body. Raise before installing new plug.
plunger and press lightly on shaft to expel air from NOTE: Removal of the welch plug to clean the
the pump passage. Using a small clean brass rod, choke piston housing should be done only if the
hold the discharge ball down firmly on its seat. Again choke piston does not move f r e e l y in its
raise plunger and press downward. No fuel should be cylinder.

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER AFB 6 M - 4 9

7. Inspect float needles and seals for burrs and ridges.


If present, replace both the needle and seat; never
replace either alone.
8. Inspect metering rods and jets. If either are bent,
burred, or distorted, replace both rod and jet.
9. Inspect edges of primary and secondary throttle
valves for gouges and other deformations. If these
or any other conditions exist which would prevent full
seating, replace the faulty valve.
10 Check pump plunger return spring and vacuum piston
spring for weakness and distortion.
11. Inspect all mating surfaces of choke housing, bowl
cover, carburetor body, and throttle flange for burrs,
gouges, or other surface irregularities. All surfaces
must be smooth to prevent leaks.
Assembly and Adjustments
During assembly of carburetor, use all new gaskets and
any additional new parts found to be necessary during in-
spection. Calibrated parts must be as specified for car- Fig. 116—Throttle Shaft Levers Installed
buretor CODE number which is stamped in red on and back out 1-1/2 turns, which will provide an
mounting flange at rear center. average initial adjustment.
Assemble Body 10. Install choke piston housing shaft, lever and rod as-
1. Install primary and secondary throttle shafts. sembly in piston housing with lever and rod pointing
2. Install primary throttle shaft dog levers and spring away from heat pipe connector.
(fig. 115). 11. Install choke piston, pin link, and lever assembly in
3. Install secondary throttle shaft dog lever and spring. piston housing. Install piston lever on flats of shaft
Wind spring one turn (fig. 116). in such a way that inner and outer levers are pointing
4. Install throttle valves in shafts with part number in same general direction. Then install screw.
identification toward bottom of flange and secure with 12. Install small round rubber gasket in housing recess,
new screws (fig. 117). then install piston housing on main body using three
5. Install pump intake check ball and ball seat assembly screws.
with a new gasket (fig. 118). Install primary and sec- 13. Install fuel bowl splash shields and accelerator pump
ondary metering jets and tighten securely. lower spring.
Assemble Bowl Cover
NOTE: The primary jets are the two having the 1. Install fuel inlet in bowl cover.
larger orifices. 2. Install choke shaft in bowl cover with attached lever
6. Install pump discharge check needle point down. In- toward choke piston housing. Install choke valve with
stall pump discharge nozzle and gasket. markings up and install new screws loosely.
7. Install auxiliary valve assembly with screw heads 3. Align choke valve by working choke shaft endwise
down (fig. 119). Then install secondary and primary while maintaining an upward pressure on choke shaft
venturi assemblies, using new gaskets (fig. 120). lever. Tighten and stake choke valve screws.
8. On models so equipped install hot idle compensator. 4. Check for uniform clearance and freedom from
sticking, as improper fit or binding may cause hard
NOTE: If a primary venturi assembly does not starting. Mechanism is free if choke valve will fall
fit in place, flush with top of main body, it be- open from its own weight.
longs on the other side.
9. Install idle mixture adjustment screws. Seat lightly

Fig. 115—Throttle Shaft Levers Fig. 117—Throttle Valve Position

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER AFB 6 M - 5 0

PUMP INTAKE PRIMARY


CHECK BALL VENTURI
CLUSTER

PRIMARY
JETS

PRIMARY

VENTURI SECONDARY
CLUSTER JETS

Fig. 118—Parts Location

5. Place pump plunger assembly in position in bowl


cover and install pump link. Install pin spring in
upper end of link. Invert bowl cover and install new
bowl cover gasket.
6. Install float needle seats and gaskets. Install float
needles, floats, and lever pins, making sure they are
installed in original locations.
Adjust Floats
1. Align Float. Sight down side of float to determine if SECONDARY
side is parallel with outer edge of bowl cover. If ad-
justment is necessary, bend float lever by applying
pressure to end of float with fingers while supporting
float lever with thumb (fig. 121). Fig. 120—Venturi Identification
2. Remove any excess clearance between arms of float gasket to outer end of each float using a scale. Bend
lever and lugs on bowl cover by bending float lever float arm tang as r e q u i r e d to obtain 3/4"
arms. Arms should also be parallel to inner surface measurement (fig. 123).
of lugs. After aligning, each float must operate
freely. Assemble Bowl Cover to Body
3. Adjust Float Level. With bowl cover inverted and 1. Install bowl cover assembly on main body, using care
bowl cover gasket in place, check clearance between to avoid distortion of floats. Install bowl cover
each float (at outer end) and bowl cover gasket using
Float Gauge J-9550 chain set (7/32") or a 7/32"
drill (fig. 122). To adjust, bend float lever. After
SIDE OF FLOAT PARALLEL
any adjustment, recheck float alignment. WITH SIDE OF COVER
4. Adjust Float Drop. With bowl cover held in upright
position, measure vertical distance from bowl cover.

Fig. 119—Auxiliary Valve Assembly Fig. 121—Float Alignment

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER AFB 6M-51

Fig. 122—Float Level Adjustment

screws and tighten evenly. (Two longer screws go in


middle holes.)
2. Install assembled fast idle rod and choke lever by
first engaging fast idle rod in fast idle cam. Then
place lever over end of choke shaft so that it points Fig. 124—Metering Rod Installation
toward accelerator pump. Install special washer on
shaft and then install choke shaft outer lever so that screw until throttle valves seat in throttle bores.
tang on outer lever is above tang on inner lever when Measure from bowl cover to top of plunger shaft
choke valve is open. with scale.
3. Install two power piston springs. Install each as- 2. Bend pump rod at lower angle as required to obtain
sembled power piston, metering rod and rod retainer 1/2" measurement using Tool J-4452. Turn throttle
spring. Carefully push down on each power piston stop screw in (from fully closed throttle position 1/2
and rod until rod enters metering jet. Use care to turn which will provide an initial idle adjustment.
avoid bending metering rods. Then install cover
plates, holding plates down while tightening screws
(fig. 124).
4. Install upper end of pump rod in pump arm.
Install upper end of choke rod in choke shaft lever,
'/*" MEASUREMENT
using pin spring on rod. WITH THROTTLE -—' * i

Adjust Accelerator Pump Rod (Fig. 125) FULLY CLOSED


1. Push fast idle cam aside and back out throttle stop

BEND HERE
USING TOOL J-4552

Fig. 123—Float Drop Adjustment Fig. 125—Accelerator Pump Rod Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER AFB 6 M - 5 2

CHOKE

Fig. 126—-Intermediate Choke Rod Adjustment

Ad/usf /nfermed/afe Choke Rod (Fig. T26)


1. Open choke valve and insert .026" wire gauge, J-9550
between bottom of slot in piston and top of slot in
choke piston housing. Close choke piston against this
gauge (using a rubber band doubled will keep tension
of piston against wire gauge leaving one hand free
for adjustment) and check clearance between top of
choke valve and web of bowl cover casting, using
proper J-9550 wire gauge for each carburetor (see
specifications).
2. If adjustment is required bend intermediate choke
rod using Bending Tool J-4552 on 327 AFB. On 409
AFB loosen choke control shaft clamp lever screw
and rotate lever on shaft, then tighten screw.
3. Remove gauges and rubber band from choke piston
lever.

Assemble and Adjust Choke Cover (Fig. \27)


1. Install choke baffle plate, gasket and thermostatic
coil housing assembly retainer ring and screws.
Fig. 127-—Choke Adjustment Leave retaining screws loose.

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER AFB 6 M - 5 3

CHOKE
VALVE
CLOSED

I
1
I^SmJiiiri BEND

PfET" BEND SECONDARY SHOE


AS REQUIRED TO OBTAIN
.020" CLEARANCE

Fig. 130—Closing Shoe Adjustment


Fig. 128—Choke Rod (Fast Idle) Adjustment
upper edge of choke valve and inner wall of bowl
2. Adjust index on coil housing to index on choke cover using a 3/16" drill.
housing. Then tighten retaining screws securely. 2. Bend unloader tang on throttle shaft lever as re-
quired to obtain clearance.
Adjust Choke Rod (Fast Idle) (Fig. 128)
1. While holding choke valve closed, fast idle cam index Adjust Closing Shoe (Fig. 130)
mark should line up with fast idle adjustment screw. 1. With primary and secondary throttle valves closed,
2. If necessary, bend fast idle rod at lower angle (using check clearance between positive closing shoes on
Tool J-5197) to adjust. primary and secondary throttle levers using Chain
NOTE: Final adjustment of the fast idle screw Gauge J-9550 or a .020" feeler gauge.
is made with the carburetor installed and engine 2. Bend secondary closing shoe as required to obtain
warm. Set screw on index of cam, then set screw this clearance.
to specified rpm. Adjust Secondary Throttle Opening (Fig. 131)
1. The pick-up lever located on the primary throttle
Adjust Choke Unloader (Fig. 129) shaft has two points of contact with the loose lever on
1. Hold throttle wide open and check clearance between the primary shaft. Caution should be taken that the
pick-up lever contacts the loose lever at both points
at the same time.
DRILL

mmi> BEND PICK-UP LEVER AS


. /rREQUIRED TO CONTACT
feg "A" & "B" AT '
TIME

i |HV TANG BEND LINK AS REQUIRED

Si
TO SYNCHRONIZE
f
M
VALVE OPENING
THROTTLE
i
WIDE OPEN

Fig. 129—Choke Unloader Adjustment Fig. 131—Secondary Throttle Opening Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


CARTER AFB 6 M - 5 4

2. If they do not make this contact, bend pick-up lever


to obtain proper engagement.
3. The primary and secondary throttle valve must come
to the wide open position simultaneously. If the sec-
ondary throttle valve opening is not synchronized
with that of the primary, bend the connecting link.
Adjust Secondary Throttle Lock-Out (Fig. 132)
SECONDARY Open primary throttle valves slightly and manually
THROTTLE SHAFT open and close choke valve. Tang on secondary throttle
lever should freely engage in notch of lockout dog while
barely missing edge of notch.
If necessary to adjust, bend tang on secondary throttle
BEND TANG lever using Tool J-9550.
USING TOOL
J-6058-A

Fig. 132—Secondary Throttle Lockout Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


HOLLEY 4150 6M-55

HOLLEY 4 1 5 0
INDEX

Page Page
General Description 6M-55 Assemble Main Body 6M-60
Repair Procedures 6M-56 Assemble Secondary Throttle Operating Assembly . . . 6M-60
Disassembly 6M-56 Assemble Choke Housing 6M-60
Disassemble into Subassemblies 6M-56 Assemble Metering Bodies 6M-60
Disassemble Fuel Bowls 6M-56 Assemble Fuel Bowls 6M-60
Disassemble Metering Bodies 6M-56 Adjust Floats (Preliminary) 6M-60
Disassemble Choke Housing 6M-56 Assemble Subassemblies 6M-60
Disassemble Secondary Throttle Operating Assembly . 6M-57 Adjust Secondary Throttle Valve Stop Screw 6M-60
Disassemble Main Body 6M-57 Adjust Fast Idle Cam 6M-61
Disassemble Throttle Body 6M-57 Adjust Accelerator Pump 6M-61
Cleaning and Inspection 6M-58 Adjust Choke Unloader 6M-61
Assembly and Adjustments 6M-59 Assemble and Adjust Choke Cover 6M-61
Assemble Throttle Body 6M-59

GENERAL DESCRIPTION
The Holley 4 barrel carburetor used on the special high This carburetor is used in conjunction with a special
performance 327 cu. in. engine in Chevelle and Chevy II camshaft, special heads (larger valves) and a dual
provides the advantages of a dual two barrel installation. exhaust system.

ADJUSTABLE METERING
FLOAT NEEDLE BODY
FUEL INLET
FUEL FITTING
BOWL

FUEL LEVEL
%* DISTRIBUTOR
SIGHT PLUG
SPARK ADVANCE
PORT
PUMP IDLE
SECONDARY THROTTLE CHOKE HEAT CHOKE OPERATING MIXTURE IDLE SPEED CRANKCASE
OPERATING ASSEMBLY TUBE CONN ASSEMBLY LEVER SCREW SCREW VENT PORT

Fig. 133-Holley 4150 Carburetor

PRIMARY
DIAPHRAGM VENTURI
CHAMBER PICK-UP IDLE
IDLE AIR BLEED TRANSFER
RESTRICTION PASSAGE
IDLE
IDLE DISCHARGE
TRANSFER PASSAGE
PASSAGE

IDLE
DISCHARGE
PASSAGE
DIAPHRAGM IDLE IDLE IDLE
ECONDARY
DIAPHRAGM THROTTLE ADJUSTING TRANSFER DISCHARGE
ROD PLATE NEEDLE M A I N JET SLOT HOLE

Fig. 134—Secondary Throttle Operating System Fig. 135—Idle Mixture System

CHEVROLET CHASSIS OVERHAUL MANUAL


HOLLEY 4150 6M-56

DISCHARGE
PUMP
DISCHARGE
CHECK

MAIN JET
PUMP INLET DIAPHRAGM
CHECK BALL RETURN SPRING MAIN WELL
MAIN WELL
Fig. 136—-Accelerator Pump System AIR BLEED

The Holley carburetor breaks down into six subas- Fig. 137—Main Metering System
semblies; (1) throttle body, (2) main body, (3) choke
housing, (4) secondary throttle operating assembly, (5)
metering bodies and (6) the fuel bowls. The throttle body
consists of primary and secondary throttles, shafts and POWER VALVE
levers. The main body consists of venturi, choke valve, RESTRICTION DISCHARGE
and the accelerator pump discharge nozzles and che£k NOZZLE
valve. The metering bodies contain the idle jets, idle
needles, main metering jets, power jet (economizing BOOSTER
valve), and their corresponding passages. The fuel bowls VENTURI
contain the fuel inlet fitting, needle and seat assembly,
and the float and float spring. The primary fuel bowl also
contains the accelerator pump diaphragm and inlet check MAIN JET
valve. A fuel line tube connects the two fuel bowl as- MAIN LL MANIFOLD
VACUUM
sembly inlet areas.
Fig. 138—Power Enrichment System

REPAIR PROCEDURES
Disassembly 3. Loosen inlet needle and seat lock screw, then turn
adjusting nut counter-clockwise to r e m o v e the
Disassemble into Subassemblies (Fig. 139)
assembly.
NOTE: Before disassembly, loosen the fuel 4. Remove sight plug and gasket.
inlet fitting, fuel bowl sight plugs and needle and 5. PRIMARY BOWL ONLY —
seat assembly lock screws. a. Remove inlet fitting.
b. Remove pump diaphragm screws and lift pump
1. Remove secondary fuel bowl screws (4) and remove housing, diaphragm and spring from fuel bowl.
fuel bowl, metering body and gaskets, then remove
fuel tube. 6. Check pump inlet ball for free movement and dam-
2. Remove primary fuel bowl screws (4) and remove age. Damage to ball, passage or retainer requires
fuel bowl, metering body and gaskets. new bowl assembly.
3. Remove hairpin retainer from choke rod at lower Disassemble Metering Bodies (Fig. 141)
end. 1. Remove main metering jets with a wide blade screw
4. Remove choke thermostat, retainer and gasket. driver (a small screw driver will damage the jets).
5. Remove choke housing and gasket from main body.
NOTE: Primary and secondary jets are dif-
6. Disconnect s e c o n d a r y throttle operating rod at
ferent size ( s e c o n d a r y larger)—keep them
throttle lever.
separated.
7. Remove secondary throttle operating assembly and
gasket from main body. 2. PRIMARY SIDE ONLY
8. Remove throttle body to main body screws, then r e - a. Remove bowl vent splash shield.
move throttle body and gasket. b. Remove vacuum fitting.
Disassemble Fuel Bowls (Fig. 140)
c. Remove idle mixture screws and seals.
d. Remove the power valve using a 1" 12 pt. socket.
1. Remove float hinge pin retainer and slide float from
bowl then, if necessary, remove spring from float Disassemble Choke Housing (Fig. 142)
assembly. 1. Remove choke shaft nut, lock washer and spacer,
2. Slide the inlet baffle out of bowl. then slide shaft and fast idle cam from housing.

