Chevrolet 1967 Chevelle User manual

“Portions of m aterials contained
herein have been reprinted w ith perm ission
of G eneral M otors Corporation
Service O perations.” License 0710896

SECTION 1
AIRCONDITIONING
COMPRESSOR
INDEX
Page
MinorOverhaulProcedures. . . . 1-2
HubandDrivePlate1-2
PulleyandBearingAssembly1-3
CoilHousingAssembly.. . . . 1-4
MajorOverhaulProcedures. . 1-4
CompressorHeadsandInternalParts1-4
Page
ShaftSealAssembly. 1-5
RearHead,OilPumpandValveAssemblies ...... 1-7
InternalMechanism.1-8
CheckingCompressorforLeaks1-13
SpecialTools. 1-14I
20212223242526272829303132333435363738
Fig. 1— SixCylinderCompressor—CrossSectionView
1. RearHead
2. RearHead to Shell
"O" Ring
3.RearDischargeValvePlate
4. RearSuctionReedPlate
5.PistonRing
6.PistonDriveBall
7.BallSeat
8.Piston
9.FrontSuctionReedPlate
10. FrontDischargeValve
Plate
11. FrontHead to Shell
"O" Ring
12. FrontHead
13. Coil and HousingAssembly
14. CoilHousingRetainerRing
15. Pulley and Bearing
Assembly
16. PulleyBearing
17. PulleyBearing
RetainerRing
18. Pulley and Bearing
RetainerRing
19. ClutchHubandDrive
PlateAssembly
20. Oil PumpGears
21. MainshaftBearing(Rear)
22. Oil InletTube "O" Ring
23. Oil InletTube
24. WobblePlate and
MainshaftAssembly
25. ThrustRace
26. ThrustBearing
27. ThrustRace
28. CompressorShell
29. CylinderAssembly
30. ShaftSeal
31. ShaftSealSeat
"O" Ring
32. ShaftSealSeat
33. ShaftSealSeat
RetainerRing
34. FeltSleeve
35. FeltSleeveRetainer
36. Spacer
37. Clutch Hub RetainerRing
38. Shaft Nut
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-2
ForallpracticalpurposesallChevroletvehiclesmake
useofthesameairconditioningcompressor.Actual
differencesbetweencompressorsarefoundintheir
mountingbrackets,connectorassembliesandcompres-
sorcapacities,noneofwhichaffectthefollowingOver-
haulProcedures.
MINORREPAIRPROCEDURES
ThefollowingoperationstotheHubandDrivePlate,
PulleyandBearing,andCoilHousingarecoveredas
"Minor"becausetheymaybeperformedwithoutfirst
purgingthesystemorremovingthecompressorfrom
thevehicle.TheShaftsealassemblymayalsobe
servicedwithoutremovingthecompressorfromthevehi-
clebutthisoperationiscoveredlaterinthissectionasa
"MajorRepairProcedure"becausethesystemmust
firstbepurgedofrefrigerant.
Illustrationsusedindescribingtheseoperationsshow
thecompressorremovedfromthevehicletomore
clearlyillustratethevariousoperations.
HubandDrivePlate
Removal
1. Ifdisassemblyisbeingperformedona bench,mount
SupportBracketJ-9396ina viseandattachthecom-
pressortothebracket.
2. UsingDrivePlateHoldingToolJ-9403andSocket
J-9399,removethelocknutfromtheshaft(fig.2).
Discardlocknut.
ToolJ-9401maynowbeusedtoremovethehuband
3.driveplateassembly(fig.3).
NOTE:Carefullysnugtoolintoplace
wrenchtoinsureengagementwiththreads.with
4. UseSnapRingPliersJ-5403toremovetheretainer
ring(Item35,fig.1).Thenremovethehubspacer.
Inspection
Ifthefrictionalsurfaceshowssignsofdamagedueto
excessiveheat,thehubanddriveplateandthepulley
shouldbereplaced.Checkfurtherfortheunderlying
Fig. 2—RemovingShaftLocknut
Fig. 3—RemovingHubandDrivePlateAssembly
causeofthedamage,i.e.lowcoilvoltageorbindingof
thecompressorinternalmechanism.
Installation
NOTE:Whenhubanddriveplateassemblyis
readyforinstallation,cleanitsfrictionalface
witha suitablecleaner.
1. Insertthesquarehubanddriveplatekeyintothe
keywayinthedriveshaftallowingittoprojectap-
proximately3/16"outoftheendofthekeyway
(fig.4).
2. Lineupthekeyintheshaftwiththekeywayinthe
hub.
3. UsingToolJ-9480andWasherJ-9480-2(fig.5),in-
stallthehubanddriveplateassembly.Pullthe
assemblyontotheshaftuntilthereisapproximately
3/32"spacebetweenthefrictionalsurfacesofthe
driveplateandpulley.(AZEROthrustraceisap-
proximately3/32"in.thicknessandmaybeusedto
roughlygaugethisoperation.)
NOTE:UseToolJ-9403toholdhubanddrive
plateifnecessary.
4. Installthehubspacerwasherand,usingSnapRing
PliersJ-5403,installtheretainerring(Item35,
fig. 1),convexsideofringfacingwasher.
5. UseJ-9399andJ-9403toinstalla newlocknut.
Tightenthenutto14-26ft.lbs.torque.Airgap
betweenthefrictionalfacesshouldnowbe.022"to
.057".
NOTE:Theshoulderorcircularprojectionon
thelocknutmustfacetowardsretainerring.
6.Thepulleyshouldnowrotatefreely.
CAUTION:Neverpoundordrivethehuband
driveplateintoposition.Alwaysusetheproper
toolswhenremovingorreplacingclutchparts.
Failuretodosomayresultinseriousinternal
compressordamage.
7. Operatetherefrigerationsystemandrapidlycycle
theclutch(byturningtheairconditioningoffandon
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-3
Fig. 4—DrivePlateKeyInstalledinKeyway
atleast20timesatapproximatelyonesecondin-
tervals)toseatthematingpartsoftheclutch.
PulleyandBearingAssembly
Removal
1. Removethehubanddriveplateassembly.
2. UsingSnapRingPliersJ-6435,removethepulley
andbearingretainerring(fig.6).
3. Removeshaftkey.
4. PlacePullerPilotJ-9395overthecompressorshaft
andpulloffthepulleyassemblyusingJ-8433pulley
puller(fig.7).
