Chevrolet Chevelle 1977 Operating instructions

IMPORTANT SAFETY NOTICE
Proper service and repair is important to the safe, reliable operation of all
motor vehicles. The service procedures recommended by Chevrolet and
described in this service manual are effective methods for performing service
operations. Some of these service operations require the use of tools specially
designed for the purpose. The special tools should be used when and as
recommended.
t is important to note that this manual contains various Warnings, and
Cautions which should be carefully read in order to minimize the risk of
personal injury to service personnel or the possibility that improper service
methods will be followed which may damage the vehicle or render it unsafe.
t also is important to understand that these Warnings, and Cautions are not
exhaustive. Chevrolet could not possibly know, evaluate and advise the
service trade of all conceivable ways in which service might be done or of the
possible hazardous consequences of each way. Consequently, Chevrolet has
not undertaken any such broad evaluation. Accordingly, anyone who uses a
service procedure or tool which is not recommended by Chevrolet must first
satisfy himself thoroughly that neither his safety nor vehicle safety will be
jeopardized by the service method he selects.

.

1977
OVERHAUL MANUAL
covering
CHEVROLET, CHEVELLE,
MONTE CARLO, NOVA,
CAMARO, CORVETTE
and
LIGHT DUTY
(SERIES 10-30)
CHEVROLET TRUCKS
FORE ORD
This manual includes procedures involved in disassembly and assembly
of major components of 1977 Chevrolet, Chevelle, Monte Carlo, ova,
Camaro, Corvette and Light Duty Trucks. Information on diagnosis, mainte
nance and adjustments, minor service operations, and removal and installa
tion for these components is contained in either the 1977 Passenger Car or
the Light Duty Truck Service Manuals.
The Section Index on this page enables the user to quickly locate any
desired section. At the beginning of each section containing more than one
major subject is a Table of Contents, which gives the page number on which
each major subject begins. An index is placed at the beginning of each
major subject within the section.
Summaries of Special Tools, when required, are found at the end of
major sections.
The manual should be kept in a handy place for ready reference. If prop
erly used, it will enable the technician to better service the owners of Chev
rolet built vehicles.
All information, illustrations and specifications contained in this literature
are based on the latest product information available at the time of publica
tion approval. The right is reserved to make changes at any time without
notice.
CAUTION
This vehicle contains some parts dimensioned in the metric system
as well as in the customary system. Some fasteners are metric and
are very close in dimension to familiar customary fasteners in the
inch system. It is important to note that, during any vehicle mainte
nance procedures, replacement fasteners must have the same
measurements and strength as those removed, whether metric or
customary. (Num ers on the heads of metric olts and on surfaces
of metric nuts indicate their strength. Customary olts use radial
lines for this purpose, while most customary nuts do not have
strength markings.) Mismatched or incorrect fasteners can result in
vehicle damage or malfunction, or possi ly personal injury. There
fore, fasteners removed from the vehicle should e saved for re-use
in the same locations whenever possi le. Where the fasteners are
not satisfactory for re-use, care should e taken to select a re
placement that matches the original. For information and assis
tance, see your Chevrolet dealer.
SECTION INDEX
SECTION
IB
3B
4B
4C
NAME
AIR CONDITIONING
COMPRESSOR
STEERING
REAR AXLE
4 WHEEL DRIVE
BRAKES
6C FUEL SYSTEMS
6D ENGINE ELECTRICAL
7A AUTOMATIC TRANSMISSION
7B
7C
MANUAL TRANSMISSION
CLUTCH
©1976 General Motors Corporation Printed In U.S.A.