CHEVROLET CHASSIS OVERHAUL MANUAL


HOLLEY 4150 6 M - 5 7

M A I N BODY

SECONDARY THROTTLE
OPERATING ASSEMBLY

(n)

Fig. 139—Subassemblies

2. Remove choke piston and lever from housing. 1. Remove pump operating lever retaining clip and
lever assembly. Disassemble spring, bolt and nut if
Disassemble Secondary Throttle Operating Assembly needed.
(Fig. 143)
1. Remove diaphragm cover.
2. Remove spring and diaphragm.
Disassemble Main Body (Fig. 144)
CAUTION: The choke rod seal must be r e -
moved before the main body is placed in cleaning
solvent.
1. File off the staked ends of shaft screws then remove
screws.
2. Remove valve from shaft slot and slide shaft from
main body.
3. Remove choke rod (upward through seal) and remove
seal from main body.
4. Remove pump discharge nozzle screw, nozzle and
gasket, then up-end the body assembly to remove
pump discharge needle valve.
Disassemble Throttle Body (Fig. 145)
NOTE: Ordinarily the throttle body need not be
disassembled for cleaning and inspection pur-
poses. If necessary, disassemble for part r e -
placement as follows:
CAUTION: If throttle body is not disassembled
clean in alcohol or gasoline. Fig. 140—Fuel Bowl Assembly

CHEVROLET CHASSIS OVERHAUL MANUAL


HOLLEY 4 1 5 0 6 M - 5 8

FUEL BOWL MAIN BODY


SIDE SIDE

SPLASH METERING
SHIELD JETS GASKETS

Fig. 141—Metering Body Assembly

2. Remove idle speed screw and spring.


3. Remove diaphragm lever from secondary throttle
shaft and fast idle cam lever from primary throttle
shaft.
4. Remove cotter keys and disconnect throttle con-
necting link (secondary lockout) from shaft levers.
5. File off the staked ends of the throttle plate attaching
screws, then remove the screws and throttle plates.
Slide the shafts out of flange.
6. If flange is being r e p l a c e d , remove secondary
throttle stop screw with a small screw driver.
Cleaning and Inspection
NOTE: The most frequent causes of carburetor
mal-function are gum, carbon, and water. Care-
fully clean and inspect all parts and castings as
the carburetor is being serviced as follows:
1. Clean throttle flange, coil h o u s i n g and all non-
metallic parts, in alcohol or gasoline.

Fig. 143—Secondary Throttle Operating Assembly


1. Screw 3. Spring 5. Housing
2. Cover 4. Diaphragm 6. Gasket

NOTE: Secondary throttle shaft bushings, ac-


celerator pump cam and choke rod seal are
plastic.
2. Wash all other parts in cleaning solvent.
3. Inspect holes in all operating levers and castings for
excessive wear.
4. Inspect bearing surfaces of all shafts for excessive
Fig. 142—Choke Assembly clearance (side play—slop). It is not necessary to
1. Cover Screw 8. Choke Piston And Lever Assembly remove shafts and plate to inspect.
2. Retainer 9. Housing Screw
3. Choke Coil Housing 10. Choke Housing NOTE: If wear is excessive to the extent of
4. Gasket 11. Gasket improper operation of the carburetor, the worn
5. Nut 12. Fast Idle Cam parts should be replaced.
6. Lock Washer 13. Retaining Clip
7. Spacer 14. Choke Shaft 5. Inspect floats for bad dents and/or possible leaks.

CHEVROLET CHASSIS OVERHAUL MANUAL


HOLLEY 4150 6M-59

If present, replace both the needle and seat; never


replace either alone as these are an assembly.
9. Inspect edges of primary and secondary throttle
valves for gouges and other deformations. If these
or any other conditions exist which would prevent full
seating, replace the faulty valve.
10. Inspect all mating surfaces of choke housing, fuel
bowl, carburetor body, and throttle flange for burrs,
gouges, or other surface irregularities. All surfaces
must be smooth and square to prevent leaks.
11. Check secondary throttle operating diaphragm for
free operation and leakage by moving diaphragm rod
to the up position then covering vacuum passage
opening in housing with thumb. The diaphragm should
hold upward. Remove thumb from vacuum passage
and diaphragm rod should move down readily.
12. After washing in solvent, clear all passages in the
metering body and main body with compressed air.
If passages or welsh plugs in either body are dam-
aged, the body must be replaced.

Assembly and Adjustments


Assemble Throttle Body
1. Install secondary throttle stop screw (if removed).
Fig. 144—Main Body Assembly
2. Install throttle shafts in throttle body.
1. Main Body 7. Choke Valve
2. Pump Discharge Needle 8. Seal NOTE: The secondary throttle shaft has plastic
3. Gasket 9. Choke Rod bushings. Roll new bushing between thumb and
4. Pump Discharge Nozzle 10. Choke Shaft first finger to help shape the bushing on the shaft
5. Gasket 11. Choke Valve Screws
6. Pump Discharge Screw for easier installation.

6. Inspect pump diaphragm for damage. 3. Install the throttle valves on the shaft (do not tighten
retaining screws).
7. If choke piston sticks in cylinder, remove piston and
link assembly, wash piston and housing in solvent and 4. Center the throttle valves on the shafts by holding the
blow dry. If washing does not clear up problem r e - valves closed while tightening the screws.
place housing and/or piston and link assembly. NOTE: The throttle valves are installed with
8. Inspect float needles and seats for burrs and ridges. identification numbers down (to manifold side).

Fig. 145-Throttle Body-Assembly

1. Fast Idle Cam Lever 6. Primary Throttle Shaft 11. Pump Operating Lever 16. Throttle Shaft Bushings
2. Fast Idle Cam Adjusting Screw 7. Primary Throttle Plates 12. Lever Retaining Clip 17. Secondary Throttle Plates
3. Throttle Flange 8. Pump Lever Adjusting Screw 13. Diaphragm Lever Assembly 18. Cotter Pin
4. Secondary Throttle Shaft 9. Spring 14. Idle Speed Screw 19. Washer
5. Accelerator Pump Cam 10. Pump Adjusting Nut 15. Spring 20. Throttle Connector Link

CHEVROLET CHASSIS OVERHAUL MANUAL


HOLLEY 4150 6M-60

Support the throttle shafts and stake the throttle t Using new seals install idle mixture screws and
valve screws. make preliminary adjustment of idle mixture
Install the throttle connecting link (secondary lock- screws by turning lightly to seat and back out one
out) to the throttle shaft levers. turn.
Install fast idle cam lever on primary throttle shaft
and diaphragm lever on secondary throttle shaft. CAUTION: Do not turn screw tightly against
8. Install idle speed screw and spring. Turn idle speed seat.
screw clockwise until contact with throttle lever is • Install vacuum fitting.
made and turn 1-1/2 additional turns for preliminary 2. PRIMARY AND SECONDARY SIDE:
adjustment. • Install main metering jets with a wide blade
9. Assemble and install pump operating lever assembly. screw driver.
Assemble Main Body NOTE: Secondary jets are larger.
1. Install pump discharge valve.
Assemble Fuel Bowls
2. Install pump discharge nozzle. Use new gaskets.
3. Install choke rod seal and choke rod in main body. 1. PRIMARY BOWL ONLY
4. Install choke shaft in main body and connect upper • Install pump spring and diaphragm in fuel bowl.
end of choke rod. • Install inlet fitting.
5. Install choke valve on choke shaft (do not tighten r e - 2. PRIMARY AND SECONDARY BOWL
taining screws). • Install sight plugs with new gaskets.
6. Center choke valve on shaft by holding valve closed • Install inlet needle and seats leaving lock nuts
while tightening screws. loose. Use new gaskets.
7. Peen screw ends with pliers. • Install inlet baffle in bowl.
• Assemble spring to float, slide float into bowl and
NOTE: The choke valve is offset and should fall install float hinge pin and retainer.
freely to wide open position from its own weight.
Adjust Float (Fig. 146)
Assemble Secondary Throttle Operating Assembly 1. Make a preliminary float adjustment by inverting fuel
1. Install diaphragm assembly and spring in housing. primary bowl and turning adjustable needle-seat until
2. Install diaphragm cover and tighten securely. top of float is parallel with top of fuel bowl.
NOTE: Diaphragm may be checked for leaks 2. Repeat step one for secondary float.
by pushing in on rod then holding finger over NOTE: Final adjustment of the float is made on
vacuum hole. Rod should remain in. the vehicle. Refer to the Service Manual.
Assemble Choke Housing Assemble Subassemblies
1. Install choke piston and lever in choke housing. 1. Invert the main body, align new throttle body to main
2. Install fast idle cam with high step of cam against pin body gasket, then position throttle flange assembly
and weight ball out. and install the six screws and tighten securely.
3. Install choke shaft with lever parallel to long arm of 2. Using a new gasket, install secondary throttle op-
fast idle cam. erating assembly on main body and tighten securely.
4. Install spacer, lock washer and nut. Connect rod at lever and install retaining clip.
Assemble Metering Bodies 3. Using a new gasket, install choke housing to main
1. PRIMARY SIDE ONLY: body and tighten securely.
• Using a new gasket, install power valve and NOTE: Guide lower end of choke rod into choke
tighten securely. (Use a 1" 12 pt. socket.) lever while installing choke housing. End of
• Install bowl vent splash shield. choke rod must be positioned under fast idle
cam.
4. Lay flange and main body on secondary side then in-
stall primary metering body (with new gasket) onto
main body aligning dowel pins and holes.
5. Install new gasket and primary fuel bowl—align pump
lever under operating lever duration spring, then in-
stall retaining screws with gaskets under heads.
6. Lay assembly on primary bowl then install secondary
metering body and gasket on main body.
7. Lubricate " O " ring seals and install on fuel tube at
very end—they will roll into position during installa-
tion.
8. Install fuel tube into primary bowl inlet.
9. Install secondary bowl (with new gaskets), aligning
fuel tube into inlet, then install retaining screws and
gaskets (fig. 147).
Adjust Secondary Throttle Valve Stop Screw (Fig. 148)
1. Back off on adjustment screw until throttle plates are
Fig. 146—Preliminary Float Adjustment fully closed.

CHEVROLET CHASSIS OVERHAUL MANUAL


HOLLEY 4150 6M-61

r
SECONDARY THROTTLE
STOP SCREW LOCATION

'w el
C/
Fig. 148—-Secondary Throttle Stop Screw Adjustment

between choke valve lower edge and main body with


Fig. 147—Installing Fuel Bowl and Fuel Tube
a drill rod (see specifications).
3. If necessary to adjust, bend choke rod (at off-set
2. Turn adjustment screw until it just touches the bend) using Tool J-4552. Recheck after adjusting.
throttle lever and turn one-half turn more to position
the valves. Assemble and Adjust Choke Cover
Adjust Fast Idle Cam
1. Install choke cover, gasket and retainer being careful
1. Open throttle slightly allowing choke plate to close to engage spring.
throttle putting fast idle screw against top step of 2. Adjust choke counter-clockwise to specifications and
cam. tighten securely.
2. Adjust fast idle screw to give specified opening of
throttle plates on idle transfer slot side of carb (see
specifications).
Adjust Accelerator Pump (Fig. 149)
1. Hold throttle lever in wide open position with a
rubber band and hold pump lever fully compressed
(down), then measure the clearance between spring
adjusting nut and arm of the pump lever.
2. Clearance should be .015"; adjust by turning nut or
screw as required while holding opposite end. (The
pump operating lever is not threaded.)
3. After adjustment is made, rotate the throttle lever
to fully closed and partly open again. Any movement
of the throttle lever should be noticed at operating
lever spring end, indicating correct pump tip-in.
Adjust Choke Unloader
1. Hold throttle lever in wide open throttle position with
a rubber band.
2. Hold choke valve toward closed position against un-
loader tang of throttle shaft, then measure opening Fig. 149—Accelerator Pump Adjustment

CHEVROLET CHASSIS OVERHAUL MANUAL


SPECIAL TOOLS 6 M - 6 2

SPECIAL TOOLS

X.

