REAR SUSPENSION AND DRIVE LINE 4-39
Fig.
103—Removing Bearing Caps
these joints are disassembled, repack bearings
and lubricate reservoir at end of trunnions with
high-melting point wheel bearing lubricant and
replace the dust seals.
1.
Remove bearing lock rings from trunnion yoke.
2.
Support trunnion yoke on a piece of 1-1/4" I.D. pipe
on an arbor bed.
NOTE:
Due to length of the propeller shaft it
may be more convenient to use a bench vise,
for removal and installation, instead of an arbor
press.
In this case, proceed with disassembly
and assembly procedure as with an arbor press.
3.
Using a suitable socket or rod, press trunnion down
far enough to drive bearing cup from yoke (fig. 103).
4.
Remove dust seals from trunnion, clean and inspect
bearing rollers and trunnion. Relubricate bearings
with a lithium base chassis lubricant.
NOTE:
In addition to packing the bearings,
make sure that the lubricant reservoir at the
end of each trunnion is completely filled with
lubricant. In filling these reservoirs, pack lu-
bricant into the hole so as to fill from the
bottom. This will prevent air pockets and ensure
an adequate supply of lubricant.
5. Place new dust seals on trunnions - cavity of seal
toward end of trunnion - then position Tool J-21548
over end of trunnion and into cavity portion of seal.
Press seal onto trunnion until tool bottoms against
trunnion (fig. 104). .
NOTE:
Installation of seal is critical to proper
sealing - use specified tool during installation to
prevent seal distortion and to assure proper
seating of seal on trunnion.
6. Partially install one bearing cup into yoke. Place
trunnion in yoke and into bearing cup. Install other
bearing cup and press both bearing cups into yoke
(fig. 105) being careful to keep trunnion aligned in
bearing cups.
7. Press bearing cups far enough to install lock rings,
and install lock rings.
Installation
1.
Inspect yoke seal in the transmission and replace, if
necessary, as described in the transmission section.
2.
Insert propeller shaft front yoke into transmission.
NOTE:
On Corvette models, install front yoke
into transmission then position propeller shaft
between yoke and companion flange; install "U"
bolts to front yoke.
3.
Align propeller shaft with companion flange, using
reference marks established in "Removal" pro-
cedure, connect the rear universal joint by installing
"U"
bolt clamps over bearing trunnions - torque
nuts to specifications.
Fig.
104—"U" Joint Trunnion Seal installation
Fig.
105—Installing Bearing Cup and Trunnion
CHEVROLET CHASSIS SERVICE MANUAL
REAR SUSPENSION AND DRIVE LINE 4-41
Fig.
109—Bearing Partially Pressed from Propeller Shaft
g. Support exposed trunnion fingers on press bed and
press splined yoke from bearing caps using
method described above,
h. Remove trunnion from splined yoke.
3.
Install trunnion and bearing assembly to the propel-
ler shaft yokes using the,following procedure:
NOTE:
The trunnion and bearing assembly used
at the differential end of the propeller shaft
incorporates two different size bearing caps.
The larger bearing caps (with the annular
grooves) must be mated with the propeller shaft
yoke.
a. Install bearing cap and seal about one-fourth way
in on one side of yoke, using a soft-faced hammer
to tap the bearing into position. Check bearing
cap during installation to ensure that it does not
become cocked in yoke.
Fig.
Ill—Installing Trunnion to Propeller Shaft
b.
Insert trunnion into yoke (fig. 111).
c. Firmly seat trunnion into bearing cup and press
bearing cup into yoke until it is flush with yoke.
d. Install opposite bearing cap and seal making sure
that rollers do not become jammed on trunnion.
Check for free movement of trunnion in yoke.
e. Install bearing retainer snap rings making sure
that gap in ring is toward yoke (fig. 112).
Installation
1.
Inspect yoke seal in the transmission extension, re-
place if necessary as described in the transmission
section.
2.
Insert propeller shaft front yoke into transmission
extension, making sure that output shaft splines
mate with propeller shaft yoke splines.
3.