AIR CONDITIONING 1B-1
SECTION IB
A/C COMPRESSORS
CONTENTS
Axial Six Cylinder Compressor ................................... B-1
Radial Four Cylinder Compressor ............................... B-22
Leak Testing..................................................................... B-33
AXIAL SIX-CYLINDER COMPRESSOR
For Compressor REMOVAL AND
NSTALLAT ON, refer to the ON CAR SERV CE
Section of this Service Manual.
For all Axial Six Cylinder compressor applications, the
compressor mechanism is basically the same. Actual
differences between compressors are found in their
mounting brackets, pulleys, connector assemblies and
compressor capacities, none of which will affect the
following Overhaul Procedures.
MINOR REPAIR PROCEDURES
The following operations to the Compressor
Clutch Plate and Hub, Pulley and Bearing, and
Coil Housing are covered as "Minor" because they
may be performed ITHOUT FIRST PURGING
THE SYSTEM OR REMOVING THE
COMPRESSOR from the vehicle.
The Compressor Shaft Seal assembly and
Pressure Relief Valve may also be serviced
ITHOUT REMOVING THE COMPRESSOR from
the vehicle but these operations are covered later
in this section as "Major Repair Procedures"
because the system MUST FIRST BE PURGED of
Refrigerant.
Illustrations used in describing these
operations show the compressor removed from
the vehicle only to more clearly illustrate the
various operations.
hen servicing the compressor, remove only
the necessary components that preliminary
diagnosis indicates are in need of service. Refer
to Fig. 1 and Fig. 2 for information relative to parts
nomenclature and location.
Removal and installation of external compressor
components and disassembly and assembly of internal
components must be performed on a clean workbench. The
work area, tools, and parts must be kept clean at
all times. Parts Tray J-9402 (see Fig. 33) should be used
for all parts being removed, as well as for replacement parts.
Although certain service operations can be performed
without completely removing the compressor from the
vehicle, the operations described herein are based on bench
over-haul with the compressor removed from the vehicle.
They have been prepared in sequence in order of
accessibility of the components.
Pad fender/skirt and secure compressor near top of
fender skirt with wire, rope, etc.
CAUTION: Do not kink or place excessive tension
on lines or hoses.
When a compressor is removed from the vehicle for
servicing, the amount of oil remaining in the compressor
should be drained and measured. This oil should then
be discarded and new 525 viscosity refrigerant oil added to
the compressor.
CLUTCH PLATE AND HUB ASSEMBLY
Remove
1. Place Holding Fixture J-9396 in a vise and clamp
the compressor in the Holding Fixture.
2. Keep clutch hub from turning with Clutch Hub
Holder J-25030 or J-9403, and remove locknut from end of
shaft using Thin Wall Socket J-9399 (Fig. 3).
CAUTION: To avoid internal damage to the
compressor, DO N OT D RIVE OR OUND on
the Clutch late and Hub assembly OR on the end
o f the shaft. I f proper tools to remove and replace
clutch parts are not used, it is possible to disturb
the position o f the axial plate (keyed to the main
shaft), resulting in compressor damage and seal
leakage due to shifting o f the crankshaft.
3. Thread Clutch Plate and Hub assembly Remover
J-9401 into hub. Hold body of Remover with a wrench and
tighten center screw to remove Clutch Plate and Hub
assembly (Fig. 4).
4. Remove square drive key from shaft or drive plate
hub. 5. Remove hub spacer retainer ring using Snap-Ring
Pliers J-5403(#21), and then remove hub spacer (Fig. 5).
6. nspect driven plate for cracks or stresses in the drive
surface. Do not replace driven plate for a scoring condition.
(Fig. 6).
f the frictional surface shows signs of damage due to
excessive heat, the clutch plate and hub and pulley and
bearing should be replaced. Check further for the
underlying cause of the damage (i.e. low coil voltage - coil
should draw 3.2 amps at 12 volts) or binding of the
compressor internal mechanism, clutch air gap too wide,
broken drive plate to hub asm. springs, etc.
Replace
1. nsert the square drive key into the hub of driven
plate; allow it to project approximately 3/16" out of the
keyway.
2. Line up the key in the hub with keyway in the
shaft (Fig. 7).
3. Position the Drive Plate nstaller J-9480-1 on the
threaded end of the shaft. The Spacer J-9480-2 should be
in place under the hex nut on the tool. This tool has a left
hand thread on the body. (Fig. 8).
4. Press the driven plate onto the shaft until there is
approximately 3/32" space between the frictional faces of
the clutch drive plate and pulley.
CAUTION: Make certain key remains in place
when pressing hub on shaft.
A ZERO thrust race is approximately 3/32" thick and

Fig. 1-Exploded View of A-6 Compressor
Shaft Seal Assembly
Seal Seat
Seal Seat Retainer Ring
Absorbent Sleeve
Seal Retainer
Pressure Relief Valve
Clutch Coil Retainer Ring
Compressor Shell
Clutch Coil and Housing Assembly
/
Pulley
/ Bearing
Bearing Retainer
/ Pulley Retainer Ring
/ / Clutch Plate and
/ / / Hub Assembly
^ )/ 1 I Retainer Ring
1 i( i Lock Nut
Suction Screen
Drain Plug
Oil Pump G ear j
Discharge Valve Plate Assembly
Rear Suction Reed Axial Plate
Bushing / /
Needle Bearing /
O - Ring
Rear Cylinder Half
Teflon Piston Ring
Suction
Crossover Cover
Thrust Bearing
Front Cylinder Half
Needle Bearing
Shoe Disc /
Teflon Ring Type Piston
Teflon Piston Ring
Dowel Pins
Discharge Crossover Tube
Thrust Races Bushing
Front
Suction Reed
Front Discharge
Valve Plate Assembly

AIR CONDITIONING 1B-3
.y/.y4±;
FRONT
HEAD ABSORBENT
SLEEVE /
CLUTCH COIL
AND HOUSING
THRUST
BEARING SPACER
REAR HEAD
OIL PUMP
GEARS
PRESSURE RELIEF
VALVE
SUCTION REED
^ -^ T E F L O N PISTON RING I
BALL SHELL /
AXIAL PLATE / /
SHOE DISC I /
SHAFT \
PISTON
FRONT CYLINDER
HALF
FRONT
DISCHARGE VALVE PLATE
SHAFT SEAL ASM.
PULLEY
PULLEY BEARING
CLUTCH PLATE
AND
HUB ASSEMBLY
SEAL SEAT
RETAINER RING
SEAL SLEEVE
OIL PICK-UP TUBE
OIL SUMP THRUST
RACE
REAR CYLINDER
HALF RETAINER RING (CONVEX.
SIDE FACING SPACER) SHAFT NUT
Fig. 2-A-6 Compressor Cross Section
may be used to roughly gage this operation. Use Clutch Hub
Holder J-25030 or J-9403 to hold clutch plate and hub if
necessary.
5. nstall the hub spacer and, using Snap-Ring Pliers
J-5403 (#21), install the retainer ring (see installed Retainer
Ring in inset of Fig. 2), with convex side of ring facing
spacer.
6. Use Thin-Wall Socket J-9399 and Clutch Hub
Holder J-25030 or J-9403 to install a new shaft locknut
with shoulder or circular projection on the
locknut facing towards retainer ring. Tighten the
nut to 14-26 lb. ft. torque. Air gap between the frictional
faces should now be .022" to .057"(Fig. 9). f not, check for
mispositioned key or shaft.
7. The pulley should now rotate freely.
8. Operate the refrigeration system under MAXimum
load conditions and engine speed at 2000 RPM. Rapidly
cycle the clutch by turning the air conditioning on-and-off
at least 15 times at approximately one second intervals to
burnish the mating parts of the clutch.
CLUTCH HUB
HOLDING TOOL
J25030 OR J9403
THIN ALL SOCKET J9399
CLUTCH ASSEMBLY
HOLDING
FIXTURE
J-9396
Fig. 3--Removing Shaft Lock ut Fig. 4--Removing Clutch Plate and Hub Assembly