J-21608
J-8879-01

J—21616
J-7825
J—21215

J-4552 1 J-5197
LI

1
J-1137
BENDING TOOLS
•if

J-5496
J-6058A J-6556 1

wi
j-8328

J-9550
J-21607

Fig. 150—Engine Fuel Special Tools

CHEVROLET CHASSIS OVERHAUL MANUAL


SECTION 6Y
CONTENTS OF SECTION
Page
Starting Motor 6Y-1 Delcotron 6Y-7
Starting Solenoid 6Y-6 Special Tools 6Y-14
STARTING MOTOR
INDEX
Page
Disassembly 6Y-1 Field Coil Test for Ground 6Y-3
Cleaning and Inspection 6Y-1 Loose Electrical Connections 6Y-3
Testing and Repairs 6Y-3 Turning the Communtator 6Y-3
Armature Test for Shorts 6Y-3 Brush Holder Replacement 6Y-4
Armature Test for Grounds 6Y-3 Assembly 6Y-4
Field Coil Test for Open Circuit 6Y-3 Pinion Clearance 6Y-5
DISASSEMBLY c. Remove snap ring from groove in shaft using
pliers or other suitable tool. If the snap ring is
Refer to Figures Is and 2s. too badly distorted during removal, it may be
1. Disconnect the field coil connector(s) from the motor necessary to use a new one when reassembling
solenoid terminal. clutch.
2. Remove through bolts. d. Slide retainer and clutch from armature shaft.
3. Remove commutator end frame, field frame as- 5. Disassemble brush rigging from field frame.
sembly and armature assembly from drive housing. a. Release "V" spring from slot in brush holder
4. Remove overrunning clutch from armature shaft as support.
follows: b. Remove support pin.
a. Slide thrust collar off end of armature shaft. c. Lift brush holders, brushes and spring upward as
b. Slide a standard half-inch pipe coupling or other a unit.
metal cylinder of suitable size (an old pinion of d. Disconnect leads from each brush.
suitable size can be used if available) onto shaft e. Repeat operation for other set of brushes.
so end of coupling or cylinder butts against edge
of retainer (fig. 3s). Tap end of coupling with CLEANING AND INSPECTION
hammer, driving retainer towards armature end With the starting motor completely disassembled ex-
of snap ring. cept for removal of field coils, the component parts

SOLENOID
CONTACT
FINGER PLUNGER RETURN SPRING

SHIFT
LEVER

SPIRAL
SPLINES
USHING

PINION
STOP
\ \ \ \ OVERRUNNING
BRUSH CLUTCH
\ \ INSULATED BRUSH HOLDER \ FIELD COIL
\ BRUSH SPRING ARMATURE
GROUNDED BRUSH HOLDER

Fig. Is—Starting Motor Cross Section

CHEVROLET CHASSIS OVERHAUL MANUAL


STARTING MOTOR 6Y-2

Fig. 2s—Starting Motor Parts Layout

1. Drive Housing 6A. Solenoid Return Spring 12. Thrust Collar 17. Braking Washer 23. Brushes
2. Shift Lever Bolt 7. Solenoid Case 13. Snap Ring 18. Commutator End Frame 24. Screws
3. Shift Lever Nut and 8. Screw and Lock 14. Retainer 19. Brush Springs 25. Field Coils
Lock Washer Washer 15. Overrunning Clutch 20. Washer 26. Insulators
4. Pin 9. Grommet Assembly 21. Insulated Brush Holders 27. Pole Shoes
5. Shift Lever 10. Field Frame 16. Armature 22. Grounded Brush Holders 28. Screws
6. Solenoid Plunger 11. Through Bolts
should be cleaned and inspected as described below. Field spring or collar can be replaced by forcing the collar
coils need be removed only where defects in the coils are toward the clutch and removing lock ring from end
indicated by the tests described below, in which case the of tube.
pole shoe screws should be removed and the pole shoes 3. Check brush holders to see that they are not de-
and field coils disassembled. Any defective parts should formed or bent, but will properly hold brushes
be replaced or repaired (see Repairs). against the commutator.
1. Clean all starting motor parts, but do not use grease 4. Check the condition of the brushes and if pitted or
dissolving solvent for cleaning the overrunning worn to one-half their original length, they should be
clutch, armature, and field coils since such a solvent replaced.
would dissolve the grease packed in the clutch 5. Check fit of armature shaft in bushing of drive
mechanism and would damage armature and field housing. Shaft should fit snugly in die bushing. If the
coil insulation. bushing is worn, it should be replaced. Apply a sili-
2. Test overrunning clutch action. The pinion should con lubricant to this bushing before reassembly.
turn freely in the overrunning direction and must Avoid excessive lubrication.
not slip in the cranking direction. Check pinion teeth 6. Check fit of bushing in commutator end frame. If
to see that they have not been chipped, cracked, or this bushing is damaged or worn excessively, the
excessively worn. Check the spring for normal ten- end frame assembly must be replaced. Apply a
sion and the drive collar for wear. If necessary the silicone lubricant to this bushing before reassembly.

CHEVROLET CHASSIS OVERHAUL MANUAL


STARTING MOTOR 6Y-3

Avoid excessive lubrication. Lubricant forced onto


the commutator would gum and cause poor com-
mutation with a resulting decrease in cranking motor
performance.
7. Inspect armature commutator. If commutator is
rough or out of round, it should be turned down and
undercut. Inspect the points where the armature
conductors join the commutator bars to make sure
that it is a good firm connection. A burned com-
mutator bar is usually evidence of a poor connection.
See "Turning the Commutator," described under
Testing and Repairs.

TESTING AND REPAIRS

Armature Test for Shorts


Check the armature for short circuit by placing on
growler and holding hack saw blade over armature core
while armature is rotated (fig. 4s). If saw blade vibrates, Fig. 4s—Armature Short Circuit Test
armature is shorted. Recheck after cleaning between the
commutator bars. If saw blade still vibrates, replace the Field Coil Test for Ground
armature.
Place one lead on the connector bar and the other on
Armature Test for Ground the grounded brush (fig. 7s). If the lamp lights, the field
coils are grounded.
Place one lead on the armature core or shaft and the
other on the commutator (fig. 5s). If the lamp lights, the NOTE: Be sure to disconnect the shunt coil
armature is grounded and must be replaced. before performing this test.
Loose Electrical Connections
Field Coil Test for Open Circuit
When an open soldered connection of the armature to
Place one lead on the insulated brush and the other to commutator leads is found during inspection, it may be
the field connector bar (fig. 6s). If the lamp does not resoldered provided resin flux is used for soldering.
light, the field coils are open and will require replace-
CAUTION: Acid flux must never be used on
ment.
electrical connections.
When inspection s h o w s commutator roughness, it
should be cleaned as follows:
Turning the Commutator
1. Turn down commutator in a lathe u n t i l it is
thoroughly cleaned.
CAUTION: Do not cut beyond section previously
turned.

-AVl• ••*•••• «7r3im

p;g# 3s—Driving Retainer off Snap Ring Fig. 5s—Armature Ground Test

CHEVROLET CHASSIS OVERHAUL MANUAL


STARTING MOTOR 6Y-4

to remove any slight burrs left from undercutting.


4. Recheck armature on growler for short circuits.

Brush Holder Replacement


If brush holders are damaged, they can be replaced by
special service units which are attached with screws and
nuts.

ASSEMBLY
After all parts have been thoroughly tested and in-
spected and worn or damaged parts replaced, the starter
should be reassembled.
1. Assemble brush rigging to field frame.
a. Assemble brushes to brush holders.
b. Assemble insulated and grounded brush holder
together with the "V" spring and position as unit
on the support pin. Push holders and spring to
bottom of support and rotate spring to engage the
" V " in slot in support.
c. Attach ground wire to grounded brush and field
lead wire to insulated brush.
d. Repeat for other set of brushes.
2. Assemble overrunning clutch assembly to armature
Fig. 6s—Field Coil Open Circuit Test
shaft.
a. Lubricate drive end of armature shaft with a sili-
cone lubricant.
2. Undercut insulation between commutator bars 1/32".
b. Slide clutch assembly onto armature shaft with
This undercut must be the full width of insulation
pinion outward.
and flat at the bottom; a triangular groove will not be
satisfactory. After undercutting, the slots should be c. Slide retainer onto shaft with cupped surface
cleaned out carefully to remove any dirt and copper facing end of shaft (away from pinion).
dust. d. Stand armature on end on wood surface with com-
mutator down. Position snap ring on upper end of
3. Sand the commutator lightly with No. 00 sandpaper
shaft and hold in place with a block of wood. Hit
wood block a blow with hammer forcing snap ring
over end of shaft (fig. 8s). Slide snap ring down
into groove.
e. Assemble thrust collar on shaft with shoulder
next to snap ring.

Fig. 7s—Field Coil Ground Test Fig. 8s—Forcing Snap Ring over Shaft

CHEVROLET CHASSIS OVERHAUL MANUAL


STARTING MOTOR 6Y-5

Fig. 9s—Forcing Snap Ring into Retainer

f. Place armature flat on work bench, and position


retainer and thrust collar next to snap ring. Then,
using two pair of pliers at the same time (one Fig. 10s—Checking Pinion Clearance
pair on either side of shaft), grip retainer and
thrust collar and squeeze until snap ring is forced After reassembly, a "Free Speed" check of the start-
into retainer (fig. 9s). ing motor may be made if equipment is available. To
make this check, connect a 12 volt battery in series with
Lubricate the drive housing bushing with a silicone an ammeter to the starting motor terminal and ground.
lubricant. Make sure thrust collar is in place against Use a mechanical drive type tachometer to determine the
snap ring and retainer and slide armature and clutch speed reached by the starting motor. Failure of the
assembly into place in drive housing engaging shift starting motor to perform according to specifications
lever with clutch. may be due to tight or dirty bushings, or high resistance
4. Position field frame over armature and apply special connections.
sealing compound between frame and solenoid case. PINION CLEARANCE
Position frame against drive housing using care to
prevent damage to the brushes. The pinion clearance should be checked (fig. 10s) after
motor has been disassembled and then reassembled. If
5. Lubricate the bushing in the commutator end frame clearance is not within specified limits, (.010-. 140) it
with a silicone lubricant. Place leather brake washer may indicate excessive wear of solenoid linkage shift
on armature shaft and slide commutator end frame lever yoke buttons or improper assembly of the shift
onto shaft. lever mechanism. Worn or defective parts should be re-
6. Reconnect the field coil connectors to the '' motor" placed since no provision is made for adjusting of pinion
solenoid terminal. clearance.

CHEVROLET CHASSIS OVERHAUL MANUAL


SOLENOID 6Y-6

SOLENOID
INDEX
Removal 6Y-6
Replacement of Contacts 6Y-6
Installation 6Y-6
REMOVAL
SOLENOID
1. Remove starting motor as previously described, BODY TO HOLD-IN
COIL,
2. Remove the outer screw and washer from the motor
SWITCH
connector strap terminal. TERMINAL
3. Remove the two screws retaining solenoid housing to
end frame assembly.
4. Twist solenoid clockwise to remove flange key from
keyway slot in housing; t h e n remove "solenoid
assembly.
TO PULL-IN
REPLACEMENT OF CONTACTS (Fig. 11s) COIL

1. With solenoid removed from motor, remove nuts and MOTOR CONNECTOR
washers from Switch (S) and Motor connector strap STRAP TERMINAL
terminals.
2. Remove the two solenoid end cover retaining screws
and washers and remove end cover from solenoid
body.
3. Remove nut and washer from battery terminal on end Fig. 11s—Exploded View of Solenoid
cover and remove battery terminal. Remove resistor
by-pass terminal and contactor.
INSTALLATION
4. Remove motor connector strap terminal and solder
new terminal in position. 1. With solenoid return spring installed on plunger,
5. Using a new b a t t e r y terminal, install terminal position solenoid body to drive housing and turn
washer and retaining nut to end cover. Install by- counterclockwise to engage the flange key in the
pass terminal and contactor. keyway slot.
6. Position end cover over switch and motor terminals 2. Install two screws retaining solenoid housing to end
and install end cover retaining screws. Also install frame.
washers and nuts on the solenoid switch and starting 3. Install outer screw and washer securing motor con-
motor terminals. nector strap terminal.
7. Bench test solenoid for proper operation. 4. Install starter motor as previously described.

CHEVROLET CHASSIS OVERHAUL MANUAL


DELCOTRON 6Y-7

DELCOTRON
INDEX
Disassembly 6Y-7 Diode Replacement . 6Y-11
5.5" Delcotron 6Y-7 5.5" Delcotron 6Y-11
6.2" Delcotron 6Y-8 6.2" Delcotron 6Y-11
Cleaning and Inspection 6Y-9 Heat Sink Replacement 6Y-11
Testing Rotor 6Y-9 Brush Replacement 6Y-11
Grounds 6Y-9 5.5" Delcotron 6Y-11
Opens 6Y-9 6.2" Delcotron 6Y-12
Short Circuits 6Y-9 End Frame Replacement 6Y-12
Testing Stator 6Y-9 Bearing Replacement 6Y-12
Grounds 6Y-9 Drive End Frame 6Y-12
Opens 6Y-9 Slip Ring End Frame 6Y-12
Short Circuit 6Y-9 5.5" Delcotron 6Y-12
Testing Diodes 6Y-9 6.2" Delcotron 6Y-13
Test Lamp Method 6Y-9 Assembly 6Y-13
Ohmmeter Method 6Y-11 5.5" Delcotron 6Y-13
Repairs 6Y-11 6.2" Delcotron 6Y-13

Overhaul Procedures described in this section are fer 3. Remove the slip-ring end frame and stator (as an
the 5.5" aluminum and 6.2" perforated stator Delcotrons assembly) from drive end and rotor assembly.
(fig. lc). Where important differences in testing and/or 4. Place a piece of tape over the slip ring end frame
overhaul operations are encountered separate mention bearing to prevent entry of dirt or other foreign
will be made of the two generators. matter.
CAUTION: Brushes may drop onto rotor shaft
DISASSEMBLY (Fig. 2c) and become contaminated with bearing lubricant.
Clean brushes prior to installing with a non-
5.5" Delcotron toxic cleaner such as tri-chlorethylene.
1. Hold generator in a vise, clamping the mounting 5. Remove the three stator lead attaching nuts and
flange lengthwise. separate stator from end frame.
2. Remove 4 thru bolts then break loose the end frames 6. Remove screws, brushes and holder assembly.
by prying at bolt locations. 7. Remove heat sink from end frame by removing

RELAY "BATT"
TERMINAL " F " TERMINAL TERMINAL
"BAT"
TERMINAL ;- TERMINAL

FIELD LIGHT
RELAY RELAY

5 . 5 " ALUMINUM DELCOTRON 6 . 2 " PERFORATED STATOR DELCOTRON

Fig. lc—Delcotrons—Full View

CHEVROLET CHASSIS OVERHAUL MANUAL


DELCOTRON 6Y-8

SLIP RING DRIVE END


END FRAME FRAME
\ 4
FAN A ROTOR FAN
THRU [ BEARING
BRUSH AND BOLT "*
TERMINAL DIODE • j j BEARING
ASSEMBLY ^

SHIELD J

SLIP RINGS fiiL


LOl
- T Hi
BEARING L

1PI If ~T it. ™

1 1
m

BEARING •/
iS TOIBUAN-
H ^

si
PULLEY
GREASE
RESERVOIR
BRUSH
ASSEMBLY ^ - ^ S ^ ^ £••;i
M
ASE
RESEiRVOIR
K/GRE
PULLEY

ROT( " " ^ T ASSEMBLY


STATOR
U SHEL L
STATOR
WINDING E
DIODES ^ 5.5" DELCOTRON 6 " DELCOTRON

Fig. 2c—Delcotron Cross-section View

"batt" and "grd" terminals and one attaching screw 6.2" Delcotron
(fig. 9c). 1. Hold generator in a vise, clamping the drive end
8. Remove slip ring end frame bearing (if necessary) mounting flange lengthwise.
by removing inner seal and slide. 2. Remove two screws securing the cover to the brush
9. Remove pulley retaining nut and slide washer, pulley holder and remove cover (fig. 4c).
and fan from shaft. 3. Remove the nut retaining indicator light wire to the
a. Single Groove Pulley—Place 15/16" box wrench blade connector post and disconnect wire lead from
on retaining nut and insert a 5/16" alien wrench post.
into shaft to hold shaft while removing nut (fig. 4. Remove two screws retaining the capacitor and brush
3c). holder to rear end frame. Remove brush holder.
b. Double Groove Pulley-Place a 15/16" socket
(with wrench flats on the drive end or use Adapter NOTE: Capacitor lead is connected inside the
J-21501 and a box wrench) on retaining nut, insert generator. Allow capacitor to remain with the
a 5/16" alien wrench through socket and adapter
into hex on shaft to hold the shaft while removing
the nut.
10. Remove rotor and spacers from end frame assembly.
11. Remove drive end frame bearing retainer plate and
bearing assembly from frame.