Inspection
Checktheappearanceofthepulleyandbearingas-
sembly.Ifthefrictionalsurfaceofthepulleyshows
signsofexcessivegroovingduetoslippageboththe
pulleyandtheclutchhubanddriveplateassemblyshould
bereplaced.Thefrictionalsurfacesofthebearingtobe
Fig. 6—RemovingPulleyandBearingAssemblyRetainerRing
usedshouldbecleanedwitha suitablesolventbefore
reinstallation.
BearingReplacement
1. Withthepulleyandbearingassemblyremovedfrom
thecompressor,usea sharppointedinstrumentto
removethewireretainerring.
CAUTION:Ifthebearingistobereusedbe
carefulnottoslipanddamagetheseal.
2. Fromtherearofthepulley,pressordrivebearing
outofpulleyusingToolJ-9398andHandleJ-8092.
3. FromthefrontofthepulleyandusingToolJ-9481
withHandleJ-8092,pressordrivethenewbearing
intothepulley.
Installation
1. UsingTool J-9481, pressordrivethepulleyand
bearingassemblyontothecompressorneck.The
pulleyshouldnowrotatefreely.
2. InstallretainerringusingSnapRingPliersJ-6435.
Fig. 5—InstallingHubandDrivePlateAssembly
Fig. 7—RemovingPulley
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-4
Fig. 8—RemovingCoilHousingRetainerRing
3.
^^^^^Hr - "3-••>•••:^Bli^^
mi
Replacethehubanddriveplateassembly.Useproper
tools. DONOTdriveorpoundonthehubassembly.
4. Installthewirebearingretainerring.
Fig. 9—InstallingCoilHousing
CoilHousingAssembly
Removal
1. Removethehubanddriveplateassembly,thepulley
andbearingassembly,andelectricalconnector.
2. Scribethelocationofthecoilhousingtothecom-
pressorbody.Thisoperationistoinsurethatthe
electricalterminalswillbereassembledinthesame
position.
3. UsingSnapRingPliersJ-6435,removethecoil
housingretainerring(fig.8).
4. Removethecoilhousingassembly.
Inspection
Checkcoilforlooseconnectorsorcrackedinsulation.
Amperageshouldnotbemorethan3.2ampsat12volts
D.C.atroomtemperature.
Installation
1. Rotatethecoilhousingtothecorrectpositionas
indicatedbythescribemarksandthelocationofthe
electricalterminalsandfitintoplace(fig.9).
2. UseSnapRingPliersJ-6435toinstallretainerring.
NOTE:Installflatsurfaceoftheretainerring
facingthecoilhousing.
3. Replacethepulleyandbearingassemblyandthehub
anddriveplateassembly.DONOTdriveorpoundon
thehubassembly.
4. Ifthecompressorisinstalledinthevehicle,connect
theelectricalconnections.
MAJORREPAIRPROCEDURES
Thefollowingserviceproceduresareconsideredmajor
sincetherefrigerationsystemmustbecompletelypurged
ofrefrigerantbeforeproceedingand/orbecausemajor
internaloperatingandsealingcomponentsofthecom-
pressorarebeingdisassembledandserviced.A clean
workbench,preferablycoveredwitha sheetofclean
paper,orderlinessintheworkareaanda placeforall
partsbeingremovedandreplacedisofgreatimportance
asistheuseoftheproperservicetools.Anyattemptto
usemake-shiftorinadequateequipmentmayresultin
damageand/orimpropercompressoroperation.
Theseproceduresarebasedontheuseoftheproper
servicetoolsandthecondition thatanadequatestockof
servicepartsisavailable.Thisservicepartsstock
shouldincludethefollowing:
1. Majorinteriormechanismassembly- readyforin-
stallationinshellasis.
2. Servicecylinderassembly- frontandrearhalves
withmainbearingsinplaceandhalvesdowelpinned
together.
3. Standardsizepistondriveballs.
4. Ballseats- totalof10sizes,includingtheZERO
seat.
5. Thrustraces- totalof14sizes,includingtheZERO
6.
race.
Pistons.
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-5
152019181716121354 3 2 1
5452434241I3635333228
50494847.464544403937343130272625232221
1. ShaftNut
2. ClutchHubRetainerRing
3.Spacer
4. ClutchHubandDrive
PlateAssembly
5.PulleyandBearing
RetainerRing
6.PulleyBearing
RetainerRing
7.PulleyBearing
8.Pulley
9.CoilHousingRetainer
Ring
10. CoilHousing
11. CompressorShell
12. FeltSleeve
13. FeltSleeveRetainer
14. OilDrain
Fig. 10~SixCylinder
15. FrontHead-to-She11
"O" Ring
16. ShaftSealSeat
RetainerRing
17. ShaftSealSeat
18. ShaftSeal
19. ShaftSealSeaf'O"Ring
20. CompressorFrontHead
21. FrontDischargeValvePlate
22. FrontSuctionReedValve
23. DischargeCrossover
TubeFront"O"Ring
andSpacer
24. MainshaftFrontBearing
25. HeadLocatingPins
26. FrontCylinderHalf
27. FrontThrustRaceand
BearingPack
Compressor—ExplodedView
28. SuctionCrossoverCover
29. DriveKey
30. DischargeCrossoverTube
31. PistonRing
32. PistonFrontDriveBall
33. PistonFrontBallSeat
34. Piston
35. PistonRearBallSeat
36. PistonRearDriveBall
37. PistonRing
38. DriveShaftandWobble
PlateAssembly
39. RearThrustRaceand
BearingPack
40. RearCylinderHalf
41. OilInletTube"O"Ring
42. OilInletTube
43. MainshaftRearBearing
44. DischargeCrossoverTube
Rear"O"Ringand
Spacer
45. RearSuctionReedPlate
46. RearDischargeValve
Plate
47. OilPumpDriveGear
48. OilPumpDrivenGear
49. RearHead-to-Shell
"O" Ring
50. StrainerScreen
51. CompressorRearHead
52. HighPressureRelief
Valveand"O"Ring
53. RearHead-to-Shell
RetainingNuts
54. Compressor-to-Connector
"O" Rings
7. Mainshaftbearings.
8.Thrust?bearings.
9.Compressorshaftandwobbleplate.
10. Suctionreedvalves.
11. Dischargevalveplate- frontandrear.
12. Sealkit- service- containsallsealsand"O"rings.
Tobeusedeachtimea compressorisrebuilt.