Align propeller shaft with companion flange using
reference marks established in "Removal" pro-
cedure; remove tape used to retain trunnion bearing
caps;
connect exposed bearing caps to companion
flange by installing retaining strap and screws—
torque screws to specifications.
Fig.
110—Removing Bearing from Propeller Shaft
Fig.
112—Installing Snap Ring to Retain Trunnion
CHEVROLET CHASSIS SERVICE MANUAL
REAR SUSPENSION AND DRIVE LINE 4-42
Fig.
113—Rear Suspension Special Tools (Chevrolet, Camaro, Chevelle and Chevy II)
1.
J-8614
2.
J-21057
3. J-21468
4. J-5748
5. J-21830
6. J-7574
7. J-7877
8. J-21474
9. J-9458
Companion Flange Remover—Consists of J-8614-1
Holder, J-8614-2 Nut and J-8614-3 Screw.
Drive Pinion Oil Seal Installer—Heavy-Duty Axle.
Drive Pinion Oil Seal Installer—Light Duty
Axle—Used with J-9458.
Positraction Torque Measuring Adapter.
Upper and Lower Control Arm Bushing Puller-
Consists of J-21830-2 Adapter, J-21830-4 Receiver,
J-21830-7 Bridge—Used with J-21058-6 Spacer,
and J-21830-3 Spacer.
Chevrolet Lower Control Arm Front Bushing
Remover/Installer—Consists of J-7574-4 Receiver,
J-7574-1 Remover, J-7574-2 Installer Adapter,
J-7574-3 Spacer.
Chevrolet Tie Rod Bushing Remover/Installer—Consists
of J-7877-1 Remover Adapter, J-7877-2 Bushing
Receiver, J-7877-3 Installer Adapter—Used with
j-7079-2
Handle.
Chevelle Control Arm Bushing Remover—Consists of
J-21474-5 Receiver, J-21474-1 Spacer and
J-21474-2 Adapter.
Drive Pinion Oil Seal Installer—Light Duty
Axle—Used with J-21468.
10.
J-21051 Rear Wheel Bearing and Oil Seal Installer-
Heavy Duty Axle—Used with J-7079-2.
11.
J-21491 Rear Wheel Bearing and Oil Seal Installer—Light
Duty Axle—Used with J-8092.
12.
J-2619 Rear Wheel Bearing and Oil Seal Remover (Slide
Hammer).
13.
J-8119 Rear Wheel Bearing and Oil Seal Remover—Used
with J-2619.
14.
J-21058 Upper and Lower Control Arm Puller—Consists of
J-21058-15 Screw and J-21058-8 Nut—Used
with J-21830.
15.
J-8092 Driver.Handle—Threaded Type.
16.
J-7079-2 Driver Handle—Insert Type.
17.
J-21548 Propeller Shaft "U" Joint Trunnion Seal Installer.
18.
J-21991 Chevelle Upper Control Arm Carrier- Bushing
Remover Adapter.
19.
J-5853 Torque Wrench—In. lbs.
20.
J-5810 Torque Wrench Adapter (3/4" to 3/8")
21.
J-1313 Torque Wrench—ft. lbs.
Tools Not Illustrated
J-22553 Rear Spring Front Bushing Remover/Installer Consists
of J-22553-1 Receiver, J-22553-2 Installer—Used
with J-21978-1 Receiver, J-21058-8 Nut and
J-21058-15 Puller Screw.
CHEVROLET CHASSIS SERVICE MANUAL
REAR SUSPENSION AND DRIVE LINE 4-43
Fig.
114—Rear Suspension Special Tools (Corvette)
1.
J-8111-23 Torque Control Arm Spacer Flaring Tool
2.
J-22602 Wheel Drive Spindle Remover
3.
J-9436 Wheel Drive Spindle Outer Bearing Installer
4.
J-21057 Drive Pinion Oil Seal Installer
5. J-8331 Wheel Drive Spindle Outer Bearing Remover
6.
J-7877 Strut Rod Bushing Replacement Sef
7. J-7817 Wheel Drive Spindle Bearing Cup Installer
8.