1B-4 OVERHAUL MANUAL
Fig. 5-Removing or Installing Retainer Ring in A-6 Clutch
Drive Plate
PULLEY AND BEARING ASSEMBLY
Remove
1. Remove clutch plate and hub assembly as described
in "Compressor Clutch Plate and Hub Asm." Removal
procedure.
2. Remove pulley retainer ring using Snap-Ring Pliers
J-6435 (#26), Fig. 10.
3. Pry out absorbent sleeve retainer, and remove
absorbent sleeve from compressor neck.
4. Place Puller Pilot J-9395 over end of compressor
shaft.CAUTION: It is important that uller ilot J-
9395 be used to prevent internal damage to
compressor when removing pulley. Under no
circumstances should Puller be used
DIRECTLY against drilled end of shaft .
5. Remove Pulley and Bearing Assembly using Pulley
Puller J-8433 (Fig. 11).
Inspection
Check the appearance of the pulley and bearing
assembly. See Fig. 6. The frictional surfaces of the pulley
and bearing assembly should be cleaned with a suitable
solvent before reinstallation.
Replace
1. f original pulley and bearing assembly is to be
reinstalled, wipe frictional surface of pulley clean. f
frictional surface of pulley shows any indication of damage
due to overheating, the pulley and bearing should be
replaced.
2. Check bearing for brinelling, excessive looseness,
noise, and lubricant leakage. f any of these conditions exist,
bearing should be replaced.See "Compressor Pulley
Bearing" Replacement Procedure.
3. Press or tap pulley and bearing assembly on neck of
compressor until it seats, using Pulley and Bearing nstaller
J-9481 with Universal Handle J-8092 (Fig. 12). The
nstaller will apply force to inner race of bearing and
prevent damage to bearing.
4. Check pulley for binding or roughness. Pulley should
rotate freely.
5. nstall retainer ring, using Snap Ring Pliers J-6435
(#26).
6. nstall absorbent sleeve in compressor neck.
7. nstall absorbent sleeve retainer in neck of
compressor. Using sleeve from Seal Seat Remover- nstaller
J-23128, install retainer so that outer edge is recessed 1/32"
from compressor neck face.
8. nstall clutch plate and hub assembly as described
in "Compressor Clutch Plate and Hub Asm."Replacement
Procedure.
SCOR NG OF DR VE AND DR VEN PL A TES S NORMAL.
DO NOT R EPLA CE FOR TH S COND T ON.
DR VEN PLA T E
DR VE PLA T E
Fig. 6-Clutch Driven Plate and Drive Plate

AIR CONDITIONING 1B-5
KEYWAY IN
SHAFT
HOLDING FIXTURE
J-9396
Fig. 7-Aligning Drive Plate Key
PULLEY BEARING
Remove
1. Remove clutch plate and hub assembly as described
in "Compressor Clutch Plate and Hub Asm." Removal
procedure.
2. Remove pulley and bearing assembly as described
in "Compressor Pulley and Bearing Asm." Removal
procedure.
3. Remove pulley bearing retainer ring with a small
screwdriver or pointed tool (Fig. 13).
4. Place pulley and bearing assembly on inverted
Support Block J-21352 and, using Pulley Bearing Remover
J-9398 with Universal Handle J-8092, drive Bearing
assembly out of pulley (Fig. 14).
Replace
1. nstall new bearing in pulley using Pulley and
Bearing nstaller J-9481 with Universal Handle J-8092 (Fig.
15). The nstaller will apply the force to the outer race of
the bearing.
CAUTION: DO NO T CLEAN N EW BEARING
ASSEMBL Y WITH A N Y TY E OF SOL VENT
Bearing is supplied with correct lubricant when
assembled and requires no other lubricant at any
time.
2. nstall bearing retainer ring, making certain that it
is properly seated in ring groove.
3. nstall pulley and bearing assembly as described in
"Compressor Pulley and Bearing Asm." Replacement
procedure.
4. nstall clutch plate and hub assembly as described
in "Compressor Clutch Plate and Hub Asm." Replacement
procedure.
CLUTCH COIL AND HOUSING ASSEMBLY
Remove
1. Remove clutch plate and hub assembly as described
in "Compressor Clutch Plate and Hub Asm." Removal
procedure.
2. Remove pulley and bearing assembly as described
in "Compressor Pulley and Bearing Asm." Removal
procedure.
3. Note position of terminals on coil housing
and scribe location on compressor front head
casting .
4. Remove coil housing retaining ring using Snap-Ring
Pliers J-6435 (#2 6) (Fig. 16).
5. Lift Coil and Housing assembly off compressor.
Replace
1. Position coil and housing assembly on compressor
front head casting so that electrical terminals line up with
marks previously scribed on compressor (Fig. 17).
2. Align locating extrusions on coil housing with holes
Fig. 9--Checking Air Gap
DRIVE PLATE
INSTALLER
J-9480-01
SPACER
J-9480-2
J-9396
HOLDING
FIXTURE
PULLEY
ASSEMBLY
SNAP RING
PLIERS J-6435
(#26)
RETAINER
RING
Fig. 8--lnstalling Drive Plate Fig. 10--Removing Pulley Retainer Ring