13. Shaftsealkit.
14. Nuts- headtoshell,andshaft.
15. Retainerrings- allnecessarysizes.
16. Cylinderlocator(dowel)pins.
17. Valveandheadlocator(dowel)pins.
18. Servicedischargecrossovertubekit.
Allpartsrequiredforservicingareprotectedbya
preservationprocessandpackagedina mannerwhich
willeliminatethenecessityofcleaning,washingorflush-
ingoftheparts.Thepartscanbeusedinthemechanism
assemblyjustastheyareremovedfromtheservice
package.
Pistonballseatsandshaftthrustraceswillbe
identifiedonthepartsthemselvestodenotetheirsizeand
dimension.
ShaftSealAssembly
Whenreplacingtheshaftsealassembly,evenifthe
compressorremainsonthevehicleduringtheoperation,
itwillbenecessarytopurgethesystemofrefrigerantas
outlinedpreviouslyinthissection.
Removal
1. Afterfirstpurgingthesystemofrefrigerant,remove
theclutchhubanddriveplate,andtheshaftkey.
2. Beforeremovingthesealseatandretainingring,
thoroughlycleantheareaoftheneckofthecom-
pressorsurroundingtheshafttoremovealldirtor
foreignmaterial.Pryoutthefeltretainingringand
removethefeltsleeve.Removethesealseatre-
tainingringusingSnapRingPliersJ-5403.
3. UsingToolJ-9393(1and2),grasptheflangeonthe
sealseatandliftoutthesealseat(fig.12).
4. Removethesealseat"O"ringfromthehousing
boreusingToolJ-9553(fig.12).
5. Engagethetabsonthesealassemblywiththelocking
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-6
STRAIGHTEDGE
WIREGAUGE
.029" SHOULD"GO"
.072" SHOULD"NOTGO"
ORSHOULD"JUSTGO"
FELTSLEEVE
SLEEVERETAINER
SEALSEAT
VRETAINERRING
SEALSEAT
"O" RING
SEALASSEMBLY
Fig. 11—CheckingforWobblePlatePositiononShaft
tangsonToolJ-9392bypressingdownandtwisting
thetool,thenliftthesealout.
Inspection
Checkthefaceofthesealfornicks,gougesorserra-
tions. Ifdamageofanykindisevident,replacetheseal.
Beextremelycarefulthatthefaceofthesealwhichisto
beinstalledisnotscratchedordamagedinanyway.
Apparentsealleaksaresometimestheresultofmis-
positioningofthewobbleplateonthecompressorshaft
causedbyimproperproceduresduringpulleyremoval
orpoundingordroppingonthecompressorshaft.Check
asshowninFigure11.Ifmeasurementisgreaterthan
shown,replacetheshaftandwobbleplateassembly.
Installation
1. EngagesealontothelockingtangsofToolJ-9392
(fig.13)and,withJ-21303installedovertheendof
theshaft,carefullyinsertthesealandtooloverthe
endoftheshaft.Turnsealtoengagetheflatonthe
shaft,thenremovethetool.
2. Coata new"O"ringandtheinterioroftheseal
cavity,shaftandsealwithcleanrefrigerationoil,
and,usingToolJ-21508,installthe"O"ringinits
groovejustabovetheseal.
Toinstallthe"O"ringplace"O"ringontoolas
showninFigure13,insertthetoolfullyintothefront
headbore,pressdowntheslider,twistentiretoolto
seat"O"ringandthenremovetool.
3. UsingToolJ-9393graspthesealseatandsetin
placeontopoftheseal.
4. UsingSnapRingPliersJ-5403,replacetheretaining
ring.Tapwiththepalmofthehandonthebarrelof
J-9393topresstheretainerringintoplace.
NOTE:Installtheretainingringwiththeflat
surfacefacingthesealseat.
5. Leaktestthecompressorasdescribedunder"Leak
TestingtheCompressor"inthissection.
6.Rollthefeltintoa cylinderandslipitintotheneck
ofthecompressorwiththeoverlappingendstoward
thecompressortop.Witha smallscrewdriveror
similartool,spreadthefeltsothattheendsbutt.
UsingtoolJ-9395,tapthefeltretainingring(flange
first)intothecompressorneckuntilflushwiththe
end.
7. Reinstalltheclutchhubanddriveplate.
8.Replacethecompressoronthevehicleifitwas
previouslyremoved,andevacuateandchargethe
system.
Fig. 12—RemovingSealSeatand"O"Ring
Fig. 13—ReplacingSealand"O"Ring
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-7
PressureReliefValve
Whena faultypressurereliefvalve,locatedintherear
headcasting,isencountered,thevalveassemblyshould
beremovedafterpurgingthesystemanda newvalveand
gasketinstalled.Theentiresystemshouldthenbe
evacuatedandrecharged.
CompressorRearHeadandInternalMechanism
Serviceoperationstotherearheadorinternalmech-
anismofthecompressorshouldbeperformedwiththe
compressorremovedfromthevehicletoinsurethatthe
necessarydegreeofcleanlinessmaybemaintained.
Cleanhandsanda cleanbench,preferablycoveredwith
cleanpaper,areofextremeimportance.
RearHead,OilPumpandValveAssemblies
Removal
1. Removethecompressorfromthevehicle,drain
compressoroilintoa cleancontainer,cleanthe
exteriorofthecompressorcaseandrearheadcast-
ingwitha suitablesolventandmountthecompres-
sor,rearheadup,inholdingFixtureJ-9396which
shouldthenbemountedsecurelyina vise.
2. Removethefournutsfromtheshellstuds.
3. Removetherearhead.Examinetheteflonsurface
onthecastingwebs.Ifthissurfaceisdamagedby
nicksorscratches,theheadshouldbereplaced.
4. Examinethesuctionscreenintherearheadforany
damageorcontamination.Cleanorreplacethe
screenasnecessary.
5. Removeandexaminetheoilpumpgears.Ifeitherof
thegearsshowsanywearordamage,replaceboth
gears.
NOTE:Keeptheendsofthetwooilpumpgears
matchedandreplacethesameendtowardthe
dischargeplateuponreassembly.
6.Removetherearhead-to-shell"O"ringanddis-
card.
7. Withtwoscrewdrivers,carefullypryupontherear
dischargevalveplateassembly(fig.14).Checkfor
brokenreedsordamagedseatsandreplaceentire
assemblyifsuchisfound.
CAUTION:Excessiveforceduringthisopera-
tionmayloosenvalvereedretainerrivets.
8.Carefullyliftofftherearsuctionreedvalve.Valve
mustbereplacedifanydamageisevident.
Installation
1. Carefullyreplacethesuctionreedvalveandthe
reardischargeplateoverthedowelpinsandportsin
thecylinderassembly.Properpositioningofthereed
platemaybedeterminedbylininguptheproper
openingintheplatewiththedischargecrossover
tubeopening.