Fig. 3c—Pulley Removal Fig. 4c—6.2" Delcotron Brush Holder Assy.

CHEVROLET CHASSIS OVERHAUL MANUAL


DELCOTRON 6Y-9

generator to avoid undue strain on the lead wire. (CHECK FOR GROUNDS)
5. Remove three slip ring end frame attaching bolts and OHMMETER
tab nuts.
6. Carefully pry the end frame and case apart (using a
screw driver) slowly all the way around the circum-
ference to remove the end frame.
7. Remove the three drive end frame attaching bolts
and tab nuts and remove the end frame, rotor and
pulley as an assembly.
8. Remove shaft nut, washer, pulley and woodruff key
from rotor shaft, then slide rotor from end frame.
9. Remove drive end frame bearing retainer plate and
bearing from end frame.
10. To remove slip ring end frame bearing from rotor
shaft, use Tool J-6627 as shown in Figure l i e .
11. Disconnect the three stator leads by cutting the leads
as close to the diode stem as possible (fig. 7c).
NOTE: Separating these three leads will allow
diode and stator tests outlined in this section.
12. Remove heat sink-to-case retaining screws and r e - OHMMETER
move heat sinks. Insulated heat sink (with batt (CHECK FOR SHORTS AND OPENS)
terminal) holds positive diodes.
CLEANING A N D INSPECTION Fig. 5c—Checking Rotor for Grounds or Opens
With generator completely disassembled, except for
removal of diodes, the components should be cleaned and 12 volt battery and an ammeter in series with the two
inspected. Be sure testing equipment is in good working slip rings. Note the ammeter reading. An ammeter
order before attempting to check the generator. reading above the specified field amperage draw indi-
1. Wash all metal parts except stator and rotor as- cates shorted windings. Refer to Specifications at the end
semblies. of this manual.
2. Clean bearings and inspect for sealing, pitting or
roughness. TESTING STATOR
3. Inspect rotor slip rings, they may be cleaned with Grounds
400 grain polishing cloth. Rotate rotor for this op-
eration to prevent creating flat spots on slip rings. Connect a 110-volt test lamp or an ohmmeter from any
4. Slip rings which are out of round may be trued in a stator lead to the stator frame. If test lamp lights or if
lathe to .001" maximum indicator reading. Remove ohmmeter reads low, the windings are grounded (fig. 6c).
only enough material to make the rings smooth and Opens
concentric. Finish with 400 grain polishing cloth and
blow dry. If lamp fails to light or if ohmmeter reads high when
5. Slip rings are not replaceable--excessive damage successively connected between each pair of stator leads,
will require rotor assembly replacement. the windings are open (fig. 6c).
6. Inspect brushes for wear. If they are worn halfway,
replace. Inspect brush springs for distortion or Short Circuit
weakening. If brushes appear satisfactory and move A short in the stator windings is difficult to locate
freely in brush holder, springs may be reused. without special test equipment due to the low resistance
TESTING ROTOR of the windings. However, if all other electrical checks
The rotor may be checked electrically with a 110-volt are normal and the generator fails to supply rated out-
put, shorted stator windings are indicated. Also, look
test lamp or an ohmmeter.
for heat discoloration on the windings.
Grounds
TESTING DIODES
Connect test lamp or ohmmeter from either slip ring
to the rotor shaft or to the rotor poles. If the lamp lights Two methods may be used to check diodes for shorts
or if the ohmmeter reading is low, the field windings are or opens, a test lamp of not more than 12 volts or an
grounded (fig. 5c). ohmmeter.
Opens CAUTION: Do not use a 110-volt test lamp to
Connect one test lamp or ohmmeter lead to each slip test diodes.
ring. If the lamp fails to light or if the ohmmeter reading TEST LAMP METHOD
is high, the windings are open (fig. 5c).
Diode in Heat Sink
Short Circuits With the stator previously disconnected connect one of
The windings are checked for shorts by connecting a the lamp leads to the heat sink and other lead to the diode

CHEVROLET CHASSIS OVERHAUL MANUAL


DELCOTRON 6Y-10

OHMMETER
(Check for Opens)

OHMMETER OHMMETER TEST LAMP TEST LAMP


(Check for Opens) (Check for Grounds)
5 . 5 " DELCOTRON
5 . 5 " STATOR
OHMMETER OHMMETER TEST
INSULATORS
LAMP

INSULATED
HEAT SINK

CUT GROUNDED
STATOR HEAT SINK
TEST LAMP LEAD
6 " STATOR
6 " DELCOTRON

Fig. 6c—Checking Stater for Grounds or Opens Fig. 7c—Checking Diodes

CHEVROLET CHASSIS OVERHAUL MANUAL


DELCOTRON 6Y-11

lead (fig. 7c). Observe condition of lamp. Reverse the


lamp leads and observe condition of lamp. A good diode
will allow the lamp to light in only one of the test direc-
tions. If lamp lights in both directions or fails to light at
all, the diode is defective.
Diode in the End Frame
Connect one lamp lead to the end frame and the other
lamp lead to the diode lead (fig. 7c), and observe lamp
condition. Reverse the lamp lead connections and observe
the lamp condition. A good diode will allow lamp to light
in only one direction. If lamp lights in both directions or
fails to light at all, the diode is defective.

OHMMETER METHOD
Use an ohmmeter with a 1 1/2 volt cell and use the
lowest range scale.
Connect the ohmmeter leads at each diode as previ-
ously described using a test lamp first in one direction
and then the other (fig. 7c). Note the readings. If both
readings are identical (very high or very low), the diode
is defective. A good diode will give one high and one low Fig. 8c—Installing Diodes with Press Tools
reading.
with J-9600-2 and an arbor press or vise. Make
REPAIRS sure diode is square with end frame and started
straight (fig. 8c).
Diode Replacement CAUTION: Avoid bending or moving diode stem
5.5" Delcotron as excessive movement can cause internal dam-
1. Support end frame with support Tool J-9717-2 and age and result in diode failure.
press out diode with diode removal Tool J-9717-1 5. Scrape enough insulation from diode stem and leads
and an arbor press or vise (fig. 8c). to insure good contact. Locate a sleeve over the
CAUTION: Do not strike diode as shock may diode and place the " T " clip from the diode package
damage other diodes. over the diode stem.
6. Place the flexible lead and, if applicable, the stator
2. Select diode with proper color marking. lead into the " T " connector. Crimp and solder
NOTE: Diodes in the heat sink are positive securely using 60% tin, 40% lead solder.
(red markings) and those in the end frame are CAUTION: Do not heat excessively, and avoid
negative (black markings). bending or moving diode stem as excessive heat
3. Support outside end frame around diode hole on a and movement can cause internal damage and
flat, smooth surface and press diode into position result in diode failure.
with J-9600-2 and an arbor press or vise. Make 7. Tie or tape the leads together to resist vibration.
sure diode is square with end frame and started
straight (fig. 8c). Heat Sink Replacement
CAUTION: Avoid bending or moving diode stem 1. Detach heat sink from end frame by removing the
as excessive movement can cause internal dam- two attaching bolts. Note carefully the proper stack-
age and result in diode failure. up of parts so the "BAT" and "GRD" terminal bolts
6.2" Delcotron can be reassembled in the same manner (fig. 9c). On
1. Cut leads connected to diode stem as close to 6.2" Delcotrons cut all leads on each side of the
stem as possible, if not previously done during three diode stems as close to the stems as possible.
disassembly. 2. Replace diodes, if necessary, as outlined in Diode
2. Support end frame with support Tool J-9717-2 and Replacement.
press out diode with diode removal Tool J-9717-1 3. Assemble heat sink to the end frame, following care-
and an arbor press or vise (fig. 8c). fully the proper stack-up of parts as noted in Step 1.
On 6.2" Delcotron reconnect leads as described
CAUTION: Do not strike diode as shock may under diode replacement.
damage other diodes.
3. Select diode with proper color marking. Brush Replacement

NOTE: Diodes in the heat sink are positive 5.5" Delcotron-(Fig. 10c)
(red markings) and those in the end frame are 1. After through bolt removal and Delcotron separation,
negative (black markings). remove stator lead nut that also holds relay terminal
connector.
4. Support outside end of frame around diode hole on a 2. Remove 2 m o u n t i n g screws and brush holder
flat, smooth surface and press diode into position assembly.

CHEVROLET CHASSIS OVERHAUL MANUAL


DELCOTRON 6Y-12

BOLT
INSULATOR
BOLT

FLAT METAL WASHER INSULATOR SCREW

LOCKWASHERS

LOCKWASHER
FLAT WASHER
FIBER INSULATOR
CONDENSER LEAD

LOCKWASHERS
FIBER INSULATOR
HEAT SINK
END FRAME

Fig. 9c—Heat Sink—Parts Location 5.5" Delcotron

3. Position new brush holder assembly and install r e - 2. Refill bearing one-quarter full with Delco-Remy No.
taining screws. 1948791 grease or equivalent. Do not overfill.
4. Connect relay terminal wire lead and install stator 3. Press bearing into end frame using tube or pipe as
lead nut. in Step 1.
6.2" Delcotron 4. Install retainer plate. Use new retainer plate if felt
Refer to disassembly and assembly procedures. seal is hardened or excessively worn.
End Frame Replacement NOTE: On 5.5" Delcotron stake retainer plate
1. Remove heat sink as outlined in Heat Sink Replace- bolts to plate.
ment.
2. Attach brush holder assembly to the new end frame Bearing Replacement—Slip Ring End Frame
and insert pin or wire through the hole to hold the 5.5" Delcotron
brushes in the h o l d e r (5.5" Delcotron). After the 1. Replace the bearing if the grease supply is ex-
Delcotron unit has been completely assembled, with- hausted. Make no attempt to re-lubricate and reuse
draw the pin or wire from the end frame hole to the bearing.
allow the brushes to drop down onto the slip rings.
3. Replace heat sinks to end frame as outlined in Heat
Sink Replacement.
Bearing Replacement—Drive End Frame
1. The drive end frame bearing can be removed by
detaching the retainer plate bolts and separating
retainer plate from end frame, and then pressing
bearing out using suitable tube or pipe on outer race.
NOTE: 5.5' Delcotron uses staked retainer
plate bolts.

Fig. 10c—Brush Assembly—5.5" Delcotron Fig. lie—Removing Bearing

CHEVROLET CHASSIS OVERHAUL MANUAL


DELCOTRON 6Y-13

HOOK LEAD TEMPORARILY


OVER STUD SECURE CLIP
WITH NUT

o
RUN LEAD BETWEEN
TERMINALS
Fig. 13c—Brush Lead Arrangement During Assembly

Fig. 12c—Torquing Pulley Nut 4. Clamp pulley in soft jaw vise and tighten shaft nut to
50-60 ft. lbs.
2. Press out from inside of housing, using suitable tool
over outer race of bearing. NOTE: Do not clamp rotor since this may
3. To install, place a flat plate over the bearing and cause rotor segment deformation.
press in from outside of housing until bearing is 5. Position rotor and drive end frame assembly into
flush with the outside of the end frame. Support in- slip ring end frame and stator. Install and tighten
side of end frame around bearing bore with a suitable through bolts.
tool to prevent distortion. Use extreme care to avoid 6. To install brushes, push brushes into holder and
misalignment. secure leads as shown in Figure 13c, to keep the
6.2" Delcotron
brushes in holder.
7. Attach brush assembly and -condenser to the end
1. Remove bearing from rotor shaft using Tool J-6627 frame with hex-head stud on the left side only.
as shown in Figure l i e . 8. Rearrange leads as shown in Figure 14c with right-
2. Install bearing over shaft using Tool J-9610 or tube hand brush lead connected under the right hand hex-
or pipe of suitable diameter over inner race and head stud.
press to locate bearing even with end of shaft. 9. Attach terminal cover with two screws, making sure
leads are not caught underneath the cover.
ASSEMBLY

5.5" Delcotron
1. Install stator assembly in slip ring end frame and
locate diode connectors over the relay, diode and
stator leads, and tighten terminal nuts.
2. Install rotor in drive end frame.
3. Install fan, spacer, pulley washer and nut.
4. Place torque wrench and adapter (J-21501) on shaft
nut and insert alien wrench into opening at end of
drive shaft. Tighten shaft nut to 40-50 ft. lbs. (fig.
12c).
5. Assemble slip ring end frame and stator assembly
to drive end frame and rotor assembly.
6. Install 4 through bolts in the end frame assemblies.
BRUSH
LEAD
6.2" Delcotron BRUSH
1 Install stator assembly in slip ring end frame and LEAD RELAY CONDENSER
LEAD GROUND LEAD
locate diode connectors over the relay, diode and STUD
stator leads, and tighten terminal nuts.
Install the front frame over rotor.
Install fan, spacer, woodruff key, pulley, washer and
nut. Fig. 14c—Lead Arrangement After Assembly

CHEVROLET CHASSIS OVERHAUt MANUAL


DELCOTRON 6Y-14

SPECIAL TOOLS

J-9717-2 J-9717-1 J-9600-2 J-21501


SUPPORT PRESS SHOULDERED PULLY
TOOL TOOL INSTALLER ADAPTER

Fig. 15c-Spec?al Tools

CHEVROLET CHASSIS OVERHAUL MANUAL


SECTION 7
CLUTCH AND TRANSMISSIONS
CONTENTS OF THIS SECTION
Page
Clutch 7-1
Three-Speed Transmission 7-4
Overdrive Transmission 7-13
Four-Speed Transmission 7-20
Powerglide Transmission 7-28
Special Tools 7-49

CLUTCH
INDEX

Clutch Assembly 7-1


Disassembly 7-1
Inspection and Repair 7-1
Pilot Bearing 7-3
Assembly 7.3

CLUTCH ASSEMBLY 2. The clutch diaphragm spring and two pivot rings are
riveted to the clutch cover. Spring, rings and cover
Two designs of the diaphragm spring clutch are used should be inspected for excessive wear or damage
with the different engine-transmission combinations. One and if there is a defect, it is necessary to replace
design has a flat-finger diaphragm spring (fig. 1) and the the complete cover assembly.
other design has a bent-finger diaphragm spring (fig. 2).
The following overhaul procedures apply to both designs.
Inspection and Repair
Disassembly (Fig. 3) 1. Wash all parts, except driven disk and throwout
1. Remove three drive-strap to pressure plate bolts bearing, in cleaning solvent.
and retracting springs and remove pressure plate
from clutch cover.
NOTE: The throwout bearing is permanently
NOTE: When disassembling, prick punch edge packed with lubricant and should not be soaked
of pressure plate and cover. These marks must in cleaning solvent as this will dissolve the
be aligned in assembly to maintain balance. lubricant.

