Chevrolet chevrolet 1973 User manual

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 some warnings against the use of specific service
methods that can damage the vehicle or render it unsafe are stated in this
service manual. t is also important to understand these warnings 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.

r

1973
OVERHAUL MANUAL
covering
CHEVROLET, CHEVELLE,
MONTE CARLO, NOVA,
CAMARO, CORVETTE
and
LIGHT DUTY
(SERIES 10-30)
CHEVROLET TRUCKS
FOREWORD
This manual includes procedures involved in disassembly
and assembly of major components of 1973 Chevrolet,
Chevelle, Monte Carlo, ova, Camaro, Corvette and Light
Duty Trucks. Information on theory of operation, diag
nosis, maintenance and adjustments, minor service opera
tions, and removal and installation for these components is
contained in either the 1973 Passenger Car or 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, while Specifications covering
vehicle components are presented at the rear of the manual.
This manual should be kept in a handy place for ready
reference. If properly used, it will enable the technician to
better service the owners of Chevrolet built vehicles.
All information, illustrations and specifications con
tained in this literature are based on the latest product
information available at the time of publication approval.
The right is reserved to make changes at any time without
notice.
CHEVROLET MOTOR DIVISION
eneral Motors Corporation
DETROIT, M IC H I A N
SEC TIO N IN D E X
SECTION NAME
1AIR CONDITIONING
COMPRESSOR
34-WHEEL DRIVE
FRONT AXLE DIFFERENTIAL
4REAR AXLE
DIFFERENTIAL CARRIER
5POWER BRAKE
CYLINDER
6ENGINE
6M CARBURETORS
6Y STARTING MOTOR
SOLENOID AND
DELC0TR0N
7TRANSMISSION
AND CLUTCH,
4-WHEEL DRIVE
TRANSFER CASE
9STEERING GEAR,
POWER STEERING
PUMP AND CONTROL
VALVE
SPECIFICATIONS
(c 1972 General Motors Corporation Printed in U.S.A.

AIR CONDITIONING COMPRESSOR 1-1
SECTION 1
AIR CONDITIONING
COMPRESSOR
INDEX
Minor Repair Procedures .. 1-1
Hub and Drive Plate ..................................................... .. 1-1
Pulley and Bearing Assembly ..................................... .. 1-2
Coil Housing Assembly................................................. .. 1-3
Major Repair Procedures .. 1-4
Shaft Seal Assembly ...................................................... .. 1-5
For all practical purposes all vehicles make use of the
same air conditioning compressor. Actual differences
between compressors are found in their mounting
brackets, pulleys, connector assemblies and compressor
capacities, none of which affect the following Overhaul
Procedures.
MINOR REPAIR PROCEDURES
The following operations to the Hub and Drive Plate,
Pulley and Bearing, and Coil Housing are covered as
"Minor" because they may be performed without first
purging the system or removing the compressor from the
vehicle. The shaft seal assembly, pressure relief valve
and superheat switch, may also be serviced without
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.
llustrations used in describing these operations show the
compressor removed from the vehicle to more clearly
illustrate the various operations.
Hub and Drive Plate
Removal
1. f disassembly is being performed on a bench,
mount Holding Fixture J-9396 in a vise and attach
the compressor to the fixture.
2. Using Clutch Hub Holding Tool J-9403 and Socket
J-9399, remove the locknut from the shaft (fig. 2).
Discard locknut.
3. Tool J-9401 may now be used to remove the hub
and drive plate assembly (fig. 3).
NOTE: Carefully snug tool into place with
wrench to insure engagement with threads.
4. Use Snap Ring Pliers J-5403 to remove the retainer
ring ( tem 39, fig. 1). Then remove the hub spacer.
Inspection
f the frictional surface shows signs of damage due to
Compressor Rear Head and nternal Mechanism 1-7
Pressure Relief Valve ..................................................... .... 1-7
Superheat Switch.............................................................. .... 1-8
Rear Head, Oil Pump and Valve Assemblies ......... 1-8
Major nternal Mechanism ......................................... .... 1-9
Leak Testing the Compressor ..................................... .... 1-14
Special Tools .... 1-15
excessive heat, the hub and drive plate and the pulley
should be replaced. Check further for the underlying
cause of the damage, i.e. low coil voltage or binding of
the compressor internal mechanism.
Installation
NOTE: When hub and drive plate assembly
is ready for installation, clean its frictional
face with a suitable cleaner.
1. nsert the square hub and drive plate key into the
keyway in the drive shaft allowing it to project
approximately 3/16" out of the end of the keyway
(fig- 4).
2. Line up the key in the shaft with the keyway in the
hub.
3. Using Tool J-9480 and Washer J-9480-2 (fig. 5), install
the hub and drive plate assembly. Pull the assembly onto
the shaft until there is approximately 3/32” space be
tween the frictional surfaces of the drive plate and
pulley. (A ZERO thrust race is approximately 3/32”
thick and may be used to roughly gauge this operation.)
NOTE: Use Tool J-9403 to hold hub and
drive plate if necessary.
4. nstall the hub spacer washer and, using Snap Ring
Pliers J-5403, install the retainer ring ( tem 39, fig.
1), convex side of ring facing washer.
5. Use Tools J-9399 and J-9403 to install a new
locknut. Tighten the nut to 14-26 ft. lbs. torque. Air
gap between the frictional faces should now be
.022" to .057".
NOTE: The shoulder or circular projection
on the locknut must face towards retainer
ring.
6. The pulley should now rotate freely.
CAUTION: Never pound or drive the hub and
drive plate into position. Always use the proper
tools when removing or replacing clutch parts.
Failure to do so may result in serious internal