J-21548 Propeller Shaft "U" Joint Trunnion Seal Installer
9. J-21556 Axle Drive Shaft "U" Joint Trunnion Sea! Installer
10.
J-5748 Positraction Torque Measuring Adapter
11.
J-7079-2 Driver Handle (Insert Type)
12.
J-8001 Dial Indicator Set
13.
J-8092 Driver Handle (Threaded Type)
14.
J-7055-1 Torque Control Arm Bushing Installer
15.
J-8614 Rear Axle Companion Flange Holder
CHEVROLET CHASSIS SERVICE MANUAL
BRAKES 5-22
2.
Replace ail push rods and pull back springs.
3.
Connect hose or line to wheel cylinder.
NOTE:
If replacing front wheel cylinder, con-
nect hose and inspect installation as outlined in
"Hydraulic Brake Hose Replacement".
4.
Install drum and wheel.
5. Bleed brakes as outlined in this section.
ANCHOR PIN
Front Wheel
1.
Raise front of vehicle and place on jack stands.
2.
Remove wheel and drum as outlined in this section.
3.
Remove brake shoe pull back springs, link and guide
plate.
4.
Disengage anchor pin lock and remove anchor pin by
turning counterclockwise.
5. Place new lock plate on anchor pin and pass pin
through the hole in flange plate and screw into tapped
hole in spindle support.
6. Torque pin to 130 lb. ft. and lock by peening over
washer tabs.
7. Install brake shoe guide plate, link and pull back
springs.
8. Adjust brakes, install drum and wheel as outlined
in this section. Test brake operation.
Rear Wheel
Two type anchor pins are used in production for the
rear wheels. The riveted type is not serviced and if
failure or damage should occur to either the anchor
pin or flange plate, both parts will have to be replaced
and the threaded type anchor pin used.
Threaded Type
1.
Raise rear of vehicle and place on jack stands,
2.
Remove wheel and drum as outlined in this section.
3.
Remove brake shoe pull back springs, link and guide
plate.
4.
Remove anchor pin retaining nut and washer and
remove pin from flange plate.
5. Position anchor pin to flange plate, install lock
washer and nut, and torque pin to 80 lb. ft.
6. Install brake shoe guide plate, link and pull back
springs.
7. Adjust brakes and install drum and wheel as outlined
in this section.
8. Test brake operation.
BRAKE DRUMS
Front brake drums are the demountable type; that is,
they can be removed without removing the hub. Rear
brake drums are demountable and may be removed
wihtout removing the axle shaft.
A lanced "knock out" area (fig. 34) is provided in
the web of the brake drum for servicing purposes in
the event retracting of the brake shoes is required in
order to remove the drum.
A small screw driver or hooked wire may be inserted
to disengage the automatic adjuster actuating lever so
the star wheel may be turned.
Removal
1.
Raise vehicle and place on jack stand.
2.
Remove wheel and tire assembly, back off brake
adjustment and remove drum.
Inspection and Reconditioning
Whenever brake drums are removed they should be
thoroughly cleaned and inspected for cracks, scores,
deep grooves, and out-of-round. Any of these conditions
must be corrected since they can impair the efficiency
of brake operation and also can cause premature failure
of other parts.
Smooth up any slight scores by polishing with fine
emery cloth. Heavy or extensive scoring will cause
excessive brake lining wear and it will probably be
necessary to rebore in order to true up the braking
surface.
An out-of-round drum makes accurate brake shoe
adjustment impossible and is likely to cause excessive
wear of other parts of brake mechanism due to its
eccentric action.
A drum that is more than .008" out-of-round on the
diameter is unfit for service and should be rebored.
Out-of^round, as well as taper and wear can be ac-
curately measured with an inside micrometer fitted
with proper extension rods.
If drum is to be rebored for use with standard size
brake facings which are worn very little, only enough
metal should be removed to obtain a true smooth braking
surface.
If drum has to be rebored more than .020" over the
standard diameter, it should be rebored to .060" diameter
oversize and the brake facing should be replaced with
.030"
oversize facings.