Fig. 1 —Flat Finger Clutch Cross-Section (Typical)

1. Flywheel 3. Pilot Bushing 5. Pressure Plate 7. Cover 9. Fork


2. Dowel-hole 4. Driven Disc 6. Diaphragm Spring 8. Throwout Bearing 10. Retracting Spring

CHEVROLET CHASSIS OVERHAUL MANUAL


CLUTCH 7-2

Fig. 2—Bent Finger Clutch Cross-Section (Typical)

1. Flywheel 3. Pilot Bushing 5. Pressure Plate 7. Cover 9. Fork


2. Dowel-hole 4. Driven Disc 6. Diaphragm Spring 8. Throwout Bearing 10. Retracting Spring

2. Inspect pressure plate and flywheel for scores on the


contact surfaces. Use a straight-edge and check for
flatness of contact surfaces.
3. Check retracting springs for looseness at the clutch
cover and evidence of looseness at pressure plate
bolt holes.
4. Check throwout bearing for roughness and free fit
on the sleeve of the transmission clutch gear bearing
retainer. Replace retainer if rough.
5. Inspect clutch disc for worn, loose or oil soaked
facings, broken springs, loose rivets or riding.
6. Examine splines in hub and make sure they slide
freely on splines of transmission clutch shaft. If
splines are worn, the clutch disc or clutch gear
should be replaced as necessary.
7. Inspect clutch fork ball socket and fingers for wear
and ball retaining spring for damage.
NOTE: Ball spring on fork may be bent in
toward fork if necessary.
Fig. 3—Retracting Spring Location (Typical) 8. Inspect ball stud for wear.

CHEVROLET CHASSIS OVERHAUL MANUAL


CLUTCH 7-3

Pilot Bearing
The clutch pilot bearing is an oil impregnated type
bearing pressed into the crankshaft. This bearing r e -
quires attention only when the clutch is removed from
the vehicle, at which time it should be cleaned and in-
spected for excessive wear or damage and should be
replaced if necessary. To remove, install Tool J-1448
and remove bearing from crankshaft (fig. 4). 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.

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 drive-
strap to pressure plate bolts and lock washers and
tighten to 11 ft. lbs. torque. The clutch is now ready
to be installed. Fig. 4—Clutch Pilot Bearing Removal (Typical)

CHEVROLET CHASSIS OVERHAUL MANUAL


3-SPEED TRANSMISSION 7-4

THREE-SPEED TRANSMISSION
INDEX
Page Page
Transmission 7-4 Clutch Gear Bearing 7.7
Disassembly 7-4 Clutch Sleeve and Synchronizer Rings 7-7
Cleaning and Inspection 7-4 Synchronizer Energizing Springs 7-7
Bearings 7-4 Transmission Extension Oil Seal,
Transmission Case and Extension 7-4 Bushing and Transmission Mount 7-9
Gears 7-4 Assembly 7-9
Reverse Idler Bushings 7-4 Reverse Idler Gear 7-9
Countergear and Reverse Idler Needle Bearings . . . 7-7 Countergear and Clutch Gear 7-10
Repairs 7-7 Clutch Sleeve 7-11
Mainshaft, Rear Bearing, Mainshaft 7-11
Second Drive Gear and Transmission Alignment 7-11
Speedometer Drive Gears 7-7 Torque Specifications 7-12

TRANSMISSION 11. Remove reverse idler gear, thrust washer, thrust


bearing, and bearing washer. On V-8 Models, also
Disassembly needle bearings (40) and bearing washers (2).
1. Remove the bolts and lock washers from the trans- 12. To remove mainshaft from extension, expand bear-
mission side cover and remove the cover and gasket. ing snap ring and tap rear of shaft with a soft ham-
NOTE: Under ordinary circumstances it is not mer to bring shaft, speedometer drive gear, second
necessary to disassemble the cover assembly. speed gear and bearing as an assembly forward out
Servicing of cover is outlined under "Mainte- of extension (fig. 4A).
nance and Adjustments," Section 7 in the Service Cleaning and Inspection
Manual.
Bearings
2. Remove extension-to-transmission case bolts and 1. Wash the bearings thoroughly in a cleaning solvent.
lock washers and pull extension and mainshaft out 2. Blow out the bearings with compressed air.
of transmission case, leaving second and third speed
clutch assembly and first and reverse gear in case. CAUTION: Do not allow the bearings to spin,
Do not force mainshaft. Rotate mainshaft and syn- but turn them slowly by hand. Spinning bearings
chronize ring to obtain alignment of lugs of synchro- will damage the race and balls.
nizer and splines of mainshaft (fig. 3A). 3. After making sure the bearings are clean, lubricate
3. Slide first and reverse gear from clutch sleeve, then them with light engine oil and check them for rough-
remove them separately through side opening in ness. Roughness may be determined by slowly turn-
transmission case. ing the outer race by hand.
4. Remove pilot bearing rollers from clutch gear.
5. Remove the four clutch gear bearing retainer screws Transmission Case and Extension
and shakeproof washers and remove the retainer. Wash the transmission case and extension inside and
Note the screw holes in the retainer are unevenly outside with a cleaning solvent and inspect for cracks.
spaced so the retainer may be assembled to the case Inspect the faces for burrs and if any are present, dress
in only one position, matching up the oil return slot them off with a fine cut mill file. Inspect oil seal, bushing
with the hole in the case. and snap ring in extension and, if worn or damaged, r e -
6. Remove the countershaft by driving it from front to place as outlined under "Repairs".
rear of the case, using a soft steel drift. Lower the Gears
countergear to bottom of case. 1. Inspect all gears and, if necessary, replace any that
NOTE: It is necessary to lower the countergear are worn or damaged.
before removing the clutch gear and bearing, 2. Check the first and reverse sliding gear to make
otherwise the bearing will strike the counter- sure it slides freely on clutch sleeve.
gear. 3. Check the clutch sleeve to see that it slides freely
on mainshaft.
7. Remove clutch gear bearing snap ring. Tap end of
shaft with soft hammer to move gear and bearing Reverse Idler Gearing Bushings (L-4 & L~6 Models Only)
assembly into case and remove through rear of case. 1. The bushings used in the idler gear are pressed into
8. Remove the countergear, rollers, and thrust washers the gear, and are accurately bored with special
from case. diamond boring tools. This insures the positive
9. Drive the idler shaft lock pin into the shaft. This pin alignment of the bushings and their shafts, as well as
is shorter than the diameter of the shaft so the shaft proper meshing of the gears. Because of the high
may be slipped out when the pin is driven in. degree of a c c u r a c y to which these parts are
10. Using a drift pin, tap rear of shaft to drive out plug machined, the bushings are not serviced separately.
ahead of shaft. Do not turn the shaft while removing 2. Check bushings for excessive wear by using a nar-
as the lock pin may drop down between the idler gear row feeler gauge between the shaft and the bushing.
bushings. The proper clearance is from .003" to .005".

CHEVROLET CHASSIS OVERHAUL MANUAL


1 2 3 4 5 6 7 19 20

Fig. 1 A—Transmission Cross Section (Typical Top View)

1. Clutch Gear Bearing Retainer 10. First and Reverse Sliding Gear 19. Extension Bushing 28. Interlock 36. Side Cover
2. Clutch Gear Bearing 11. Thrust Bearing and Washer 20. Extension Oil Seal 29. Roller 37. First and Reverse
3. Clutch Gear 12. Reverse Idler Shaft Pin 21. Front Pilot Bearing Rollers 30. Detent Cam Shifter Shaft and
4. Energizing Spring 13. Second Speed Gear 22. Thrust Washer 31. Fork Retainer Ring and Washer Plate Assembly
5. Reverse Idler Shaft 14. Thrust Washer 23. Thrust Washer 32. Detent Cam Spring 38. First and Reverse
6. Thrust Washer 15. Extension 24. Rear Pilot Bearing Rollers 33. " O " Ring Oil Seal Shifter Fork
7. Reverse Idler Gear 16. Mainshaft Rear Bearing 25. Synchronizer Ring 34. Second and Third 39. Interlock Retainer
8. Second and Third Speed Clutch 17. Speedometer Drive Gear 26. Second and Third Shifter Fork Shifter Lever 40. Clutch Gear Bearing Nut
9. Case 18. Mainshaft 27. Second and Third Shifter Shaft 35. First and Reverse Shifter Lever 41. Snap Ring
1 2 3 4X 5 6 7 8 5 4 9 10 11 12 13
/ / / yX
\ \ i
HHMHH
\ "^i
M^^MlSilllSiiiiiJJl^ 11

'5"16'"W
17
'''It*IOMIP™'1I^ f l B , Jt
19-^f

21 Jl
22
23
^ \ ^ - 20
24 •""' X %
\ 22

25

Fig. 2A—Three-Speed Transmission Cross-Section (Typical Side View)


1. Clutch Gear Bearing Retainer 6. Second and Third Speed Clutch 11. Mainshaft Rear Bearing 16. Thrust Washer 21. Countershaft
2. Clutch Gear Bearing 7. First and Reverse Sliding Gear 12. Extension 17. Snap Ring 22. Thrust Washer
3. Clutch Gear 8. Transmission Case 13. Mainshaft 18. Thrust Washer 23. Roller Bearing
4. Energizing Spring 9. Second Speed Gear 14. Clutch Gear Bearing Nut 19. Rear Pilot Bearing Rollers 24. Countergear
5. Synchronizer Ring 10. Thrust Washer 15. Front Pilot Bearing Rollers 20. Roller Thrust Washer 25. Reverse Idler Gear
3-SPEED TRANSMISSION 7-7

ALIGN LUG ON
SYNCHRONIZER
WITH SLOT IN
MAINSHAFT
HELICAL SPLINE

Fig. 4A-—Mainshaft Assembly


Fig. 3A—Synchronizer Alignment
1. Second Speed Gear 4. Energizing Spring
2. Rear Bearing 5. Thrust Washer
Countergear and V-8 Model Reverse Idler Needle Bearings 3. Speedometer Drive Gear 6. Snap Ring
All needle bearings should be inspected closely and if
excessive wear shows, they should all be replaced as well
as the shaft. CAUTION: The bearing must turn as freely
after it is installed to the shaft as it turned
Repairs before being placed on the shaft.
Mainshaft, Rear Bearing, Second Speed Gear, Clutch Sleeve and Synchronizer Rings
and Speedometer Drive Gears (see Fig. 4A) 1. Remove the first and reverse sliding gear.
1. Press speedometer drive gear off mainshaft, using 2. Turn the synchronizer ring in the clutch sleeve until
suitable split plates in an arbor press. the ends of the synchronizer ring retainer can be
2. Remove bearing to mainshaft snap ring and press seen through the slot in the clutch sleeve.
bearing off shaft. 3. Using Tool J-0932 expand the retainer into the
3. Remove second speed gear thrust washer and second counterbore in the clutch sleeve. This raises the
speed gear. retainer from the groove in the ring so ring may be
4. Coat bore with transmission lubricant and slide easily slipped out (fig. 8A).
second speed gear on mainshaft and install thrust 4. Check the synchronizing cones for wear or for being
washer with oil grooves toward gear. loose in the clutch sleeve. If cones are damaged in
5. Install new bearing, groove in O.D. of bearing to- any way, it will be necessary to replace the clutch
ward second speed gear. sleeve assembly and both synchronizer rings.
6. Select one of four available snap rings so end play 5. Inspect the synchronizer rings for smoothness.
of bearing on shaft is a maximum of .004", This 6. Place the synchronizer rings in the synchronizing
may be easily determined by installing successively cones and check with thumbs to see that rings do
larger rings. Use the thickest ring that will enter not rock. Excessive rocking indicates a poor fit
snap ring groove on shaft. between the rings and cone, which will not permit
7. Start speedometer drive gear on shaft with cham- proper synchronizing of gears during shifting.
fered I.D. of gear toward bearing. Press gear on 7. Install the synchronizer ring retainers in the coun-
shaft until rear face of gear is 1-7/16" from face of terbores in the ends of the clutch sleeve.
bearing. 8. Using Tool J-0932 in slot in clutch sleeve, expand
Clutch Gear Bearing
each retainer in the counterbore, lubricate each
1. Place the clutch gear in a vise with soft jaws, and synchronizer ring with light oil and install in clutch
remove the bearing retainer nut and oil slinger, sleeve.
using Tool J-0933 (fig. 6A). The retaining nut and NOTE: Make sure retainers seat in groove
oil slinger is a one-piece steel casting machined all the way around the rings so rings will turn
with a left-handed thread and is locked in place on freely.
the clutch gearshift by being staked into a hole
provided for that purpose. 9. Install the first and reverse sliding gear on the
2. Install gear and bearing in transmission case and clutch sleeve.
install snap ring on bearing, Synchronizer Energizing Springs
3. Support rear of case in arbor press as shown in 1. It will be noticed upon examining these springs that
Figure 7A and press shaft from bearing. Tap bearing one of the ends is slightly offset. Each spring must
from case. be assembled in its groove in the clutch gear and the
4. Using an arbor press, press the clutch gear bearing second speed gear with the offset or locking end
on the clutch gear with the locating ring groove to- between the third and fourth teeth of either of the
ward the front of the gearshaft. two banks of teeth on these gears, thus keeping the
5. Install the combination clutch bearing retaining nut spring from turning in its groove (fig. 9A).
and oil slinger on the clutch gearshaft and draw it 2. Under normal operation it should never be necessary
up tight, using Tool J-0933. to replace the energizing springs; however, should
6. Lock the retaining nut oil slinger in place by staking an energizing spring be removed for any reason, a
it into the hole with a center punch. Care must be new spring should be installed. The spring may be
used not to damage the threads on the shaft. removed by slipping a thin blade under the spring