1B-6 OVERHAUL MANUAL
PULLEY A N D
BEAR IN G
ASSEMBLY
Fig. 1 1-Removing Pulley and Bearing Assembly
in front head casting.
3. nstall coil housing retainer ring with flat side of
ring facing coil , using Snap-Ring Pliers J-6435 (#26).
4. nstall pulley and bearing assembly as described in
"Compressor Pulley and Bearing Asm." Replacement
procedure.
5. nstall clutch plate and hub assembly as described
in "Compressor Clutch Plate and Hub Asm." Replacement
Procedure.
MAJOR A-6 COMPRESSOR REPAIR
PROCEDURES
Service repair procedures to the Compressor
Shaft Seal, Pressure Relief Valve and Superheat
Switch, if so equipped, or disassembly of the
Internal Compressor Mechanism are considered
"MAJOR" SINCE THE REFRIGERATION SYSTEM
MUST BE COMPLETELY PURGED OF
REFRIGERANT before proceeding, and/or
because major internal operating and sealing
components of the compressor are being
disassembled and serviced.
A clean workbench, preferably covered with
a sheet of clean paper, orderliness in the work
area and a place for all parts being removed and
Fig. 13-Removing Pulley and Bearing Retainer Ring
replaced is of great importance, as is the use of
the proper, clean service tools. Any attempt to use
make-shift or inadequate equipment may result in
damage and/or improper compressor operation.
These procedures are based on the use of the
proper service tools and the condition that an
adequate stock of service parts is available.
All parts required for servicing are protected
by a preservation process and packaged in a
manner which will eliminate the necessity of
cleaning, washing or flushing of the parts. The
parts can be used in the mechanism assembly just
as they are removed from the service package.
Piston shoe discs and shaft thrust races will
be identified by "number" on the parts
themselves for reference to determine their size
and dimension (see Fig. 41).
BEARI G
RETAI ER
U IVERSAL
HA DLE
J—8092
PULLEY A D
BEARI G
I STALLER
J—9481
UNIVERSAL HANDLE. __ _
J-8092
PULLEY & BEARING
INSTALLER
J-9398 PULLEY
ASSEMBLY
Fig. 1 2—Installing Pulley and Bearing Assembly Fig. 14-Removing Bearing from Pulley Assembly

AIR CONDITIONING 1B-7
THIS RIDGE
OF TOOL
MUST BE
UP HEN
INSTALLING
BEARING
SUPPORT
BLOCK
J -2 1
PULLEY A N D
BEARING
INSTALLER
ELECTRICAL
TERMINALS
Fig. 1 5--Installing Bearing on Pulley
SHAFT SEAL
Seal Leak Detection
A SHAFT SEAL SHOULD NOT BE CHANGED
BECAUSE OF AN OIL-LINE ON THE HOOD
INSULATOR. The seal is designed to seep some
oil for lubrication purposes. Only change a shaft
seal when a leak is detected by the following
procedure .
When refrigerant system components other than the
compressor are replaced, the compressor must be removed
and oil drained from the compressor if oil was sprayed in
large amounts due to leaks or a broken shaft seal.
Fig. 16-Removing Coil Housing Retainer Ring
Fig. 17—1 nsta lling Coil Housing
Compressor shaft seals, unless replaced during a
compressor overhaul, are to be replaced only on the basis
of actual refrigerant leakage as determined by test with leak
detector.
WHEN REPLAC NG THE SHAFT SEAL
ASSEMBLY, even if the compressor remains on the vehicle
during the operation, T W LL BE NECESSARY TO
PURGE THE SYSTEM OF REFR GERANT as outlined
earlier in the Service Manual.
Remove
1. After first purging the system of refrigerant, remove
the clutch plate and hub assembly and shaft key as described
in "Compressor Clutch Plate and Hub Asm." Removal
procedure.
2. Pry out the sleeve retainer and remove the absorbent
sleeve. Remove the shaft seal seat retaining ring, using Snap-
Ring Pliers J-5403 (#21). See Fig. 18.
3. Thoroughly clean inside of compressor neck area
surrounding the shaft, the exposed portion of the seal seat
and the shaft itself. This is absolutely necessary to
prevent any dirt or foreign material from getting
into compressor .
4. Place Seal Protector J-22974 over the end of the shaft
to prevent chipping the ceramic seat. Fully engage the
knurled tangs of Seal Seat Remover- nstaller J-23128 into
the recessed portion of the seal seat by turning the handle
clockwise . Lift the seat from the compressor with a
rotary motion (Fig. 19).
CAUTION: DO NO T tighten the handle with a
wrench or pliers; however, the handle must be
hand-tightened securely to remove the seat.
5. With Seal Protector J-22974 still over the end of the
shaft, engage the tabs on the seal assembly with the tangs
Clutch Coil and
HousinaAssembly
Retain er Ring