A brake drum must not be rebored more than .060"
over the maximum standard diameter, since removal
of more metal will effect, dissipation of heat and may
cause distortion of drum. Chevrolet brake facing is
not furnished larger than .030" oversize and this will
not work efficiently in drums bored more than .060"
oversize.
Brake drums may be refinished either by turning or
grinding. Best brake performance is obtained by turning
drums with a very fine feed. To insure maximum lining
life,
the refinished braking surface must be smooth and
free from chatter or tool marks, and run-out must not
exceed .005" total indicator reading.
Cleaning
New brake drums in parts stock are given a light.
coating of rust proofing oil to prevent the formation of
rust on the critical braking surfaces during the time
that the drums are in storage.
This rust proofing oil must be carefully removed
before the drum is placed in service to prevent any
of this oil from getting on the brake shoe facings, which
might cause an extreme brake grab condition.
It is recommended that a suitable volatile, non-toxic,
greaseless type solvent be used to clean the oil from the
braking surface of the new brake drums before they are
•placed in service to insure the cleanest possible surface.
Gasoline or kerosene should not be used as there is
danger that a portion of the diluated oil substance may
be left on the braking surface that may later cause
difficulty.
Installation
1.
Make brake adjustment as outlined in this section.
CHEVROLET CHASSIS SERVICE MANUAL
BRAKES 5-28
Fig.
40—Installing Piston in Caliper Bore Using
Tool J-22591
Fig.
41—Installing Boot Seal in Caliper Bore
Using Tool J-22592
5.
Check the fit of the piston in the bore using a feeler
gage.
Clearance should be as follows:
2 1/16 inch Bore .0045 to .010
1 7/8 inch Bore .0045 to .010
1 3/8 inch Bore .0035 to .009
If the bore is not damaged, and the clearance exceeds
either of the upper limits, a new piston will be required.
Assembly
1.
Assemble the seal in the groove in the piston which
is closest to the flat end of the piston. The lip on
the seal must face toward the large end of the
piston. Be sure lips are in the piston groove and do
not extend over the step in the end of the groove.
2.
Place the spring in the bottom of the piston bore.
3.
Lubricate the seal with dean brake fluid.
4.
Install the piston assembly in the bore using appli-
cable piston rign compressor Tool J-22639, 22629
or 22591 as shown in Figure 40. Use care not to
damage the seal lip as piston is pressed past the
edge of the bore. .
5.
Assemble the boot in the groove of the piston closest
to the concave end of the piston. The fold in the boot
must face toward the end of the piston with the seal
on it.
6. Depress the pistons and check that they slide
smoothly into the bore until the end of the piston is
flush with the end of the bore. If not, re check piston
assembly and location of the piston spring and the
seal.
7.
Position applicable boot seal installer Tool J-22592,
J-22628, or J-22638 over the piston and seat the
steel boot retaining ring evenly in the counterbore
as shown in Figure 41. The boot retaining ring must
be flush or below the machined face of the caliper.
Any distortion or uneven seating could allow con-
taminating and corrosive elements to enter the bore.
8. Position the t:O}> rings in the small cavities around
the brake fluid transfer holes in both ends of the
outboard caliper halves. Lubricate the hex head
. bolts with Delco Brake Lube or clip in clean brake
fluid. Fit caliper halves together and secure with
bolts.
Refer to torque specifications in rear of
manual for correct torque valves.
Installation
1.
Carefully mount the assembled caliper over the edge
of the disc. Use a putty knife to depress pistons so
that the caliper can be lowered into position on the
disc (fig. 42). Use care to prevent damage to boots
• on the edge of the disc as the caliper is mounted.
2.
Secure the caliper to the mounting bracket with two
hex head bolts. Refer to torque specifications in
rear of manual for correct torque values.
CAUTION: If replacing old shoe assemblies,
be sure to get the shoes in the same position
from which they were removed. New shoe as-
semblies have an arrow printed on the back,
showing the direction of forward disc rotation.
3.
Install the shoe and lining assemblies as outlined in
this section.