Positiontherearheadcastingtoalignwiththedowel
pins. Thetwolowermountingpadswillbeinalign-
mentwiththeoilsumpintheshell.Rotatethe
cylinderassemblybackandforthbyhand,ifneces-
sary,topermitthisalignment.Removetherear
headfromthistrialassembly.
Installtheinneroilpumpgearoverthe"D"flaton
theshaftandplacetheouteroilpumpgearoverthe
innergear.Positiontheoutergearasfollows:
a.Observethepositionoftheoilsumpintheshell.
2.
3.
Fig. 14—RemovingRearDischargeValvePlate
5.
6.
b. Locatetheapproximatecenterlineofthispump.
c.Facingthecenterlineofthesumpandviewing
fromthesumpside(bottom)ofthecompressor,
movetheOUTERgeartowardtheright(side
havingthe^oildrainfitting)untilitisatapproxi-
mately90°(3o'clockposition)fromthecenterline
oftheoilsump(fig.15).
Coatthehead-to-shell"O"ringwithcleanrefrig-
erationoilandgenerouslylubricatetheareaaround
theouteredgeofthevalveplatewherethe"O"ring
willbeplaced.Oilalsotheoilpumpgears,valve
reedsandtheareawheretheteflongasketwill
contactthevalveplate.
Installthehead-to-shell"O"ring.
Besurethatthesuctionscreenisproperlyposi-
tionedintherearhead,thenassembletherearhead
tothecompressorshellbeingcarefulnottodamage
theteflongasket.
Fig. 15—ProperOil"PumpGearPositioning
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-8
CAUTION:Besureheaddoesnotbindagainst
oilpumpgearswhenbeinginstalled.
7. Installnewnutstothethreadedshellstudsand
tightento19-25ft.lbs.torque.
8.Leaktestthecompressorasoutlinedunder"Leak
TestingtheCompressor"inthissection.
9.Installcompressorinthevehicle.
MajorInternalMechanism
Theclutchhubanddriveplateassembly,drivekey,
pulleyandcoilhousingshouldberemovedbeforepro-
ceedingwiththefollowingcompressordisassembly.
RemovalfromShell
1. Removetherearhead,dischargeplateandsuction
reedvalvefromthecompressorasoutlinedunder
"RearHeadandReedValveAssemblies"above.
2. Removetheoilinlettubeand"O"ringwithJ-5139
asshowninFigure16.
3. Carefullylaythecompressorshellonitssideand
slideoutinteriormechanismandfrontheadas-
sembly.Donothammeroruseundueforcetore-
movethemechanism;however,gentletapsonthe
headcastingmayaidinremovingtheassembly.
4. Removefrontheadcasting,frontdischargevalve
plateandsuctionreedvalvefromthemechanism.
Examinepartsfordamageandreplaceifnecessary.
Checkparticularlyfordamagetotheteflonsurfaces
onthefrontheadcastingwebs.
5. Examinethemechanismforanyobviousdamage.
6.Removethesuctioncrossovercover(fig.17).
7. Ifdesired,themechanismmaybeassembledin
checkingCageJ-9397andoperatedona motortest
stand,orbysomeothersuitablemeans,toobserve
soundlevelandgeneraloperation.Tightencagenuts
evenlyto14-16ft.lbs.torque.
Fig. 16—RemovingOilInletTubeand"O"Ring
Fig.17—RemovingSuctionCrossoverCover
8.Removemechanismfromthecage.
Disassembly
Ifthemechanismhassustainedmajordamage,due
possiblytolossofrefrigerantand/oroil,itmaybe
necessarytoreplaceitwitha completeserviceinterior
mechanismassemblyratherthantoreplaceindividual
parts. Iffurtherdisassemblyisconsideredworthwhile,
proceedasfollows:
1. Beforedisassemblingthecylinderandmechanism,
numberthepistonsandcylinderlocationssothatall
partsmaybereplacedintheiroriginallocation.
Pistonsandcylinderboresmaybeidentifiedby
numberingthem1,2 and3 witha pencil.
2. Useanolddischargetubetodrivedischargetube
outofcylinder(fig.18).(DrivefromREARof
cylinder.)
3. Drivethecylinderhalvesapartandfreefromthe
dowelpinsanddischargecrossovertubeusinga
fiberblockandmallet(fig.19).Discardthedis-
chargecrossovertube.
NOTE:Beforedrivingcylinderapart,position
wobbleplatetowardfrontofcompressorinarea
ofthecrossovertube.
4. Carefullyremovetherearhalfofthecylinderfrom
thepistonsandsetthefrontcylinder half, withthe
piston,shaftandwobbleplate,inJ-9397.
5. Pushupontheshaftand,oneassemblyata time,
removepistons,rings,seatsandballsplacingall
partsinTrayJ-9402inthecompartmentassociated
withtheproperendofthepiston.Discardallpiston
ballseats.
NOTE:Thefrontofthepistonmaybeidentified
bya notchinthecastingweb.SeeFigure20.The
pistoncompartmentsinTrayJ-9402havea boss
atthisnotchlocationtoindicatethefront.
6.Removeandinspectallpistonrings.Replaceall
brokenordamagedrings.Damagedpistonsmust
alsobereplaced.
7. Examinepistonballs.Replaceiftheyshowburning
orexcessivewear.
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-9
Fig. 18—UnseatingDischargeCrossoverTube
8.
10.
11.
12
13
Removetherearcombinationofthrustracesand
bearingfromtheshaftanddiscardallthreepieces
9.Removetheshaftandwobbleplateassemblyfrom
thefronthalfofthecylinder.
Removethefrontcombinationofthrustwashersand
bearinganddiscardallthreepieces.
Examineallsurfacesofthewobbleplateand,if
satisfactory,reuse.Ifitshowssignsofwear,re-
placetheshaftandwobbleplateasanassembly.'Use
carenottomovewobbleplateontheshaft.Thisis
factoryset.
Examinethefrontandrearcylinderhalvesand
replaceifcylinderboresaredeeplyscoredor
damaged.
Washallpartstobereusedina suitablecleaner.
Blowdryallparts.
14. Ifcylindermainbearingsaretobereplacedthey
mayberemovedandreinstalledatthistimeusing
ToolJ-9432.Driveagainsttheletteredendofthe
bearingsandfromtheoutsideofthecylinder.Bear-
ingmustbenotmorethan1/8"belowsurface.