1-2 AIR CONDITIONING COMPRESSOR
1. Rear Head 15. Pulley and Bearing Assembly 28. Thrust Bearing
2. Rear Head to Shell " 0 " Ring 16. Pulley Bearing 29. Thrust Race
3. Rear Discharge Valve Plate 17. Pulley Bearing Retainer Ring 30. Compressor Shell
4. Rear Suction Reed Plate 18. Pulley and Bearing Retainer Ring 31. Cylinder Assembly
5. Piston Ring 19. Clutch Hub and Drive Plate Assembly 32. Shaft Seal
6. Piston Drive Ball 20. Super Heat Switch, “0 " Ring and 33. Shaft Seal Seat “0 " Ring
7. Ball Seat Retainer Ring 34. Shaft Seal Seat
8. Piston 21. High Pressure Relief Valve 35. Shaft Seal Seat Retainer Ring
9. Front Suction Reed Plate 22. Oil Pump Gears 36. Absorbent Sleeve
10. Front Discharge Valve Plate 23. Mainshaft Bearing (Rear 37. Absorbent Sleeve Retainer
11. Front Head to Shell “0 ” Ring 24. Oil Inlet Tube " 0 " Ring 38. Spacer
12. Front Head 25. Oil Inlet Tube 39. Clutch Hub Retainer Ring
13. Coil and Housing Assembly 26. Wobble Plate and Mainshaft Assembly 40. Shaft Nut
14. Coil Housing Retainer Ring 27. Thrust Race
Fig. 1 -Six Cylinder Compressor- Cross Sectional View
compressor damage and seal leakage due to
shift of crankshaft.
7. Operate the refrigeration system and rapidly cycle
the clutch (by turning the air conditioning off and
on at least 20 times at approximately one second
intervals) to seat the mating parts of the clutch.
Pulley and Bearing Assembly
Removal
f
1. Remove the hub and drive plate assembly.
2. Using Snap Ring Pliers J-6435, remove the pulley
and bearing retainer ring (fig. 6).
3. Remove shaft key.
4. Place Puller Pilot J-9395 over the compressor shaft
and pull off the pulley assembly using J-8433 pulley
puller (fig. 7).
Inspection
Check the appearance of the pulley and bearing
assembly. f the frictional surface of the pulley shows
OVERHAUL MANUAL

AIR CONDITIONING COMPRESSOR 1-3
Fig. 2--Removing Sha t Locknut
signs of excessive grooving due to slippage, both the
pulley and the clutch hub and drive plate assembly
should be replaced. The frictional surfaces of the pulley
and bearing assembly should be cleaned with a suitable
solvent before reinstallation.
Bearing Replacement
1. With the pulley and bearing assembly removed
from the compressor, use a sharp pointed
instrument to remove the wire retainer ring.
CAUTION: If the bearing is to be reused be
careful not to slip and damage the seal.
2. From the rear of the ‘pulley, press or drive bearing
out of pulley using Tool J-9398 and Handle J-8092.
3. From the front of the pulley and using Tool J-9481
with Handle J-8092, press or drive the new bearing
into the pulley.
Installation
1. Using Tool J-9481, press or drive the pulley and
bearing assembly onto the compressor neck. The
pulley should now rotate freely.
2. nstall retainer ring using Snap Ring Pliers J-6435.
3. nstall the wire bearing retainer ring.
4. Replace the hub and drive plate assembly. Use
proper tools. DO NOT drive or pound on the hub
assembly.
Coil Housing Assembly
Removal
1. Remove the hub and drive plate assembly, the
pulley and bearing assembly, and electrical
connector.
2. Scribe the location of the coil housing to the
Fig. 3-Removing Hub and Drive Plate Assembly
Fig. 4-Drive Plate Key Installed in Keyway
compressor body. This operation is to insure that
the electrical terminals will be reassembled in the
same position.
3. Using Snap Ring Pliers J-6435, remove the coil
housing retainer ring (fig. 8).
4. Remove the coil housing assembly.
Inspection
Check coil for loose connectors or cracked insulation.
Amperage should not be more than 3.2 amps at 12 volts
D.C. at room temperature.
Installation
1. Rotate the coil housing to the correct position as
indicated by the scribe marks and the location of
the electrical terminals and fit into place (fig. 9).
2. Use Snap Ring Pliers J-6435 to install retainer ring.
NOTE: nstall flat surface of the retainer
ring facing the coil housing.
3. Replace the pulley and bearing assembly and the
hub and drive plate assembly. DO NOT drive or
pound on the hub assembly.
4. f the compressor is installed in the vehicle, connect
the electrical connections.