4.
On Chevrolet and Corvette front calipers, place a
new copper gasket on the male end of the front
wheel brake hose. On all models, install brake hose
in the calipers. With the wheels straight ahead,
pass the female end of the brake hose through the
support bracket.
5.
Make sure the tube seat is clean and connect the
break line tube nut to the caliper. Tighten securely.
6. Allowing the hose to seek a normal position, without
twist, insert hex of the hose fitting into the 12-point
hole in the support bracket and secure it in place
with the "V"-shaped retainer. Turn the steering
geometry from lock to lock while observing the hose.
CHEVROLET CHASSIS SERVICE MANUAL
SECTION 6
ENGINE
CONTENTS
OF
THIS SECTION
Page
Engine Tune Up
6-1
Torque Sequence
Engine Mechanical
(In
Line)
6-12
Special Tools
. .
Engine Mechanical (V8)
6-24
Page
6-39
6-40
ENGINE TUNE UP
INDEX
Page
General Description
. 6-1
Mechanical Checks and Adjustments
6-1
Spark Plug Removal
6-1
Test Compression
6-1
Service and Install Spark Plugs
6-2
Service Ignition System
6-3
Service Battery
and
Battery Cables
6-5
Service Delcotron
and
Regulator
6-5
Service
Fan
Belt
6-5
Service Manifold Heat Valve
6-5
Tighten Manifold
6-5
Service Fuel Lines
and
Fuel Filter ..........
6-6
Service Cooling System
6-6
Check and Adjust Accelerator Linkage
6-6
Service Crankcase Ventilation
6-6
Service
Air
Injection Reactor System
6-6
Choke Adjustment
6-7
Page
Instrument Cheek-Out
6-7
Instrument Hook-Up.
. 6*7
Check and Adjust Dwell
6-7
Check Dwell Variation
6-7
Check and Adjust Timing
6-8
Adjust Idle Speed
and
Mixture
6-8
Additional Checks and Adjustments
. 6-8
Testing Crankcase Ventilation Valve
. 6-8
Testing Cranking Voltage
6-8
Cylinder Balance Test
. 6-8
Battery
6-8
Ignition
; 6-8
Carburetor
6-11
Fuel Pump
6-11
Cooling System
. 6-11
Cylinder Head Torque and Valve Adjustment
..... 6-11
GENERAL DESCRIPTION
The engine tune up
is
important
to the
modern automo-
tive engine with
its
vastly improved power and perform-
ance.
The
higher compression ratios, improved electri-
cal systems
and
other advances
in
design, make today1 s
engines more sensitive
and
have
a
decided effect
on
power, performance and fuel consumption.
It
is
seldom advisable
to
attempt
a
tune up
by
correc-
tion
of one or two
items only. Time will normally
be
saved
and
more lasting results assured
if the
technician
will follow
a
definite
and
thorough procedure
of
analysis
and correction
of all
items affecting power, performance
and economy.
The tune
up
will
be
performed
in
two parts.
The
first
part will consist
of
visual and mechanical checks and
ad-
justments;
the
second part will consist
of
an instrument
checkout that
can be
performed with
any one of the
units
of service equipment available
for
this purpose. Always
follow
the
instructions provided
by the
manufacturer
of
the particular equipment
to be
used.
Additional checks
and
adjustments
are
included
in the
latter part
of
this section
for use as
required. Many
of
these operations
can be
used
to
isolate and correct trou-
ble located during
the
tune up. Where conditions
are
UB-
covered requiring major corrective action, refer
to the
appropriate section
of
this manual
or the
Passenger
Chassis Overhaul Manual
for
detailed service informa-
tion.
Typical illustrations
and
procedures
are
used except
where specific illustrations
or
procedures
are
necessary
to clarify
the
operation. Illustrations showing bench
op-
erations
are
used
for
clarification however
all
operations
can
be
performed
on the
vehicle.
MECHANICAL CHECKS
AND
ADJUSTMENTS
Spark Plug Removal
Remove any foreign matter from around spark plugs
by
blowing
out
with compressed
air,
then disconnect wires
and remove plugs.