CHEVROLET CHASSIS OVERHAUL MANUAL


3-SPEED TRANSMISSION 7-8

Fig. 5A—Layout of Transmission Parts (Typical)

1. Clutch Gear Bearing Retainer 21. Snap Ring 36. Shifter Interlock Retainer Stud Nut
2. Bearing Retainer Gasket 22. Speedometer Drive Gear 37. Shifter Interlock Retainer Stud Nut Lock
3. Bearing Nut and Oil Slinger 23. Extension Gasket 38. Shifter Interlock Retainer
4. Bearing Snap Ring 24. Rear Bearing Snap Ring 39. Second and Third Shifter Fork
5. Clutch Gear Bearing 25. Extension 40. First and Reverse Shifter Fork
6. Clutch Gear 26. First and Reverse Shifter Shaft 41. Shifter Interlock
7. Energizing Spring " O " Ring 42. First and Reverse Shifter Shaft and
8. Front Pilot Bearing Roller 27. Second and Third Shifter Shaft Plate Ass'y.
9. Thrust Washer " O " Ring 43. Shifter Fork Roller
10. Thrust Washer 28. Thrust Washer 44. Shifter Fork Washer
11. Rear Pilot Bearing Rollers 28a. Thrust Bearing 45. Shifter Fork Retainer
12. Transmission Case 28b. Thrust Bearing Washer 46. Second and Third Shifter Shaft and
13. Synchronizer Ring 29. Reverse Idler Gear Plate Ass'y.
14. Snap Ring 30. Reverse Idler Shaft Pin 47. Detent Cam Retainer
15. Second and Third Speed Clutch 31. Reverse Idler Shaft 48. First and Reverse Detent Cam
16. First and Reverse Sliding Gear 32. Countershaft 49. Detent Cam Spring
17. Mainshaft 33. Countergear and Roller Thrust 50. Second and Third Detent Cam
18. Second Speed Gear Washers 51. Side Cover
19. Thrust Washer 34. Bearing Roller 52. First and Reverse Shifter Lever (Outer)
20. Mainshaft Rear Bearing 35. Countergear 53. Second and Third Shifter Lever (Outer)

CHEVROLET CHASSIS OVERHAUL /MANUAL


3-SPEED TRANSMISSION 7-9

Fig. 6A—Removing Bearing Retainer Nut and Oil Slinger

and raising it sufficiently to slide it off over the


gear teeth.
Transmission Extension Oil Seal, Bushing
and Transmission Mount
If bushing in rear of extension requires replacement,
remove oil seal and use Tool J-5778 to drive bushing
into extension. Using the same tool, drive new bushing Fig. 8A—Removing Synchronizer Ring
in from rear until end of bushing is slightly below coun-
terbore for oil seal. Coat I.D. of bushing with trans- ing against end with chamfered gear teeth; large
mission lubricant, then use cup grease between lips to washer against bearing; small washer at opposite
prelubricate seal and install new oil seal using Tool end of gear (fig. 10A). Coat bushings with trans-
J-5154. mission lubricant.
If extension or transmission mount is to be replaced, V-8 Models Only
remove mount-to-extension bolts and washers. a. Place some cup grease in the roller bearing area
To install mount-to-extension, install two bolts and of each end of the idler gear and install 20 rollers
washers and tighten bolts. in each end. Then install a roller thrust washer
Assembly
in each end.

Reverse Idler Gear


1. Coat thrust washers and the needle thrust bearing ENERGIZING SPRING
with grease and position them on gear; needle bear-

LOCATE OFFSET END OF SPRING BETWEEN


3RD AND 4TH TEETH OF EITHER BANK OF TEETH

Fig. 7A—Removing Clutch Gear from Bearing Fig. 9A—Position of Energizing Spring

CHEVROLET CHASSIS OVERHAUL MANUAL


3-SPEED TRANSMISSION 7-10

Fig. 11A—Countergear and Rollers

Apply grease to bearing thrust washers and counter-


gear thrust washers and place one of each at each
PROPER ANGLE end of countergear.
Insert the countergear (with Tool J-5777) in trans-
mission case and rest it on bottom of case.
Place some cup grease in the mainshaft pilot hole in
the clutch gear and install the roller bearings (fig.
12A). Install the 14 group and small I.D. spacer,
then the large I.D. spacer and the 24 group.
After being assembled in the pilot hole, care must
be taken in handling to avoid misplacing rollers.
Insert clutch gear in case from inside case and
using a brass drift, tap the outer race of the clutch
RADIAL ROLLER
THRUST BEARING
gear bearing until the bearing locating ring groove
is outside the front of the case, being careful to
drive the assembly straight to prevent damage (fig.
13A).
Install snap ring on bearing and tap clutch gear
rearward until snap ring is firmly against case.
Fig. 10A— L-4 and L-6 Reverse Idler Gear Shaft Install the clutch gear bearing retainer and gasket,
and Lock Pin (Typical) making sure the oil slot in the retainer lines up
with the oil slot in the front face of the transmission
b. Insert an old idler shaft or an 11/16" diameter
rod 2-3/4" long in idler gear to retain rollers
while installing.
2. Place gear assembly in position in case so thrust
bearing is toward rear.
3. Install the idler shaft, making sure the lock pin hole
in the shaft lines up with the hole in the case at the
same angle. On roller bearing models the dummy
shaft will move out the opposite end of the case as
shaft is installed.
4. Use a new idler shaft lock pin, coat the pin with
Permatex or its equivalent and drive it in approxi-
mately 1/16" beyond flush with case; peen the hole
slightly. This lock pin must be a tight fit in the case
to prevent oil leaks.
5. Install the idler shaft expansion plug in the case. A
new plug should be used whenever possible.

Countergear and Clutch Gear


1. Place some cup grease in the roller bearing area of
each end of the counter gear and install the 25 rollers
in each end. The grease will hold the rollers in
place while installing (fig. 11A).
2. Insert Tool J-5777 in countergear. Fig. 12A—Mainshaft Pilot Roller Bearings in Clutch Gear

CHEVROLET CHASSIS OVERHAUL MANUAL


3-SPEED TRANSMISSION 7-11

corrected, the alignment of the engine crankshaft pilot,


clutch housing bore and the transmission should be
checked.
A special tool on which is mounted a dial indicator is
necessary to check the transmission rear bearing bore
alignment. This tool may be made from a new or good
used clutch gear which has a good bearing surface on the
crankshaft pilot and front main bearing.
The splines on the clutch gear shaft should be ground
off so the shaft may be rotated in a clutch disc hub with-
out interference when assembled in the car. Weld a
piece of 1/4" rod 8" long in the mainshaft pilot bore.
Assemble a good bearing on the shaft and secure it with
Fig. 13A—Installing Clutch Gear and Bearing clutch gear bearing nut.
Procedure
case. Do not allow the gasket to protrude beyond
the edge of the retainer. 1. Remove the transmission from the car and com-
9. Coat the retainer screws with Permatex No. 2 or pletely disassemble.
equivalent and install in retainer, using the special NOTE: In any case where the clutch gear pilot
shakeproof washers. Tighten the retaining cap- or pilot bearing is excessively loose or worn,
screws to torque specification. the pilot bearing should be replaced before
10. Lubricate and insert countershaft in rear of case, checking the transmission rear bearing bore
align countergear with shaft and tap shaft through, alignment by the dial indicator method.
pushing assembly tool out front of case (fig. 14A).
11. Turn countershaft so flat on end of shaft is hori- 2. Install the extension on the case and tighten the
zontal. extension-to-case bolts securely.
3. Carefully install the special tool with the dial indi-
NOTE: The flat on shaft must be horizontal cator into the transmission case with the face of the
at the BOTTOM or the transmission case ex- indicator and the tracing finger to the rear of the
tension cannot be assembled to transmission transmission. Secure in place with a clutch gear
case. On Overdrive equipped transmission, flat bearing retainer.
must be horizontal and at TOP of shaft to en- 4. Carefully rotate the gear and make final adjustment
gage the overdrive adapter. of the indicator with the tracing finger of the indi-
12. Make sure front end of shaft is in line with hole in cator pointing to the rear and in the center of the
front of case, and drive shaft into case until flat on rear bearing bore in the extension.
shaft is flush with rear of case. 5. Assemble the t r a n s m i s s i o n case to the clutch
Clutch Sleeve
housing and tighten the four transmission mounting
bolts securely.
Assemble first and reverse gear on the clutch as-
sembly. Insert both pieces into the side opening of the NOTE: Be sure to clean off any paint or other
case by tipping the front end of the assembly into the foreign material on the mating faces of the
opening first. Align the lug of the synchronizing ring
with the synchronizing slot of the clutch gear, and posi-
tion the assembly on gear to receive the mainshaft.
Mainshaft
1. Install the mainshaft assembly in the transmission
case extension.
2. Install gasket on transmission case.
3. Align lugs on synchronizer rings with slots in main-
shaft so lugs on the synchronizer rings slide in slots
on gear. Check clutch gear to make sure rollers
are still in position. Push the shaft into the clutch
sleeve until transmission case extension (or the
overdrive adapter) is tight against case. Install bolts
and lock washers.
CAUTION: Keep mainshaft in line with clutch
gear during installation to a v o i d disrupting
rollers in clutch gear.
NOTE: The extension lower bolt should be
coated with Permatex No. 2 or equivalent before
installation. Torque to specification.
Fig. 14A—Assembly of Countergear
TRANSMISSION ALIGNMENT
If transmission slips out of high gear, particularly at 1. Countergear Assembly 2. Countershaft
50 MPH and up, after all other probable causes have been Tool J-5777 3. Clutch Gear

CHEVROLET CHASSIS OVERHAUL MANUAL


3-SPEED TRANSMISSION 7-12

clutch housing and transmission as any foreign 10. After the position and quantity of shims has been
material on these faces will change alignment; determined and recorded transmission case may be
also, check carefully for dings or burrs on these removed.
mating surfaces and remove carefully as neces-
NOTE: The clutch housing should t h e n be
sary.
stamped, showing the position where shims are
6. Install t r a n s m i s s i o n support and support-to- to be installed and the thickness of shims at
transmission mounting block bolts. each location.
7. Remove the jack or other support from under the
11. Inspect the external clutching teeth of the clutch
engine and let the weight of the engine rest on the
gear and second speed gear. Inspect the second and
transmission mounting in the normal position.
third speed clutch synchronizer rings. If the teeth
8. Dial indicate the transmission rear bearing bore are worn or tapered, the gears should be replaced.
and record the indicator readings in the 12, 3, 6, Reassemble transmission.
and 9 o'clock positions, with the weight on the
12. Install the transmission assembly to the clutch
transmission mounting as outlined above.
housing, using the correct number of shims at the
NOTE: It is best to start the reading at the proper locations as previously determined. Shims
6 o'clock position with the indicator set at are available by unit part number 3694977 each unit
" 0 " in this position and then record the 9, 12, consisting of the following shims:
and 3 o'clock readings in rotation.
9. Install temporary slotted shims between the trans- 4 - .002" shims Identification -
mission case and the clutch housing in the quantities two corners cut off
and at the bolt locations as necessary to bring 2 - .005" shims Identification -
misalignment at the transmission rear bearing bore one corner cut off
to a maximum of .010" indicator reading in either
the vertical or horizontal plane. 1 - .010" shim Identification -
all corners square
NOTE: Installation of a .002" shim between
the transmission case and the clutch housing at
two bolt locations opposite to the high indicator NOTE: These special shims have a tab on one
reading will change the transmission rear bore end for ease of installation. Do not slot the
reading approximately .003" to .004". shims for the permanent installation.

TORQUE SPECIFICATIONS

Clutch Gear Retainer to Case Bolts 12-15 ft. lbs,


Side Cover to Case Bolts . . 15-18 ft. lbs.
Extension to Case Bolts 40-45 ft. lbs.
Shift Lever to Shifter Shaft Nut 6-9 ft. lbs.
Shift Lever Clamping Bolt Nut 12-15 ft. lbs.
Lubrication Filler Plug 25-35 ft. lbs.
Shifter Interlock Retainer Stud and Nut 3-5 ft. lbs.
Clutch Gear Bearing Retainer Nut 40 ft. lbs.

CHEVROLET CHASSIS OVERHAUL MANUAL


TRANSMISSION OVERDRIVE 7-13

TRANSMISSION OVERDRIVE
INDEX
Page Page
Overdrive Housing 7-13 Parts at Rear of Adapter 7-16
Removal from Adapter 7-13 Removal 7-16
Disassembly 7-14 Cleaning and Inspection 7-16
Cleaning and Inspection 7-15 Installation 7-17
Assembly 7-15 Lubrication 7-18
Installation to Adapter 7-15
3. Disconnect wires from solenoid and from governor
OVERDRIVE HOUSING switch.
Removal from Adapter 4. Disconnect speedometer cable from driven gear
1. Place car on stand jacks. fitting.
2. Remove drain plug and drain overdrive. 5. Remove propeller shaft as outlined in Section 4.