GaugingProcedure
Thegaugingoperationswhichfollowhavebeenworked
outona simplebasistoestablishandprovidenec-
essaryrunningclearances.Twogaugingproceduresare
necessary.
Thefirstgaugingoperationismadetochoosethe
propersizeballseatstoprovide,ateachpiston,a
.0005" to.0010"totalpreloadbetweentheseatsand
thewobbleplateatthetightestplacethroughthe360°
rotationofthewobbleplate.Thebronzeballseatsare
providedin.0005"variationsincludinga basicZERO
seat.
Fig. 19—SeparatingCylinderHalves
Thesecondgaugingoperation,performedattherear
shaftthrustbearingandracepack,isdesignedtoobtain
.0005" to.0015"preloadbetweenthehubsurfacesofthe
wobbleplateandthefrontandrearhubsofthecylinder.
Atotalof14steelthrustraces,includinga basicZERO
race, areprovidedinincrementsof.0005"thicknessto
providetherequiredfit.Properselectionofthrustraces
andballseatsisofextremeimportance.
1. Securefromservicepartsstock:
Four-ZEROthrustraces
Three-ZEROballseats
Two-Newthrustbearings
Assemblea ZEROthrustrace,a newneedlethrust
bearingandanotherZEROthrustrace,inthatorder
tothefrontendoftheshaft.(Adabofpetroleum
jellywillholdthebearing-racepacktogetherandin
placeoftheshaft.)Lubricatefrontandrearfaces
ofthewobbleplatewithrefrigerationoil.
3. Withthefronthalfofthecylinderassemblyresting
onToolJ-9397,inserttheshaft,threadedendthrough
thefrontmainbearinguntilthethrustraceassembly
restsonthefrontcylinderhub.
4. Assemblea ZEROthrustrace,a newneedlebearing
anda secondZEROthrustraceinthatorder,tothe
rearoftheshaft.
Applya lightsmearofcleanpetroleumjellytothe
ballpocketsofeachofthethreepistons.
2.
5.
Fig. 20-NorchIdentifyingFrontEndofPiston
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-10
RearBall
FeelerGages
FrontThrustRaces
andBearin
Compressing
FixtureJ-9397
Fig. 21—InstallingPiston,FrontBallandSeatandRearBall
6.Placetheballsinthepistonpockets.Thepetroleum
jellywillholdtheballsinplace,j
7. Applya lightsmearofpetroleupijellytothecavity
ofthreenewZEROballseatsandplaceoneseat
overeachfrontpistonball.Th^reshouldnowbea
ballandseatinthefrontballpocketofeachpiston
anda ballonlyintherearballpocket.
NOTE:Donotassembleanyofthepistonrings
atthistime.|
8.Rotatetheshaftandwobble£lateuntilthehigh
pointofthewobbleplateisdirectlyoverthecylinder
borepreviouslydesignatedasNb.1.Liftupslightly
ontheshaftandwobbleplateAssembly,insertthe
front(notched)endoftheNo.1 pistonintothe
cylinderbore,andatthesametime,placethefront
ballandseatandtherearballonlyoverthewobble
plate(fig.21).Holdfrontthrustbearingpacktight
Fig. 22—AssemblingCylinderHalves
Fig. 23—CheckingClearanceBetweenRearBallandWobble Plate
againstwobbleplatehubwhileliftingshaft.
9.RepeatthisoperationwithpistonsNo.2 andNo.3.
10. Aligntherearheadcastingwithbores,suction
passage,dischargecrossoverholes,anddowelpins.
Tapintoplace,usinga plasticblockandmallet
(fig.22).
11. Placethecylinderassemblyinthecheckingcage
withthefrontofthecompressorshaftpointingup,
positioningthedischargetubeopeningbetweenthe
cagebolts.Thiswillprovideaccessforthefeeler
gauge.Assemblethecageandtightenallnutsevenly
to14-16ft.lbs.torque.
12. Usea leaftypefeelergaugeanda suitablespring
scaletocheckclearancebetweentheREARballand
thewobbleplate(fig.23)oftheNo.1 piston.Usea
suitablecombinationoffeelergaugeleafsuntil4 to
8oz.offorceisrequiredtopullgaugefrombetween
theballandtheplate.
NOTE:Useundamagedfeelergaugesgener-
ouslylubricatedwithrefrigerationoil.Support
thespringscalesothatonlytheactualforce
requiredtopullthefeelergaugefreeis
measured.
Rotatetheshaftapproximately120°andagaincheck
witha feelergaugebetweentheparts.Rotatethe
shaftanother120°andmakea thirdcheck.From
thistotalofthreefeelergaugechecks,usethe
MINIMUMreadingtoselecta numberedseatto
correspondtothefeelergaugereading(i.e.- if
minimumreadingwas.019,usea No.19seat.If
readingwas.0195,usea No.19-1/2seat).Place
thisseatinthepartstrayinthecompartment
correspondingtotherearballpositionoftheNo.1
piston.
13. RepeattheoperationdescribedinStep12forpistons
No. 2 andNo.3.
14. Thenextgaugingoperationistodeterminethespace
betweentheREARthrustbearingandtheupper
(outer)rearthrustrace.Usea suitablecombination
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR 1-11
Fig. 24—CheckingClearanceBetweenRearThrust
Bearing and OuterThrustRace
offeelergaugeleafs so that 4 to8 oz.of force is
required to pullgaugefree (fig.24). Select a num-
beredthrustrace to correspond to thisfeelergauge
reading and placethisrace in partstray inthe rear
thrustracecompartment.
15. Loosen the nuts and ringfrom the checkingcage.
16. Drive the cylinderhalvesapart,using a fiberblock
andmallet.
17. Carefullyremove the rearhalf ofthe cylinder and
set the fronthalf(including the pistons and shaft and
wobbleplateassembly) on J-9397.
18. Carefullyremove one piston ata timefrom the
wobbleplate andthe fronthalf ofthe cylinder.
Transfereachpiston,ball and seat toits proper
place inthe partstrayalongwith the numberedrear
seatchosen in Steps 12and13 above.
CAUTION:When the balls and seat are removed
from the piston, be surethatthey are placed in
theproperpartstraypocket soasnotto lose
therelationship ofthe balls and seats tothe
proper endofthe piston.
19. Remove the rearouter(upper)ZEROthrustrace
from the compressorshaft and replace it with the
numberedtiirustrace(determined in Step 14 above)
from the partstray.
NOTE:ThisZEROthrustrace maybeput
aside for reuse in futuregaugingand/orrebuild
operations.