Test Compression
(Fig. 1)
The compression check
is
important because
an
engine
with
low or
uneven compression cannot
be
tuned success-
fully.
It is
essential that improper compression
be cor-
rected before proceeding with
the
engine tune
up.
1.
Remove
air
cleaner
and
block throttle
and
choke
in
wide open position.
2.
Hook
up
starter remote control cable
and
insert
compression gauge firmly
in
spark plug port.
CAUTION: Whenever
the
engine
is
cranked
CHEVROLET
C*
IS SERVICE MANUAL
ENGINE
6-3
(ROUND) Y~~fll^H
CENTRIFUGAL
A ^k
ADVANCE--jflgKpl
MECHANISM
UB|
CAM
KSK^2
LUBRICATOR
VlSMi
REPLACEMENT
^BK
-^ADJUST
SQUARELY
AND
JUST
TOUCHING
LOBE
OF
CAM
/ROTOR
HBB
__
I^BH^F
?
(SOUARE)
^K^ I /—
CAM
jKft^J / LUBRICATOR
H^T^
CAUTION!
QV NEVER
OIL
•L-^
CAM LUBRICATOR-
REPLACE
WICK
WHEN
NECESSARY
LATERAL
MISALIGNMENT
PROPER
LATERAL ALIGNMENT
Fig.
4- Distributor (V8)
CAUTION: Use extreme care
-when
using tap to
prevent cross threading. Also crank engine sev-
eral times to blow out any material dislodged
during cleaning operation.
7. Install spark plugs with new gaskets and torque to
specifications.
NOTE:
The following are some of the
greatest causes of unsatisfactory spark plug
performance.
•
Installation of plugs with insufficient torque to
fully seat the gasket.
•
Installation of the plugs using excessive torque
which changes gap settings.
•
Installation of plugs on dirty gasket seal.
•
Installation of plugs into corroded spark plug hole
threads.
8^ Connect spark plug wiring.
Service
Ignition System
1.
Remove distributor cap, clean cap and inspect for
cracks, carbon tracks and burned or corroded ter-
minals. Replace cap where necessary.
2.
Clean rotor and inspect for damage or deterioration.
Replace rotor where necessary.
3.
Replace brittle, oil soaked or damaged spark plug
wires.
Install all wires to proper spark plug. Proper
positioning of spark plug wires in supports is impor-
tant to prevent cross-firing.
4.
Tighten all ignition system connections.
5. Replace or repair any wires that are frayed, loose or
damaged.
Us
CORRECT
LATERAL MISALIGNMENT BY
j BENDING
FIXED CONTACT SUPPORT
[NEVER
BEND BREAKER LEVER
Fig.
5 - Point Alignment
Magnetic
Pulse(Breakerless)
Distributor
There are no moving parts in the ignition pulse ampli-
fier, and the distributor shaft and bushings have perma-
nent type lubrication, therefore no periodic maintenance
is required for the magnetic pulse ignition system. Refer
to Section 6Y for an analysis of problems and/or repair
procedures encountered on the Transistorized (Magnetic
Pulse) ignition system.
Standard
(Breaker Point) Distributor
(Figs.
3 or 4)
1.
Check the distributor centrifugal advance mechanism
by turning the distributor rotor in a clockwise direc-
tion as far as possible, then releasing the rotor to
see if the springs return it to its retarded position.
If the rotor does not return readily, the distributor
must be disassembled and the cause of the trouble
corrected.
2.
Check to see that the vacuum spark control operates
freely by turning the movable breaker plate counter-
clockwise to see if the spring returns to its retarded
position. Any stiffness in the operation of the spark
control will affect the ignition timing. Correct any
interference or binding condition noted.
3.
Examine distributor points and clean or replace if
riecessary.
DO
NOT SUCK
IN
TOO MUCH
ELECTROLYTE
TAKE
READING
AT
EYE LEVEL
Fig.
6 - Testing Specific Gravity of Battery
CHEVROtET
CHASSIS SERVICE MANUAL