1B-8 OVERHAUL MANUAL
Fig. 18-Removing or Installing Shaft Seal Seat Retaining
Ring
on Seal nstaller J-9392 by twisting the tool clockwise,
while pressing the tool down . Then lift the seal
assembly out (see Fig. 20).
6. Remove the seal seat O-ring from the compressor
neck using O-Ring Remover J-9533 (See Fig. 19).
7. Recheck the shaft and inside of the compressor neck
for dirt or foreign material and be sure these areas are
perfectly clean before installing new parts.
Inspection
SEALS SHOULD NOT BE REUSED. AL AYS
USE A NE SEAL KIT ON REBUILD. Be
extremely careful that the face of the seal to be
installed is not scratched or damaged in any way
. Make sure that the seal seat and seal are free of lint and
dirt that could damage the seal surface or prevent sealing.
Replace
1. Coat new seal seat O-ring with clean 525 viscosity
refrigerant oil and install in compressor neck, making
certain it is installed in bottom groove (Fig. 20 and
Fig. 21). Top groove is for retainer ring. Use O-Ring
nstaller J-21508.
2. Coat the O-ring and seal face of the new seal
assembly with clean 525 viscosity refrigerant oil. Carefully
mount the seal assembly to Seal nstaller J-9392 by engaging
the tabs of the seal with the tangs of the tool (Fig. 20).
3. Place Seal Protector J-22974 (Fig. 20) over end of
shaft and carefully slide the new seal assembly
onto the shaft. Gently twist the tool CLOCK
ISE, while pushing the seal assembly down the
shaft until the seal assembly engages the flats on the shaft
and is seated in place. Disengage the tool by pressing
downward and twisting tool counterclockwise.
O-RING
INSTALLER
J-21508
SEAL
INSTALLER
J-9392^
SEAL
PROTECTOR
J-22974
Fig. 20--Replacing Seal and O-Ring
SEAL ASSEMBLY
ABSORBENT SLEEVE
SLEEVE RETAINER
SEAL SEAT
RETAINER RING
SEAL SEAT
O RING
1/32" (APPROX.) S
-------- r - ----------
STRAIGHT EDGE
IRE GAGE
.026 SHOULD "GO"
.075 SHOULD "NOT GO'
Fig. 19--Removing Shaft Seal Seat and O-Ring Fig. 2 1--Compressor Shaft and Seal

AIR CONDITIONING 1B-9
LEAK TEST
ADAPTER
J-9625
OIL FITTING
Fig. 22--Leak Testing A-6 Compressor
4. Coat the seal face of the new seal seat with clean 525
viscosity refrigerant oil. Mount the seal seat on Seal Seat
Remover- nstaller J-23128 and install it in the compressor
neck, taking care not to dislodge the seal seat O-ring and
being sure the seal seat makes a good seal with the O-ring.
Remove Seal Protector J-22974 from the end of the shaft
(see Fig. 19).
5. nstall the new seal seat retainer ring with its flat
side against the seal seat , using Snap-Ring Pliers J-
5403 (#21). See Fig. 18. Use the sleeve from Seal Seat
Remover- nstaller J-23128 (Fig. 19) to press in on the seal
seat retainer ring so that it snaps into its groove.
6. nstall Compressor Leak Test Fixture J-9625 on rear
head of compressor and connect gage charging lines as
shown for bench test in Fig. 22 or pressurize SUCT ON
S DE of compressor on car with Refrigerant-12 vapor to
equalize pressure to the drum pressure. Temporarily install
the shaft nut and, with compressor in horizontal position
and oil sump down, rotate the compressor shaft in normal
direction of rotation several times by hand. Leak test the
seal with a Leak Detector. Correct any leak found. Remove
and discard the shaft nut.
7. Remove any excess oil, resulting from installing the
new seal parts, from the shaft and inside the compressor
neck.8. nstall the new absorbent sleeve by rolling the
material into a cylinder, overlapping the ends, and then
slipping the sleeve into the compressor neck with the
overlap towards the top of the compressor. With a small
screwdriver or similar instrument, carefully spread the
sleeve until the ends of the sleeve butt at the top vertical
centerline.
9. Position the new metal sleeve retainer so that its
flange face will be against the front end of the sleeve. Pulley
Puller Pilot J-9395 (See Fig. 11) may be used to install the
retainer. Press and tap with a mallet, setting the retainer and
sleeve into place (retainer should be recessed approximately
1/32" from the face of the compressor neck). See Fig. 21.
10. Reinstall the clutch plate and hub assembly as
described in "Compressor Clutch Plate and Hub Asm."
Replacement procedure.
Some compressor shaft seal leaks may be the
result of mispositioning of the axial plate on the
compressor shaft. The mispositioning of the axial plate
may be caused by improper procedures used during pulley
and driven plate removal, pounding, collisions or dropping
the compressor. f the axial plate is mispositioned, the
carbon face of the shaft seal assembly may not contact the
seal seat and the rear thrust races and bearing may be
damaged.
f there appears to be too much or insufficient air gap
between the drive and driven plates, dislocation of the shaft
should be suspected. f the carbon seal is not seating against
the seal seat, it will not be possible to completely evacuate
the system.
To check for proper positioning of the axial plate on
the shaft, remove the clutch driven plate and measure the
distance between the front head extension and the flat
shoulder on the shaft as shown in Fig. 21. To measure this
distance, use a wire gage (the clearance should be
between .026" and .075"). f the shaft has been pushed
back in the axial plate (measurement greater than .075"),
disassemble the compressor and replace the shaft and axial
plate assembly rear thrust races and thrust bearing.
11. Evacuate and charge system.
PRESSURE RELIEF VALVE
When necessary to replace the pressure relief valve,
located in the compressor rear head casting, the valve
assembly should be removed after PURG NG THE
SYSTEM OF REFR GERANT and a new valve and gasket
installed. The entire system should then be "Evacuated and
Recharged." (Fig. 23).
INTERNAL MECHANISM
Service operations to the rear head or internal
mechanism of the compressor should be performed
with the compressor removed from the vehicle to
insure that the necessary degree of cleanliness may be
maintained. Clean hands, clean tools and a clean bench,
preferably covered with clean paper, are of extreme
importance.
An inspection should be made of the internal
mechanism assembly to determine if any service operations
should be performed. A detailed inspection of parts should
be made to determine if it is economically feasible to replace
them.
Remove
1. Before proceeding with disassembly, wipe exterior
surface of compressor clean.
2. All oil in compressor should be drained and
measured. Assist draining by positioning compressor with
oil drain plug down. Record the amount of oil drained
from the compressor.
Fig. 23—Hi. Press. Relief Valve Location
DISCHARGE SYSTEM BEFORE
REMOVING HIGH PRESSURE
RELIEF VALVE
HI. PRESS.
RELIEF
VALVE
REAR HEAD