20. The gaugingoperations arenow complete.
Assembly
Afterproperlyperforming the gaugingprocedure and
choosing the correctballseats and thrustraces as
outlinedunder"GaugingProcedures," the cylinder
assembly maybe reassembled. Be sure to install all
newseals andUO" rings. Allare included inthecom-
pressorsealservice kit.
Assemblyprocedure isas follows:
1. Support the fronthalf ofthe cylinderassembly on
FixtureJ-9397 and install the shaft and wobble
plate,threaded end down,with its frontbearing
racepack(ZEROrace,bearing and ZEROrace)
and its rearbearingracepack(ZEROrace,bearing,
numberedrace) if this wasnot alreadydone atthe
end ofthe "GaugingProcedure."
2. Assemble a pistonring,scrapergroovetoward the
center ofthe piston, to each endofthe threepistons.
3. Apply a lightsmear of petroleumjelly tothenum-
beredballseatschosen inthe gaugingprocedure
andinstall all balls and seats (if removed in Step 18
of the gaugingprocedure) in theirproperplace in
thepiston.
4. Rotate the wobbleplate so that the highpoint is
abovecylinderbore No.1. Carefullyassemble
piston No.1, completewithball and ZEROseat on
thefront and ball and numberedseat onthe rear,
over the wobbleplate.Holdfrontthrustpacktight
againstwobbleplate hub whileliftinghub.Compress
andenter the pistonringinto the frontcylinder half.
5. Repeatthisoperation for pistons No.2 andNo.3.
6.Assemble oneendofa servicedischargecrossover
tubeinto the hole inthe frontcylinder half,
7. Rotate the shaft to position the pistons ina stair-
steparrangement,thencarefullyplace the rear
cylinderhalfover the shaft and start the pistons
into the cylinderbores.
8.Compress the pistonring on eachpiston to permit
itsentranceinto the cylinder.
i
Fig. 25—InstallingSuctionCrossoverCover
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-12
9.Whenallthreepistonsandringsareintheirre-
spectivecylinders,aligntheendofthedischarge
crossovertubewiththeholeintherearhalfofthe
cylinder.
NOTE:Besuretheflattenedportionofthis
tubefacestheinsideofthecompressorto
allowforwobbleplateclearance.
10. Whenallpartsareinproperalignment,tapwitha
fiberblockandmallettoseattherearhalfofthe
cylinderoverthelocatingdowelpins.Ifnecessary,
clampthecylinderinJ-9397tocompletedrawing
thecylinderhalvestogether.
11. Generouslylubricateallmovingpartswithclean
refrigerationoilandcheckforfreerotationofthe
parts.
NOTE:Itmaybedesirabletoclampthecylin-
derassemblyincompressingFixtureJ-9397
andcheckonthemotorteststandforproper
operationbeforeproceedingfurther.Ifanyim-
properoperationisobserved,themechanism
shouldberegaugedtoinsureproperoperation.
Completetheassemblyprocedurewhencor-
rectoperationisobtained.
12. Replacethesuctioncrossovercoverasshownin
Figure25.Compressthecoverasshowntostartit
intotheslotandthenpressitinuntilflushonboth
ends.
InstallationIntoShell
1. SupportthecylinderonFixtureJ-9521withthe
threadedendoftheshaftup.
2. Assemblethetwodowelpinsinthefrontcylinderif
theyarenotalreadyinplace.
NOTE:A roddrilled1/4"deeptotheO.D.of
thedowelpinswillaidininstalling.
3. Installthedischargecrossovertubefront"O"ring
andspacer(fig.26).
4. Aligningthedowelpinholes,dischargecrossover
andoilreturnslot,assemblethesuctionreedvalve
tothefrontendofthecylinder.
5. Assemblethefrontdischargevalveplate,aligning
theholeswiththedowelpinsandproperopeningin
thehead.
NOTE:Thefrontdischargeplatehasa larger
diameterholeinthecenterthanthereardis-
chargeplate.
6.Checktheteflonsurfaceonthecompressorfront
headcastingwebsandreplacetheentirecasting
ifthereisanyevidenceofdamage.Discardthe
"O" ring.
7. Coatthevalveplatewithcleanrefrigerationoil.
Rotatethefrontheadcastinguntilitisproperly
positionedoverthedischargereedretainersand
dowelpins,thenset • itinplace(beingcarefulnot
todamagetheteflonsurfaces)andseatitover
dowelswithlightmallettaps.
NOTE:Dowelpinandholelocationcanbe
markedwithpenciltoaidinlocatingproper
position.
8.Applycleanrefrigerationoiltoa new"O"ringand
"O" ringgrooveattheloweredgeofthefronthead
castingandcarefullyassemblethe"O"ringinthe
groove.
Fig. 26—InstallingDischargeCrossoverTubeFront
"O" RingandSpacer
Fig. 27—InstallingShellOverInternalMechanism
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-13
9.Coattheinsidemachinedsurfacesofthecompressor
shellwithrefrigerationoil.
10. Locatetheoilintaketubeholeinthereardischarge
plate.Lineuptheoilsumpwiththisholelocation
andslidetheshelldownoverthemechanismwhile
supportingthemechanismonJ-9521(fig.27).
11. PlaceCompressorSupportBracketJ-9396ina vise
and,carefullyinvertingthecompressorshellwith
themechanisminside,mountthefrontcompressor
flangeonthesupportbracket.
12. Placea new"O"ringintheoilintaketubehole
applyingcleanrefrigerationoiltotheoilintaketube
holeandthe"O"ring.Rotatingthecompressor
mechanismtolineupwiththeholeinthecompressor
oilsumpbaffle,installthepickuptube.Besurethat
the"O"ringandintaketubeareproperlyseated.
13. Assemblethedowelpinsintotherearcylinder.
14. Installthedischargecrossovertuberear"O" ring
andspacer.
15. Replacetherearsuctionreedvalve,reardischarge
valveplate,oilpumpgears,rearheadandheadnuts
asoutlinedpreviouslyunder"RearHeadandReed
Assemblies- Installation."
LeakTestingtheCompressor
Wheneverserviceoperationsareperformedonthe
compressorshaftsealassemblyorontheinterior
mechanism,usethefollowingproceduretoleaktestthe
reassembledcompressor.
1. Install"O"ringsandCoverPlateJ-9527overthe
suctionanddischargeportsofthecompressorhead.
2. Hookupa Refrigerant-12containerandchargingline
(usingAdapterJ-5420)tocoverplatefittingoverthe
suctionport,chargethecompressoruptocanpres-
sure, andleaktestcompressorwitha leakdetector.