Fig. IB—Overdrive Cross Section

1. Sun Gear 7. Clutch Cam Roller 11. Output Shaft Bearing 15. Solenoid Assembly
2. Sun Gear Control Plate Retainer 12. Clutch Cam Roller 16. Shift Rail
3. Sun Gear Shift Collar 8. Cam 13. Control Shaft 17. Sun Gear Pawl
4. Pinion Cage Assembly 9. Output Shaft and Lever 18. Blocker Ring
5. Output Shaft Ring Gear 10. Speedometer and Governor 14. Shift Fork 19. Transmission Mainshaft
6. Pinion Drive Gear

CHEVROLET CHASSIS OVERHAUL MANUAL


TRANSMISSION OVERDRIVE 7-14

Fig. 4B-—Removing Output Shaft from Housing


Fig. 2B—Removing Control Shaft Tapered Pin
12. Remove gasket from adapter and install one bolt
6. Remove speedometer driven gear fitting, gear and removed from housing to hold the adapter to the
shaft. transmission case.
7. Disconnect control cable from control lever.
Disassembly
8. Drive out the control shaft tapered pin (fig. 2B) and
pull control shaft out. 1. Remove governor and p i n i o n if not previously
9. Support rear of engine and remove transmission removed.
support bracket to mount bolts and washers. Remove 2. Pierce plug in rear bearing snap ring access hole in
support to frame bolts, lock washers and nuts (also top of housing and pry plug out of housing.
plain washers beneath bolt heads on left side only): 3. Spread rear bearing snap ring with snap ring pliers
Then remove transmission support. and lightly tap end of shaft with a soft hammer to
10. Remove seven bolts and lock washers attaching the free bearing from snap ring (fig. 4B), then pull shaft,
overdrive h o u s i n g to the transmission case and including ring gear, speedometer drive gear and rear
adapter. bearing, from housing.
11. Pull overdrive Jiousing including overdrive output 4. Remove shift rail retractor spring from housing.
shaft and ring gear assembly to rear, being careful 5. Remove output shaft rear bearing snap ring from
to keep adapter from pulling away from transmission housing.
case (fig. 3B) (catch the clutch rollers as they drop 6. Remove oil seal and press bushing from rear of
out of the retainer). housing, using Tool J-5778.

CAUTION: If adapter moves away from trans-


mission case the transmission mainshaft pilot
needle bearings will drop out of clutch gear and
necessitate disassembly of transmission.

Fig. 5B—Overdrive Output Shaft Assembly

1. Ring Gear 4. Rear Bearing


2. Snap Ring 5. Speedometer Drive Gear
3. Oil Collector 6. Snap Ring
Fig. 3B—Removing Overdrive Housing and Shaft Assembly Ring (Part of Shaft) 7. Output Shaft

CHEVROLET CHASSIS OVERHAUL MANUAL


TRANSMISSION OVERDRIVE 7-15

Remove ring gear snap ring (large) and slide ring


gear off shaft (fig. 5B). The oil collector ring is spun
securely to the shaft to form an oil tight seal.
Remove speedometer drive gear (small) snap ring
from output shaft.
Support front face of bearing and tap end of shaft to
start speedometer drive gear off shaft. If necessary
to use arbor press to start gear (fig. 6B) do not
press shaft more than 3/8" through bearing or
woodruff key in shaft may gouge bearing. Pull gear
off shaft.
10. Remove woodruff key and slide bearing off shaft.
Cleaning and Inspection
As each part is removed from the housing assembly,
wash in cleaning solvent, dry, and protect from subse-
quent dirt accumulation.
Inspect housing, shift rail retractor spring, shift fork Fig. 7B—Installing Housing and Shaft Assembly
spring, snap rings, gears and bearings for cracks, de-
fects or damage and s u b s t i t u t e new parts where
necessary. 4. Using Tool J-5778, press bushing into housing flush
If clutch rollers show surface markings of any kind with bore for seal. Coat new oil seal with Permatex
they should be replaced. or equivalent and install in housing, using Tool
A general inspection of the overdrive parts remaining J-5154. Prelubricate new seal between lips with cup
on the transmission mainshaft, particularly the clutch grease.
cam and roller retainer assembly and the shift rail and 5. Install output shaft rear bearing snap ring in slot in
fork assembly, should be made at this time. housing.
Assembly 6. Install shift rail retractor spring inside housing and
1. Slide rear bearing straight on shaft with snap ring insert long 3/8" drift pin through spring to align
groove in bearing closer to ring gear end of shaft. spring with holes in housing.
2. Install woodruff key in shaft, start speedometer drive 7. Slide output shaft assembly into housing until rear
gear onto shaft and align keyway in gear with key in bearing contacts snap ring. Spread snap ring and
shaft. Tap gear tight against bearing and install push shaft in until snap ring engages bearing.
small snap ring. 8. Install new plug in snap ring access hole in top of
3. Engage ring gear an teeth of overdrive shaft and housing.
install large snap ring in ring gear.
Installation to Adapter
1. Snap a tight fitting rubber band around clutch cam
roller retainer, insert rollers under rubber band in
retainer and, with low gear of transmission engaged,
turn retainer and rollers counter-clockwise until
rollers are in their low position.
2. Remove the one bolt holding adapter to transmission
case and install gasket on case.
3. Position shift rail so flat for control shaft faces out-
ward, then start housing, output shaft and ring gear
assembly into place with shift rail entering spring
in housing (fig. 7B) while the output shaft is being
turned counter-clockwise as it assembles over the
clutch rollers. Slide housing against adapter. Install
seven bolts and lock washers to adapter and case.
4. Install control shaft lever oil seal, shaft and lever,
clutch shaft locating pin and connect control wire to
lever.
5. Install governor assembly and speedometer driven
gear, shaft and fitting.
6. Notice the transmission support (Crossmember) is
shaped so the upper surface has a slight slant when
the bottom is flat. Position the support so the slant
is down toward the rear of the vehicle, align the
mounting holes with the holes in the frame and install
the support-to-frame bolts, washers and nuts.
7. Install the support-to-mounting block b o l t s and
washers.
Fig. 6B—Removing Speedometer Drive Gear 8. Install propeller shaft as outlined in Section 4.

CHEVROLET CHASSIS OVERHAUL MANUAL


TRANSMISSION OVERDRIVE 7-16

Fig. 8B—Removing Clutch Cam Retaining Clips

PARTS AT REAR OF ADAPTER


Removal

1. Remove overdrive housing, output shaft and ring


gear assemblies as outlined in preceding pages.
2. Pull " U " clips at each end of clutch cam (fig. 8B)
and slide the cam and roller retainer from pinion Fig. ]0B—Removing Solenoid
cage hub and transmission mainshaft. If roller r e -
tainer or cam is to be replaced separate these pieces 12B). If control plate or blocker ring is to be r e -
by pulling retainer out until the hooked ends of placed they may be separated by pulling blocker ring
spring can be pulled out of holes in cam. off plate.
3. Slide pinion cage assembly off sun gear and main- 7. Lift sun gear pawl out of adapter.
shaft.
Cleaning and Inspection
4. Remove sun gear and shift rail assemblies from
shaft (fig. 9B). Shift rail collar may be separated As each part is removed from the rear of the trans-
from sun gear by removing snap rings at either end mission, wash in cleaning solvent, dry, and protect from
of collar. Shift rail, fork, and spring may be sepa- subsequent dirt accumulation.
rated by removing snap ring btetween cupped washer
and shift fork. 1. Inspect " U " clips, control plate retainer, control
plate, blocker ring and pawl for defects or damage
5. Remove sun gear solenoid, oil seal and cable bracket and substitute new parts where necessary.
(fig. 10B). 2. Inspect the fit and tension of the blocker ring on hub
6. Remove large snap ring from adapter (fig. 11B) and as follows:
remove sun gear control plate retainer. Then slide a. Push one end of ring toward the other. The ring
control plate and blocker ring out of adapter (fig. should grip and hold to the hub. If the ring does

Fig. 9B—Removing Sun Gear and Shift Rail Assemblies Fig. 1 IB—Removing Control Plate Retainer Snap Ring

CHEVROLET CHASSIS OVERHAUL MANUAL


TRANSMISSION OVERDRIVE 7-17

not hold when correctly installed (flat surface of


ring facing out), it should be replaced.
b. Push one end of ring away from opposite end and
check the frictional drag required to slide the
ring around the hub as follows:
(1) Hold one lug of control plate in a soft jawed
vise and hook a spring balance into the notch
of the nearest blocker ring lug (fig. 15B).
(2) Measure the pull required to rotate the ring
after it has started moving. The pull should
be 4-6 pounds on new parts, which will fall to
1-1 1/2 pounds when thoroughly broken in.
While low friction may be c o r r e c t e d by
squeezing the ring together for a tighter fit,
installation of new parts is recommended.
3. Inspect the clutch cam and if the 12 flat surfaces
show slight lengthwise indentations, replace the cam.
If rollers show markings of any kind, they should all
be replaced.
4. Test the tension of the cam retaining springs after Fig. 12B—Control Plate, Blocker Ring and
the a s s e m b l y has been thoroughly washed. (The Pawl Positions for Assembly
springs are designed to twist the cam to return the
rollers to the high side of the cam). Hold hub of cam 1. Control Plate 2. Blocker Ring
and turn roller retainer counter-clockwise, then
release retainer. The retainer should snap back
quickly. If the action is slow or retarded, replace 6. Install pinion cage assembly over mainshaft and sun
the springs or the complete assembly. gear, turning cage assembly clockwise to engage sun
NOTE: If the spring t e n s i o n is weak or r e - gear.
tarded, the unit will free-wheel at all times.
7. If free wheeling cam and roller retainer were sepa-
When installing springs be sure both springs are rated, assemble these parts by positioning springs
coiled in the same direction (clockwise when looking so both are coiled clockwise when looking at flanged
toward flanged end of r e t a i n e r ) , with " S " end of end of retainer (fig. 16B), then place retainer over
springs hooked into holes in retainer (fig. 16B) and slotted end of cam, hook free ends of springs in holes
opposite ends hooked into holes in cam. in cam, turn retainer clockwise and push springs
Inspect the shift rail, fork, and spring for cracks, into place around cam.
burrs or damage and replace defective parts.
7. When shift rail, fork and spring are assembled,
make sure the parts bear the correct relationship as
shown in Figure 17B, with snap ring inside cupped
washer.

Installation
1. Insert sun gear pawl in adapter with notched side up.
2. If blocker ring was removed from control plate,
position ring on plate with flat surface of ring facing
out, then start the assembly over transmission main-
shaft with ring toward rear. Slide the assembly into
position with slot in ring toward sun gear pawl (fig.
12B).
3. Slide control plate retainer over mainshaft, against
control plate and install snap ring in adapter.
4. Install solenoid oil seal, solenoid, and cable bracket.
5. Start the sun gear onto the mainshaft. Hold shift rail
so arm of fork fits in collar on sun gear and forward
end of shift rail enters opening in adapter and trans-
mission case (fig. 9B). Slide both assemblies for-
ward so pin in adapter locates the fork, and sun gear
engages control plate. Fig. 13B—Removing Adapter from Transmission Case

CHEVROLET CHASSIS OVERHAUL /MANUAL


TRANSMISSION OVERDRIVE 7-18

8. Slide cam and roller retainer assembly over main- Lubrication


shaft and pinion cage hub. Install "U" clips at each The transmission and overdrive unit are connected
end of free wheeling cam. with oil passages so the same oil is used for both.

Fig. 14B—Layout of Overdrive Parts

1. Transmission Mainshaft 17. Sun Gear 33. Ring Gear Snap Ring
2. Energizing Spring 18. Pinion Cage Assembly 34. Output Shaft Bearing
3. Second Speed Gear 19. Cam Retaining " U " Clip (Large) 35. Woodruff Key
4. Thrust Washer 20. Cam Rollers 36. Speedometer Drive Gear
5. Mainshaft Bearing 21. Cam Roller Cage 37. Drive Gear Snap Ring
6. Snap Ring 22. Roller Cage Retracting Spring 38. Bearing Snap Ring
7. Snap Ring 23. Free-Wheeling Cam 39. Governor Switch
8. O i l Baffle 24. Cam Retaining " U " Clip (Small) 40. Plug
9. Gasket 25. Shift Rail Retractor Spring 41. Control Shaft Locating Pin
10. Adapter 26. Shift Rail Assembly (Also see Fig. 17B) 42. O i l Seal
11. Sun Gear Control Plate 27. Sun Gear Solenoid 43. Gasket
12. Blocker Ring 28. Sun Gear Pawl 44. Overdrive Housing
13. Control Plate Retainer 29. Sun Gear Pawl Rod O i l Seal 45. Shift Rail Control Shaft and Lever
14. Control Plate Retainer Snap Ring 30. Control Cable Bracket 46. Speedometer Driven Gear
15. Shift Rail Collar Snap Ring 31. Ring Gear and Fitting
16. Shift Rail Collar 32. Output Shaft 47. Lock Plate

CHEVROLET CHASSIS OVERHAUL MANUAL


TRANSMISSION OVERDRIVE 7-19

Fig. 15B—Measuring Blocker Ring Tension

However, the following precautions must be used in the


filling, in order that the proper amount of oil may be
carried.
Fig. 16B—Installation of Cam Roller Retaining Springs
1. In making the initial filling, first fill the overdrive
unit with the proper oil until oil runs out the filling
hole, then replace plug. Fill the transmission with
the same type of oil, until oil runs out the filling
hole, then replace plug.

2. In subsequent filling (at each chassis lubrication),


inspect the transmission only, for oil level, and fill
as necessary.