IB-10 OVERHAUL MANUAL
Fig. 24-Compressor Installed in Holding Fixture
REAR
HEAD
SHELL
HOLDING
FIXTURE
3. nvert compressor and Holding Fixture J-9396 with
front end of compressor shaft facing downward. (Fig. 24).
Additional oil may leak from compressor at this time.
All oil must be drained into a container so that TOTAL
amount can be measured. A liquid measuring cup may be
used for this purpose. Drained oil should then be discarded.
4. Remove four locknuts from threaded studs on
compressor shell and remove rear head. Tap uniformly
around rear head if head is binding. (Fig. 24)
5. Wipe excess oil from all sealing surfaces on rear head
casting webs, and examine sealing surfaces (Fig. 25). f any
damage is observed, the head should be replaced.
6. Remove suction screen and examine for any damage
or contamination. Clean or replace if necessary.
7. Paint an identifying mark on exposed face of inner
and outer oil pump gears and then remove gears. dentifying
marks are to assure that gears, if reused, will be installed
REAR DISCHARGE REED RETAINERS
Fig. 26-Removing Rear Discharge Valve Plate
on identical position.
8. Remove and discard rear head to shell O-ring.
9. Carefully remove rear discharge valve plate
assembly. Use two small screwdrivers under reed retainers
to pry up on assembly (Fig. 26). Do not position
screwdrivers between reeds and reed seats .
10. Examine valve reeds and seats. Replace entire
assembly if any reeds or seats are damaged.
11. Using two small screwdrivers, carefully remove
rear suction reed (Fig. 27). Do not pry up on horseshoe
shaped reed valves .
12. Examine reeds for damage, and replace if necessary.
13. Using Oil Pick-Up Tube Remover J-5139 (Fig. 28),
remove oil pick-up tube. Remove O-ring from oil inlet.
14. Loosen compressor from Holding Fixture J-9396,
place nternal Assembly Support Block J-21352 over oil
pump end of shaft and, holding Support Block in position
with one hand, lift compressor from Holding Fixture with
other hand. nvert compressor and position on bench with
nternal Assembly Support Block resting on bench.
15. Lift front head and compressor shell assembly up,
leaving internal mechanism resting on nternal Assembly
Support Block.
CAUTION: To prevent damage to shaft, DO NO T
TA ON END OF COM RESSOR SHAFT to
remove internal mechanism. I f mechanism will
not slide out o f compressor shell, tap on front head
with a plastic hammer.
16. Rest compressor shell on its side and push front
head assembly through compressor shell, being careful
not to damage sealing areas on inner side of front
EA LING
SURFACES
U C T IO N SCREEN
EAR HEAD
HELL TO HEAD
O ' R IN G
OIL PUMP
RO TO RS
Rear
Suction Reed
Fig. 25-Rear Head Removal Fig. 27-Removing Rear Suction Reed

■|
AIR CONDITIONING IB-11
OIL PICK-UP TUBE REMOVER J-5139
OIL PICK-UP TUBE
Fig. 28--Removing Oil Pick-Up Tube
head. Discard O-ring.
t may be necessary to tap on outside of front head,
using a plastic hammer, to overcome friction of O-ring seal
between front head and compressor shell.
17. Wipe excess oil from sealing surfaces on front head
casting webs and examine sealing surface. f any surface
damage is observed, the head should be replaced.
18. Remove front discharge valve plate assembly and
front suction reed plate. Examine reeds and seats. Replace
necessary parts.
19. Remove suction cross-over cover by prying with
screwdriver between cylinder casting and cover (Fig. 29).
20. Examine internal mechanism for any obvious
damage. f internal mechanism has sustained major damage,
due to loss of refrigerant or oil, it may be necessary to use
the Service internal mechanism Assembly rather than
replace individual parts.
INTERNAL MECHANISM
Disassembly
Use Parts Tray J-9402 (Fig. 33) to retain compressor
parts during disassembly.
1. Remove internal mechanism from compressor as
described in "Compressor nternal Mechanism" Removal
procedure.
2. dentify by pencil mark, or some other suitable
means, each piston numbering them as 1,2, and 3 (Fig. 30).
Number the piston bores in the front cylinder half in
like manner, so that pistons can be replaced in their original
locations.
3. Separate cylinder halves, using a wood block and
mallet (Fig. 31). Make certain that discharge cross-over tube
does not contact axial plate when separating cylinder halves
(a new Service discharge cross-over tube will be installed
later).
CAUTION: UNDER NO CIRCUMSTANCES
SHOULD SHAFT BE STRUCK A T EITHER
END in an effort to separate upper and lower
cylinder halves because the shaft and the axial
plate could be damaged.
4. Carefully remove the rear half of the cylinder from
the pistons and set the front cylinder half, with the piston,
shaft and axial plate in Compressing Fixture J-9397.
5. Pull up on compressor shaft and remove piston
previously identified as No. 1, with balls and shoe discs,
from axial plate.
a. Inspect the Teflon piston rings for nicks, cuts
or metal particles imbedded in exposed ring surface and
Fig. 30- umbering Piston and Cylinder Bores
Piston Front
Cylinder Half
SUPPORT
CYLINDER
ASSEMBLY
SUCTION
PASS COVER
Fig. 29-Removing Suction Cross Over Cover Fig. 3 1--Separating Cylinder Halves