Turnofftherefrigerantcontainervalve.Transfer
gaugelineandadaptertocoverplatefittingoverthe
dischargeportandrepeattheprocedureoutlinedin
Step2.
3.Correctanyleakspresent.
CHEVROLETCHASSISOVERHAULMANUAL

AIRCONDITIONINGCOMPRESSOR1-14
SPECIALTOOLS
y
34
V
181920212324
Fig. 28—AirConditioningSpecialTools
1. J-8393ChargingSystem
2. J-5453Goagles
3. J-945990GaugeLineAdapter
4. J-5420GaugeLineAdapter
5.J-6084LeakDetector
6. J-8433Puller
7.J-9395PullerPilot
8. J-6272Multi-Opener(4Can)
9.J-6271FitzallValve(SingleCan)
10. J-7151Non-MagneticClutchShims
11. J-5421PocketThermometers(2)
12. J-5403#21SnapRingPliers
13. J-6435#26SnapRingPliers
14. J-9396CompressorHoldingFixture
15. J-9397CompressingFixture
16. J-9403ClutchHubHoldingTool
17. J-93999/16"ThinWallSocket
18. J-9480HubandDrivePlateAssemblyInstaller
19. J-9401HubandDrivePlateAssemblyRemover
20. J-9392SealRemover
21. J-9393SealSeatRemover
22. J-9398PulleyBearingRemover
23. J-9481PulleyandBearingInstaller
24. J-8092Handle
25. J-9521InternalAssemblySupportBlock
26. J-5139OilPickupTubeRemover
27. J-9432NeedleBearingInstaller
28. J-9553SealSeat"O"RingRemover
29. J-21508SealSeat"O"RingInstaller
30. J-21303ShaftSealProtector
31. J-9527PressureTestConnecfor
32. J-9402PartsTray
CHEVROLETCHASSISOVERHAULMANUAL

SECTION4
REARAXLEDIFFERENTIALCARRIER
CONTENTSOFTHISSECTION
Page
ConventionalDifferentialCaseandDrivePinion
(Chevrolet,Camaro,ChevelleandChevyII)......4-1
ConventionalDifferentialCaseandDrivePinion
(Corvette)4-10
Page
PositractionDifferentialCaseandDrivePinion
(Dana)4-19
PositractionDifferentialCaseandDrivePinion
(Eaton)4-21
CONVENTIONALDIFFERENTIALCASEANDDRIVEPINION
(CHEVROLET,CAMARO,CHEVELLE,ANDCHEVYII)
INDEXI
Page
DifferentialCaseandDrivePinion4-1
Removal4-1
Inspection4-2
Repairs4-2
Pinionand/orBearingReplacement.........4-2
DifferentialBearingReplacement4-4
DifferentialCaseandDrivePinion
Removal
1. Raisevehicleandremoveaxleshafts.
NOTE:OnCamaromodelsitwillbenecessary
toremovetheenginemufflertoobtainsufficient
clearancefordifferentialcaseremoval.
2. Rolloutthedifferentialpinionsandthrustwashers,
thenremovesidegearsandthrustwashers.Mark
pinionsandsidegearssothattheycanbereassem-
bledinoriginalposition.
3. Markonebearingcapandhousingforreassemblyin
sameposition.Removebearingcapboltsandbearing
capstapsurfaceofbearingcapstoloosenthem.
CAUTION:Donotattempttoprycapsoffas
thismaydamagemachinedfaceofcaps.
Page
RingGearorDifferentialCaseReplacement....4-4
Installation. 4-5
DrivePinionandBearing4-5
DifferentialBearingPreload4-6
RingGearandPinionAdjustment4-7
RingGearandPinionContactPattern4-8
Usinga prybarasshowninFigure1,prydifferen-
tialcaseoutofcarrier.Exercisecautioninprying
oncarriersothatgasketsealingsurfaceisnot
damaged.Ifthebearingsarepreloaded,thecase
willsuddenlyfallfreewhenitispriedpasta certain
point;therefore,makesurecaseisproperlysup-
portedtopreventdamage.Thebearingcapsmaybe
looselyinstalled,asshowninFigure1,toprevent
casefromfalling.
Placeleftandrightbearingcupswithbearingcaps
sothattheymaybereinstalledinoriginalpositions.
Placeshimswithappropriatecups.
InstallToolJ-8614-1onpinionflangeandremove
pinionflangenutandwasher(fig.2).(Position
J-8614-1onflangesothatthefournotchesare
towardflange.)Discardnutandusea newoneupon
reassembly.
ThreadpilotendofToolJ-8614-3intosmallO.D.
endofJ-8614-2.ThenwithJ-8614-1installedasin
Step6,insertJ-8614-2intoJ-8614-1andturnit45
Fig. 1—DifferentialCaseRemoval
Fig. 2—DrivePinionNutRemoval
CHEVROLETCHASSISOVERHAULMANUAL

REARAXLEDIFFERENTIALCARRIER4-2
Fig. 3—DrivePinionFlangeRemoval
degreestolockedposition.Removeflangebyturning
J-8614-3whileholdingJ-8614-1(fig.3).
Pryoldsealoutofbore,usinga screwdriverora
hammerandchisel.
Ifdeflectorrequiresreplacement,removebytapping
fromflange,cleanupstakepoints;installnew
deflector,andstakedeflectoratthreenewequally
spacedpositions.
NOTE:Stakingoperationmustbeperformedin
sucha mannerthatthesealoperatingsurfaceis
notdamaged.
Removedrivepinionbytappingonfrontendwitha
softfacedhammer.Thenremovepinionfrontbear-
ingconefromcarrierbore.Discardpinionbearing
spacerandusea newoneuponreassembly.
Inspection
1. Cleanallgearsandbearingsinanapprovedcleaning
solventandinspectallbearingcups,racesand
rollersforscoring,chippingorevidenceofex-
cessivewear.Onpinionbearingrollers,inspect
largeendofrollersforwear.Thisiswherewear
ismostevidentontaperedrollerbearings.
NOTE:Thepinionbearingsareofthetapered
type, andthenaturalwearpatternisa frosted
10.
condition withoccasionalslightscratcheson
racesorrollers.Thisdoesnotindicatea
defectivebearing.
Inspectpinionsplinesandflangesplinesforevidence
ofexcessivewear.
Inspectringgearandpinionteethforpossible
scoring,crackingorchipping.
Inspectdifferentialcaseforcracksorscoreson
sidegears,thrustwashers,andpinionthrustfaces.
Checkfitofdifferentialsidegearsincase.