Fig. 17B—Shift Rail, Fork and Spring Assembly


1. Fork 2. Snap Ring 3. Washer 4. Spring 5. Shift Rail

CHEVROLET CHASSIS OVERHAUL MANUAL


4-SPEED TRANSMISSION 7-20

FOUR SPEED TRANSMISSION


INDEX

Page Page
Transmission 7-22 Reverse Shifter Shaft and Seal Replacement 7-24
Disassembly 7-22 Extension Oil Seal or Bushing 7-24
Cleaning and Inspection 7_23 Clutch Keys and Springs Replacement 7-24
Transmission Case 7-23 Assembly 7-24
Front and Rear Bearings 7_23 Mainshaft Assembly 7.24
Bearing Roller and Spacers 7_23 Countergear Assembly 7-25
Gears 7-24 Transmission Assembly 7-25
Reverse Idler 7-24 Torque Specifications 7_27
Repairs 7_24

Fig. 1M—Four-Speed Transmission Cross Section

1. Bearing Retainer 6. Third Speed Gear 11. First Speed Gear 18. Countershaft Bearing
2. Main Drive Gear 7. Second Speed Gear 12. First Speed Gear Sleeve Roller Spacer
CO

3. Fourth Speed Second Speed 13. Reverse Gear 19. Countershaft Bearing
Synchronizing Ring Synchronizing Ring 14. Mainshaft Roller
4. Third and Fourth Speed 9. First and Second Speed 15. Reverse Idler Shaft 20. Countershaft
Clutch Assembly Clutch Assembly Roll Pin 21. Reverse Idler Gear (Front)
5. Third Speed 10. First Speed 16. Reverse Idler Gear (Rear) 22. Reverse Idler Shaft
Synchronizing Ring Synchronizing Ring 17. Countergear 23. Speedo Drive Gear

CHEVROLET CHASSIS OVERHAUL MANUAL


4-SPEED TRANSMISSION 7-21

31

Fig. 2M—Four-Speed Transmission—Exploded View

1. Bearing Retainer 19. Clutch Key Spring 40. Reverse Idler Shaft 58. Countergear Roller
2. Gasket 20. Clutch Hub 41. Reverse Idler Shaft Spacer
3. Bearing Retaining Nut 21. Clutch Keys Roll Pin 59. Bearing Rollers (20)
4. Bearing Snap Ring 22. First and Second Speed 42. Reverse Shifter Shaft 60. Spacers (2)
5. Main Drive Gear Bearing Clutch Sliding Sleeve Lock Pin 61. Bearing Rollers (20)
6. Transmission Case 23. First Speed Gear 43. Reverse Shifter Shaft 62. Spacer
7. Rear Bearing Retainer Synchronizing Ring Lip Seal 63. Tanged Washer
Gasket 24. First Speed Gear 44. Reverse Shift Fork 64. Countershaft
8. Main Drive Gear 25. First Speed Gear Sleeve 45. Reverse Shifter Shaft 65. Gasket
9. Bearing Rollers (17) 26. Rear Bearing Snap Ring and Detent Plate 66. Detent Cams Retainer Ring
and Cage 27. Rear Bearing 46. Reverse Shifter Lever 67. Forward Speed Shift Forks
10. Snap Ring 28. Rear Bearing Retainer 47. Reverse Shifter Shaft 68. First and Second Speed
11. Third and Fourth Speed 29. Selective Fit Snap Ring Detent Ball Gear Shifter Shaft and
Clutch Sliding Sleeve 30. Reverse Gear 48. Reverse Shifter Shaft Detent Plate
12. Fourth Speed Gear 31. Speedometer Drive Gear Ball Detent Spring 69. Third and Fourth Speed
Synchronizing Ring 32. Rear Bearing Retainer to 49. Speedometer Driven Gear Shifter Shaft and
13. Third Speed Case Extension-Gasket Gear and Fitting Detent Plate
Synchronizing Ring 33. Case Extension 50. Retainer and Bolt 70. Detent Cams
14. Third Speed Gear 34. Extension Bushing 51. " O " Ring Seal 71. Detent Cam Spring
15. Mainshaft 35. Rear Oil Seal 52. Tanged Washer 72. Lip Seals
16. Second Speed Gear 36. Reverse Idler Front Thrust 53. Spacer 73. Transmission Side Cover
17. Second Speed Gear Washer (Tanged) 54. Bearing Rollers (20) 74; Third and Fourth Speed
Synchronizing Ring 37. Reverse Idler Gear (Front) 55. Spacers (2) Shifter Lever
18. First and Second Speed 38. Reverse Idler Gear (Rear) 56. Bearing Rollers (20) 75. First and Second Speed
Clutch Assembly 39. Flat Thrust Washer 57. Countergear Shifter Lever

CHEVROLET CHASSIS OVERHAUL MANUAL


4-SPEED TRANSMISSION 7-22

Fig. 3M—Removing Main Drive Gear Retaining Nut Fig. 5M—Removing Speedometer Gear with J-5814

TRANSMISSION Remove speedometer gear and reverse gear. The


Disassembly speedometer gear may be removed using Tool J-5814
1. Remove transmission side cover as outlined under as shown in Figure 5M.
"Maintenance and Adjustments," Section 7 of the NOTE: Slide 3-4 synchronizer clutch sleeve to
Service Manual. 4th speed gear position (forward) before trying
2. Remove four bolts and (2) bolt lock strips from front to remove mainshaft assembly from case (fig
bearing retainer and remove retainer and gasket. 6M).
3. Remove the main drive gear retaining nut (fig. 3M) Carefully remove the rear bearing retainer and en-
using Tool J-0933, after locking up transmission by tire mainshaft assembly from the case by tapping
shifting into two gears. bearing retainer with a soft hammer.
4. With transmission gears in neutral, drive lock pin Unload bearing rollers from main drive gear and
from reverse shifter lever boss, as shown in Figure remove fourth speed synchronizer blocker ring.
4M, and pull shifter shaft out about 1/8". This dis- 10. Lift the front half of reverse idler gear and its
engages the reverse shift fork from reverse gear. tanged thrust washer from case.
5. Remove six bolts attaching the case extension to the 11. Press main drive gear down from front bearing (fig
case. Tap extension with soft hammer in a rearward 7M).
direction to start. When the reverse idler shaft is 12. From inside case, tap out front bearing and snap
out as far as it will go, move extension to left so ring.
reverse fork clears reverse gear and remove exten- 13. From the front of the case, press out the counter-
sion and gasket. shaft (fig. 8M) using Tool J-5589; then remove the
6. The rear reverse idler gear, flat thrust washer, counter gear and both tanged washers.
shaft and roll spring pin may now be removed.

Fig. 6M—Third and Fourth Speed Synchronizer Clutch


Fig. 4M—Removing Reverse Shifter Shaft Lock Pin Sleeve in Fourth Gear Position

CHEVROLET CHASSIS OVERHAUL MANUAL


4-SPEED TRANSMISSION 7-23

Fig. 9M—-Removing Mainshaft Front Snap Ring

Fig. 7M—Removing Main Drive Gear Inspect the front face which fits against clutch housing
for burrs and if any are present, dress them off with a
14 Remove the 80 rollers, six .050" spacers and roller fine cut mill file.
spacer from counter gear.
15 Remove mainshaft front snap ring as shown in Figure Front and Rear Bearings
9M and slide third and fourth speed clutch assembly, 1. Wash the front and rear bearings thoroughly in a
third speed gear and synchronizing ring from front cleaning solvent.
of mainshaft. 2. Blow out bearings with compressed air.
16 Spread rear bearing retainer snap ring and press
CAUTION: Do not allow the bearings to spin,
mainshaft out of the retainer (fig. 10M). but turn them slowly by hand. Spinning bearings
17. Remove the mainshaft rear snap ring. Support sec-
will damage the race and balls.
ond speed gear and press on rear of mainshaft to r e -
move rear bearing, 1st speed gear and sleeve, 1st 3. Make sure bearings are clean, then lubricate them
speed synchronizing ring, 1-2 speed synchronizer with light engine oil and check them for roughness.
clutch assembly, 2nd speed synchronizer ring and Roughness may be determined by slowly turning the
second speed gear. outer race by hand.
Cleaning and Inspection
Transmission Case Bearing Rollers and Spacers
Wash the transmission case inside and out, with a All main drive gear and countergear bearing rollers
cleaning solvent and inspect for cracks. should be inspected closely and replaced if they show

Fig. 8M—Removing Countershaft with J-5589 Fig. TOM—Removing Rear Bearing Retainer

CHEVROLET CHASSIS OVERHAUL MANUAL


4-SPEED TRANSMISSION 7-24

wear. Inspect countershaft at the same time and replace


if necessary. Replace all worn spacers.
Gears
vl
Inspect all gears and replace all that are worn or
damaged.
Reverse Idler
1. The bushings used in the idler gear are pressed into
the gear then peened into holes in the bores, and are
bored in place. This insures the positive alignment
It
*!mm " ~~S&\
jSk *

of the bushings and their shafts, as well as proper


meshing of the gears. Because of the high degree of
accuracy to which these parts are machined, the B ^ KCLUTCH
EY -'!
bushings are not serviced separately. ¥
2. Check bushings for excessive wear by using a nar-
row feeler gauge between the shaft and the bushing
or use a micrometer. The proper clearance is from
.003" to .005".
Repairs
Reverse Shifter Shaft and Seal Replacement
1. With case extension removed from transmission the Fig. 12M—Installing Synchronizing Ring
reverse shifter shaft lock pin will already be r e -
moved. (See Step 4 under Disassembly.) into case extension. Using the same tool, drive new bush-
2. Remove shift fork. ing in from the rear. Coat I.D. of bushing with trans-
3. Carefully drive shifter shaft into case extension, al- mission lubricant, then install new oil seal using Tool
lowing ball detent to drop into case. Remove shaft J-5154. Prelubricate seal between lips with cup grease.
and ball detent spring.
Clutch Keys and Springs Replacement
4. Place ball detent spring into detent spring hole and
from inside extension install shifter shaft fully into NOTE: The clutch hubs and sliding sleeves are
its opening until the detent plate is butted against in- a select fit assembly and should be kept together
side of extension housing. as originally assembled, but the three keys and
5. Place detent ball on spring (fig. 11M) and, holding two springs may be replaced if worn or broken.
ball down with your thumb or a suitable tool push 1. Push the hub from the sliding sleeve. The keys will
the shifter shaft back in away from case until it is fall free and the springs may be easily removed.
directly over the ball and turn until the ball drops 2. Place the two springs in position (one on each side
into detent on the shaft detent plate. of the hub), so all three keys are engaged by both
6. Install shift fork. springs. Place the keys in position and, holding them
NOTE: Do not drive the shifter shaft lock pin in place, slide the hub into the sleeve.
into place until the extension has been installed
on the transmission case. Assembly

Extension Oil Seal or Bushing Mainshaft Assembly


If bushing in rear of extension requires replacement, 1. From the rear of the mainshaft, assemble the second
remove oil seal and use Tool J-5778 to drive bushing speed gear (with hub of gear toward rear of shaft).
2. Install 1-2 Synchronizer clutch assembly to main-
shaft (sliding clutch sleeve taper toward the rear,
hub to the front); together with a synchronizing ring
on either side of clutch assembly so their keyways
line up with the clutch keys (fig. 12M).
3. Press the 1st gear sleeve onto the mainshaft using a
1-3/4 I.D. pipe cut to a convenient length or other
suitable tool.
4. Install the first speed gear (with hub toward front)
and using 1-5/8" I.D. pipe cut to a suitable length,
press on the rear bearing with the snap ring groove
toward the f r o n t of the transmission (fig. 13M).
Firmly seat the bearing.
5. Choose the correct selective fit snap ring (.087",
.090", .093", or .096") and install it in the groove in
mainshaft behind the rear bearing. With proper ring,
maximum distance between snap ring and rear face
of bearing will be from zero to .005".
NOTE: Always use new snap rings when r e -
Fig. 11M—Installing Reverse Shifter Shaft and Detent Ball assembling transmission and do not expand the

CHEVROLET CHASSIS OVERHAUL MANUAL


4-SPEED TRANSMISSION 7-25

snap ring further than is necessary for


assembly.
6. Install the third speed gear (hub to front of trans-
mission) and the third speed gear synchronizing ring
(notches to front of transmission).
7. Install the third and fourth speed gear clutch as-
sembly (hub and sliding sleeve) with both sleeve
taper and hub toward the front, making sure the keys
in the hub correspond to the notches in the third
speed gear synchronizing ring.
8. Install snap ring in the groove in mainshaft in front
of the third and fourth speed clutch assembly, with
ends of snap ring seated behind spline teeth.
9. Install the rear bearing retainer (fig. 10M). Spread
the snap ring in the plate to allow the snap ring to
drop around the rear bearing and press on the end
of the mainshaft until the snap ring engages the
groove in the rear bearing.
10. Install the reverse gear (shift collar to rear).
11. Press speedometer drive gear onto the mainshaft Fig. 14M—Installing Speedometer Drive Gear
using a suitable press plate such as J-1453. Position
the speedometer gear to get a measurement of
4-7/8" from the forward side of the gear to the flat 3. Position the transmission case resting on its front
surface of the rear bearing retainer (fig. 14M). face.
4. Lubricate and insert countershaft in rear of case.
Countergear Assembly
Turn countershaft so flat on end of shaft is horizontal
1. Install roller spacer in countergear. and facing bottom of case.
2. Using heavy grease to retain the rollers, install 20 NOTE: The flat on shaft must be horizontal
rollers in either end of the countergear, two spacers, and toward the bottom to mate with rear bearing
20 more rollers, then one spacer. Install in the other retainer when installed.
end of the countergear, 20 rollers, two spacers, 20
more rollers, and another spacer (fig. 15M). 5. Align countergear with shaft in rear and hole in
3. Insert Tool J-5589 into countergear. front of case, and press countershaft into case
(pushing assembly tool out front of case) until flat
Transmission Assembly on shaft is flush with rear of case. Be sure thrust
1. Rest the transmission case on its side with the side washers remain in place (fig. 16M).
cover opening toward the assembler. Put counter- 6. Attach a dial indicator as shown in Figure 17M and
gear tanged thrust washers in place, retaining them check end play of the countergear. If end play is
with heavy grease, making sure the tangs are resting greater than .025" new thrust washers must be
in the notches of the case. installed.
2. Set countergear in place in bottom of transmission 7. Install cage and the seventeen roller bearings into
case, making sure that tanged thrust washers are main drive gear, using heavy grease to hold the
not knocked out of place. bearings in place.

1 % " I.D. PIPE

SNAP RING
GROOVE

Fig. 13M—Installing Rear Bearing Fig. 15M—Cross-Section of Countergear Assembly

CHEVROLET CHASSIS OVERHAUL MANUAL


4-SPEED TRANSMISSION 7-26

I NOTCH IN 0
SYNCHRONIZING

Fig. 16M-lnstalling Countershaft Fig. 18M—Installing Mainshaft Assembly

8. Install main drive gear and pilot bearings through 13. With the guide pin in rear bearing retainer aligned
the side cover opening and into position in trans- with hole in rear of case, tap rear bearing retainer
mission front bore. into position with a soft hammer.
9. Place gasket in position on front face of rear bearing 14. From the rear of the case, insert the rear reverse
retainer. idler gear, engaging the splines with the portion of
10. Install the fourth speed synchronizing ring on main the front gear inside the case.
drive gear with the notches toward the rear of the 15. Using heavy grease, place gasket in position on rear
transmission. face of rear bearing retainer.
11. Position the reverse idler g e a r thrust washer 16. Install the remaining flat thrust washer on reverse
(tanged) on the machined face of the ear cast in the idler shaft. If new idler shaft is being used, drive
case for the reverse idler shaft and hold with heavy out the roll pin and press it into new shaft.
grease. Position the front reverse idler gear next to 17. Install reverse idler shaft, roll pin, and thrust
the thrust washer, with the hub facing toward rear of washer into gears and front boss of case. Make sure
the case. to pickup front tanged thrust washer.
CAUTION: Before attempting to install main-
shaft assembly to case, slide the 3-4 synchro- NOTE: Roll pin should be in a vertical position.
nizing clutch sleeve forward into fourth speed 18. Pull reverse shifter shaft to left side of extension
detent position (fig. 6M). and rotate shaft to bring reverse shift fork forward
12. Lower the mainshaft assembly into the case making in extension (reverse detent position). Start the ex-
certain the notches on the fourth speed synchronizing tension onto the transmission case (fig. 19M), while
ring correspond to the keys in the clutch assembly slowly pushing in on the shifter shaft to engage the
(fig. 18M).

Fi