IB-12 OVERHAUL MANUAL
TEFLON RING GROOVE
(PISTON FRONT END)
Fig. 32-- otch Identifying Front End of A-6 Piston
replace the piston rings as required if either condition exists.
See "Teflon Piston Ring" Replacement procedure.
6. Remove and discard the piston shoe discs.
7. Remove and examine piston balls, and if satisfactory
for re-use, place balls in No. 1 compartment of Parts Tray
J-9402 (Fig. 33).
8. Place piston in No. 1 compartment of Parts Tray
J-9402, with notch in casting web at front end of piston (Fig.
32) into the dimpled groove of Parts Tray compartment.
9. Repeat Steps 5 through 9 for Pistons No. 2 and No.
3. 10. Remove rear combination of thrust races and thrust
bearing from shaft. Discard races and bearing.
11. Remove shaft assembly from front cylinder half. f
the discharge cross-over tube remained in the front cylinder
half, it may be necessary to bend discharge cross-over tube
slightly in order to remove shaft.
12. Remove front combination of thrust races and
bearing from shaft. Discard races and bearing.
13. Examine surface of axial plate and shaft. Replace
as an assembly , if necessary.
A certain amount of shoe disc wear on axial plate is
normal, as well as some markings indicating load of needle
bearings on shaft.
14. Remove discharge cross-over tube from cylinder
half, using self-clamping pliers.
This is necessary only on original factory
equipment, as ends of the tube are swedged into cylinder
halves. The discharge cross-over tube in internal mechanism
assemblies that have been previously serviced have an O-
ring and bushing at EACH END of the tube, and can be
easily removed by hand (see Fig. 53).
15. Examine piston bores and needle bearings in front
Fig. 34--Removing Front Thrust Races and Bearings
and rear cylinder halves. Replace front and rear cylinders
if any cylinder bore is deeply scored or damaged.
16. Needle bearings may be removed if necessary by
driving them out with special Thin-Wall Socket J-9399.
nsert socket in hub end (inner side) of cylinder head and
drive bearing out. To install needle bearing, place cylinder
half on Support Block J-21352, and insert bearing in end
of cylinder head with bearing identification marks UP.
Use Needle Bearing nstaller J-9432 and drive bearing into
cylinder head (Fig. 35), until tool bottoms on the cylinder
face.
Two different width needle bearings are used in
Production compressors - a 1/2" size and a 5/8" size. The
bearings ARE interchangeable. Service replacement
bearings are all 1/2".
17. Wash all parts to be re-used with trichlorethylene,
Stoddard solvent, kerosene, or a similar solvent. Air-dry
parts using a source of clean, dry air.
Compressor internal components may be identified by
referring to Fig. 1 and Fig. 2.
Thrust Races
SUPPORT
BLOCK J-21352
Needle Bearing
Installer J-9432
Needle Bearing
Cylinder
Head
SUPPORT
BLOCK J-21352
Fig. 33--A-6 Parts Tray Fig. 3 5--I nsta 11 i ng eedle Bearing

AIR CONDITIONING 1B-13
Thrust Bearing
Fig. 36—Installing Rear Thrust Races and Bearings
INTERNAL MECHANISM
Gaging Operation
1. nstall Compressing Fixture J-9397 on Holding
Fixture J-9396 iri vise. Place front cylinder half in
Compressing Fixture, flat side down. Front cylinder half has
long slot extending out from shaft hole.
2. Secure from Service parts stock four ZERO thrust
races and three ZERO shoe discs.
3. nstall a ZERO thrust race, thrust bearing, and a
second ZERO thrust race on front end of compressor shaft.
Lubricate races and bearing with petrolatum.
4. nsert threaded end of shaft through needle bearing
in front cylinder half, and allow thrust race and bearing
assembly to rest on hub of cylinder.
5. Now install a ZERO thrust race on rear end of
compressor shaft (Fig. 36), so that it rests on hub of axial
plate. Then install thrust bearing and a second ZERO thrust
race. Lubricate races and bearing with petrolatum.
6. Lubricate ball pockets of the No. 1 Piston with 525
viscosity refrigerant oil and place a ball in each socket. Use
balls previously removed if they are to be re-used.
7. Lubricate cavity of a ZERO shoe disc with 525
viscosity refrigerant oil and place shoe disc over ball in
front end of piston (Fig. 37). Front end of piston has
an identifying notch in casting web (Fig. 32).
CAUTION: Exercise care in handling the iston
and Ring Assembly, particularly during assembly
into and removal from the cylinder bores to
prevent damage to the Teflon piston rings.
Shoe discs should not be installed on rear of
piston during following "Gaging" operation.
8. Rotate shaft and axial plate until high point of axial
plate is over the No. 1 Piston cylinder bore.
9. Lift shaft assembly up and hold front thrust race and
bearing assembly against axial plate hub.
10. Position piston over No. 1 cylinder bore (notched
end of piston being on bottom and piston straddling axial
plate) and lower the shaft to allow piston to drop into its
bore (Fig. 38).
11. Repeat Steps 6 through 10 for Pistons No. 2 and
No. 3.
12. nstall rear cylinder half on pistons, aligning
cylinder with discharge cross-over tube hole in front
cylinder. Tap into place using a plastic mallet or piece of
Holding
Fixture J-99396
Compressing
Fixture J-9397 BALL
Fig. 37—1 nsta lling FRO T Shoe Disc
clean wood and hammer (Fig. 39).
13. Position discharge cross-over tube opening between
a pair of Compressing Fixture bolts to permit access for
feeler gage.
14. nstall top plate on Compressing Fixture J-9397.
Tighten nuts to 15 lb. ft. torque using a 0-25 lb. ft. torque
wrench.
Gaging Procedure (Steps 15 thru 18)
The gaging operations which follow have been worked
out on a simple basis to establish and provide necessary
running tolerances. Two gaging procedures are necessary.
The first is made to choose the proper size shoe discs
to provide, at each piston, a .0016" to .0024" total preload
between the seats and the axial plate at the tightest place
through the 360-degree rotation of the axial plate at the
tightest plate. The bronze shoe discs are provided in .0005"
variations, including a basic ZERO shoe.
The second , performed at the rear shaft thrust
bearing and race pack, is designed to obtain .0025" to .0030"
preload between the hub surfaces of the axial plate and the
front and rear hubs of the cylinder. A total of 14 steel thrust
races, including a basic ZERO race, are provided in
increments of .0005" thickness to provide the required fit.
Feeler Gage Set J-9564 or J-9661-01 may be used for
gaging proper shoe disc size. Feeler Gage Set J-9564-01 or
PISTON DRIVE
BALL ONLY
AT REAR FR O N T THRU S T
RACES
AND BE ARING
REAR NEEDLE
THRUST BEARING
AND "ZERO" THRUST
RACES
PISTON DRIVE
BALL AND
'ZERO” SHOE
DISC AT FRONT FRONT CYLINDER
Fig. 3 8—1 nsta lling Piston During Gaging Operation