Checkfitofsidegearandaxleshaftsplines.
Inspectdifferentialpinionshaftforscoringorevi-
denceofexcessivewear.
Repairs
Pinionand/or Bearing Replacement
1. Removepinionfrontandrearbearingcupsfrom
theirpositionsinthecarrier,usinga brassdrift
ofsuitablelength.Tapalternatelyonoppositeside
ofcupsduringremovaltopreventcupsfromcock-
inginthecarrier.
2. Positionnewbearingcupincarrier,thickedgeof
cuptowardshoulderincarrier,thenusingCupIn-
stallerJ-7137forheavy-dutyaxleandJ-7817for
light-dutyaxletoinstallfrontcupandJ-0270-14
forlight-dutyaxleandJ-8608forheavy-dutyaxle
toinstallrearcup,presscupintocarrieruntilit
seatsagainstshoulder(fig.4).Checkinstallation
tomakecertainthatcupisnotcockedandthatitis
fullyseatedagainstshoulder.
3. Removepinionrearbearingconeandrollerassem-
bly,usingsplitplateholder(ToolJ-0358-1)incon-
junctionwithbearingremover(splitplate)J-7028
forlight-dutyaxleandJ-9771forheavy-dutyaxle
asshowninFigure5.Recordthicknessofshim
removedfrombetweenbearingconeandpinionhead.
4. Iftheoriginalringgearandpinionandthepinion
rearbearingassemblywillallbereinstalled,the
originalshimoroneofthesamethicknessmaybe
used.Iftheringgearandpinionorthepinionrear
bearingassemblyarereplaced,thecorrectshim
thicknessmaybedeterminedasfollows.
a.Lubricatepinionbearingconeandrolleras-
sembliesandpositiontheminpropercups.
b. PositionappropriatePinionDepthSettingGauge
Plateinpinionrearbearing(fig.6).
Fig. 4—DrivePinionFrontandRearBearingCupInstallation
CHEVROLETCHASSISOVERHAULMANUAL

REARAXLEDIFFERENTIALCARRIER4-3
J-9771(HEAVY-DUTY)
J-7028(LIGHT-DUTY)
Fig. 5—DrivePinionConeandRollerAssemblyRemoval
GaugePlateUsage
J- 6266- 3 5- - Chevrolet,Camaro,ChevyII,and
Chevellewithlight-dutyaxle.
J-6266-36--Chevrolet,Camaro,Chevelleand
ChevyIIwithheavy-dutyaxle.
c.Insertclampscrewthroughgaugeplateandboth
ofthepinionbearings.
d.PositionJ-6266-25onthreadedendofclamp
screwandindexitinfrontbearing,installhex
nutandrotatebearingsseveraltimestomake
surethattheyareseated.
e.Tightenhexnutuntil20to30in.lbs.oftorque
isrequiredtorotatebearings(fig.7).
f.Aftertorquehasbeenestablished,positiongauge
plateincarriersothatthelargeoverhanging
Fig. 7—MeasuringDrivePinionBearingSimulatedPreload
Fig. 8—DrivePinionDepthSettingGaugePlateInstalled
endisintheupposition(fig.8).
g.Positiondialindicator(ToolJ-8001-3)ongauge
postofToolJ-6266-28sothatindicatorbutton
restsontopoftoolplunger,
h.PositionToolJ-6266-28incarrierasshownin
Figure9.Swingtoolbodysothatplungerdoes
nottouchgaugeplate,andsetindicatordialat
zero.
NOTE:BarrelAdaptersToolJ-6266-31must
beusedwhengaugingChevrolet,Camaro,
Chevelle,andChevyIIwithheavy-dutyaxle.
Makesureadaptersareseatedindifferential
bearingboresofcarrierbeforemeasuring
depth.
Fig. 6—InstalledViewofPinionDepthGauge
Fig. 9—MeasuringDrivePinionShimRequirement
CHEVROLETCHASSISOVERHAULMANUAL

REARAXLEDIFFERENTIALCARRIER4-4
Fig. 10-DrivePinionConeandRollerAssemblyInstallation
i.
j.
Slowlyswinginnerendoftoolplungeracross
gaugeplateuntilhighestindicatorreadingis
obtained.Recordthismeasurementandrecheck
toseethatitiscorrect.
Allpiniongearsarestampedwitha codenumber
onthethreadedendofthepinion.Thenumerical
differencebetweenthecodenumberandthe
gaugereadingobtainedinStepi determinesthe
requiredthicknessofthepinionlocatingshim
PROTECTIVE
TUBEORPIPE
J-9772
#2
45
16
29
.029"
Fig. 12-DifferentialBearingRemoval
EXAMPLE:
PinionCodeNumber
DialIndicatorReading
Difference
ProperShimThickness
NOTE:Shimsareavailablein .001" increments
from .021" to.037".Eachshimhasthethickness
etchedonflatsurfaceforeasyidentification.
5. RemoveToolJ-6266andpinionbearingconeand
rollerassembliesfromcarrier
6.Positionshimselectedinaboveprocedureonpinion
shaftandagainstpinionhead.
7. Installnewconeandrollerassembly,usingTool
J-5590forlight-dutyaxle(fig.10)orToolJ-9772
forhea^y-dutyaxle (fig.H).Pressconeagainst
andrearfaceofpinion.
Differential Bearing Replacement
1 Itll Tl
Fig. 11-DrivePinionConeandRollerAssemblyInstallation
InstallToolJ-7112andAdapterPlugJ-8107-4
making surepullerlegsarefittedsecurelyin
notchesincaseandagainstbearingcone.Then
tightenpulleryokeagainstpullerlegs.
2. Tightenpullerscrewtoremovebearing(fig12)
3. Placenewbearingonhubwiththicksideofinner
TaQ^7TrVlS+e^ drlVeint°place>usinSTool
J-9537forlight-dutyaxleandToolJ-8359for
heavy-dutyaxle.
4*Jef?re+infallingbearinSonoppositehub,support
differentialcaseonAdapterPlugJ-8107-4This
allowsdifferentialcasetorestonadapterinstead
ofbearingcage(fig.13).Installremainingbearing
asinstructedinStep3."earing
Ring Gear or Differential Case Replacement
1. Removeringgearscrewsandlockwashersand
usinga softfacedhammer,tapringgearoffthe
case.
NOTE:Donotattempttopryringgearfrom
case, todosomaydamagemachinedsurfaces.
2. Installguidepins,madefrom3/8"-24x 1-1/2" long
CHEVROLETCHASSISOVERHAULMANUAL