IB-14 OVERHAUL MANUAL
Fig. 39-Assembling Cylinder Halves
Dial ndicator Set J-8001-3 may be used to determine proper
thrust race size.
PROPER SELECT ON OF THRUST RACES AND
BALL SEATS S OF EXTREME MPORTANCE.
15. Measure clearance between rear ball of No. 1 Piston
and axial plate, in following manner:
a. Select a suitable combination of well-oiled Feeler
Gage leaves to fit snugly between ball and axial plate.
b. Attach a spring scale, reading in 1-ounce increments,
to the feeler gage. A distributor point checking scale or
Spring Scale J-544 may be used.
c. Pull on Spring Scale to slide Feeler Gage stock out
from between ball and axial plate, and note reading on
Spring Scale as Feeler Gage is removed (Fig. 40). Reading
should be between 4 and 8 ounces.
d. f reading in Step c. above is under 4 OR over 8
ounces, reduce or increase thickness of Feeler Gage leaves
and repeat Steps a. through c. above until a reading of 4 to
8 ounces is obtained. Record clearance between ball and
axial plate that results in the 4 to 8-ounce pull on Spring
Scale.
16. Now rotate shaft 120° and repeat Step 15 between
same ball and axial plate. Record this measurement.
f shaft is hard to rotate, install shaft nut onto shaft and
turn shaft with wrench.
17. Rotate shaft another 120° and again repeat Step 15
between these same parts and record measurements.
18. Select a "numbered" shoe disc corresponding to
minimum feeler gage reading recorded in the three checks
above. (See example in Fig. 42). Place shoe discs in Parts
Tray J-9402 compartment corresponding to Piston No. 1
and rear ball pocket position.
Shoe discs are provided in .0005" (one-half
thousandths) variations, There are a total of 11 sizes
available for field servicing. All shoe discs are marked with
the shoe size, which corresponds to the last three digits of
the piece part number. (See Shoe Disc size Chart in Fig. 41
above.)
Once a proper selection of the shoe has been
made, THE MATCHED COMBINATION OF SHOE
DISC TO REAR BALL AND SPHERICAL CAVITY
IN PISTON MUST BE KEPT IN PROPER
RELATIONSHIP during disassembly after gaging
operation, and during final assembly of internal
mechanism.
19. Repeat in detail the same gaging procedure outlined
in Steps 15 through 18 for Piston No. 2 and No. 3.
20. Mount Dial ndicator J-8001-3 on edge of
Compressing Fixture J-9397 with Clamp J-8001-1 and
Sleeve J-8001-2 (Fig. 43). Position Dial ndicator on rear
end of shaft and adjust to "zero".
Apply full hand-force at end of mainshaft a few times
before reading clearance. This will help squeeze the oil out
from/between mating parts. Push upward and record
measurement. Dial ndicator increments are .001";
therefore, reading must be estimated to nearest .0005".
An alternate method of selecting a proper race is to use
Gage Set J-9661-01, selecting a suitable feeler gage leaf until
the result is a 4 to 8 ounce pull on the scale between the
rear thrust bearing and upper (or outer rear) thrust race
(Fig. 44). f the pull is just less than 4 ounces, add .0005"
to the thickness of the feeler stock used to measure the
clearance. f the pull on the scale reads just over 8 ounces,
then subtract .0005" from the thickness of the feeler stock.
Select a race T O (2) FULL SIZES LARGER than
feeler gage thickness ( f feeler gage is .007", select a
No. 9 or 090 race).
21. Select a thrust race with a "number"
corresponding to T O (2) FULL SIZES LARGER
than Dial Indicator or feeler gage measurement of
the amount of end play shown. ( f measurement is
.007", select a No. 9 or 090 race). Place thrust race in
right-hand slot at bottom center of Parts Tray J-
9402 .
Fifteen (15) thrust races are provided in increments of
.0005" (one-half thousandths) thickness and one ZERO
gage thickness, providing a total of 16 sizes available for
field service. Thrust races are identified on the part by their
thickness in thousandths, in excess of the thickness of the
ZERO thrust race.
This "number" also corresponds to the last three digits
of the piece part number. See Thrust Race size Chart in Fig.
41.
AXIAL PLATE REAR BALL
FEELER GA G ES
Fig. 40--Gaging Rear Piston Ball