1-4 AIR CONDITIONING COMPRESSOR
Fig. 6--Removing Pulley and Bearing Assembly
Retainer Ring
Fig. 5 -Installing Hub and Drive Plate Assembly
MAJOR REPAIR PROCEDURES
The following service procedures 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 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. Service parts stock should
include the following:
1. Major interior mechanism assembly—ready for
installation in shell as is.
2. Service cylinder assembly-front and rear halves
with main bearings in place and halves dowel
pinned together.
3. Piston drive balls.
4. Ball seats—total of 10 sizes, including the ZERO
seat.
5. Thrust races-total of 14 sizes, including the ZERO
race.
6. Pistons-low and high compression.
7. Piston rings.
8. Main shaft bearings.
9. Thrust bearings.
10. Compressor shaft and wobble plate.
11. Suction reed valves.
12. Discharge valve plate-front and rear.
13. Compressor front head.
14. Compressor rear head.
15. Pulley and pulley bearing.
16. Clutch hub and drive plate assembly.
17. Seal kit—service—contains all seals and "O"
rings.(a)
18. Shaft seal kit.(a)
19. Nuts—head to shell, and shaft.(a)
20. Retainer rings—all necessary sizes.
21. Cylinder locator (dowel) pins.
Fig. 7--Removing Pulley
OVERHAUL MANUAL

AIR CONDITIONING COMPRESSOR 1-5
22. Valve and head locator (dowel) pins.
23. Service discharge crossover tube kit.
(a)To be used each time a compressor is rebuilt.
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 ball seats and shaft thrust races will be identified
on the parts themselves to denote their size and
dimension.
Shaft Seal Assembly
When replacing the shaft seal assembly, even if the
compressor remains on the vehicle during the operation,
it will be necessary to purge the system of refrigerant as
outlined in the Chassis Service Manual.
Removal
1. After first purging the system of refrigerant,
remove the clutch hub and drive plate, and the
shaft key.
2. Pry out the sleeve retainer and remove the
absorbent sleeve. Remove the seal seat retaining
ring using Snap Ring Pliers J-5403.
3. Thoroughly clean the area of the compressor neck
surrounding the shaft, the exposed portion of the
seal seat, and the shaft itself of any dirt or foreign
material before removing the seal seat.
Fig. 9—Installing Coil Housing
4. Place Tool J-22974 over the end of the shaft to
prevent chipping the ceramic seat. Fully engage the
knurled tangs of Tool 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. 11).
CAUTION: D N T tighten the handle with a
wrench or pliers; however, the handle must be
hand tightened securely to remove the seat.
5. With Tool J-22974 still over the end of the shaft,
engage the tabs on the seal assembly with the tangs
on Tool J-9392 by twisting the tool clockwise while
pressing the tool down. Then lift the seal assembly
out.
6. Remove the seal seat "O" ring from the compressor
neck using Tool J-9553 (fig. 11).
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. Always use a new 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.

1-6 AIR CONDITIONING COMPRESSOR
1. Shaft Nut 16. Shaft Seal Seat 29. Drive Key 44. Discharge Crossover
2. Clutch Hub Retainer Retainer Ring 30. Discharge Crossover Tube Rear " 0 " Ring
Ring 17. Shaft Seal Seat Tube and Spacer
3. Spacer 18. Shaft Seal 31. Piston Ring 45. Rear Suction Reed
4. Clutch Hub and Drive 19. Shaft Seal Seat " 0 " 32. Piston Front Drive Plate
Plate Assembly Ring Ball 46. Rear Discharge Valve
5. Pulley and Bearing 20. Compressor Front 33. Piston Front Ball Plate
Retainer Ring Head Seat 47. Oil Pump Drive Gear
6. Pulley Bearing 21. Front Discharge 34. Piston 48. Oil Pump Driven Gear
Retainer Ring Valve Plate 35. Piston Rear Ball Seat 49. Rear Head-to-Shell
7. Pulley Bearing 22. Front Suction Reed 36. Piston Rear Drive "O ” Ring
8. Pulley Valve Ball 50. Strainer Screen
9. Coil Housing Retainer 23. Discharge Crossover 37. Piston Ring 51. Compressor Rear
Ring Tube Front " 0 ” Ring 38. Drive Shaft and Head
10. Coil Housing and Spacer Wobble Plate 52. Superheat Switch,
11. Compressor Shell 24. Mainshaft Front Assembly " 0 " Ring and
12. Absorbent Sleeve Bearing 39. Rear Thrust Race and Retainer R ing
13. Absorbent Sleeve 25. Head Locating Pins Bearing Pack 53. High Pressure Relief
Retainer 26. Front Cylinder Half 40. Rear Cylinder Half Valve and "0 " R ing
14. Oil Drain Plug and
Gasket 27. Front Thrust Race
and Bearing Pack 41. Oil Inlet Tube " 0 "
Ring
54. Rear Head-to-Shell
Retaining Nuts
15. Front Head-to-Shell 28. Suction Crossover 42. Oil Inlet Tube 55. Compressor-to-
"O" Ring Cover 43. Mainshaft Rear
Bearing
Connector “O '” Ring
Fig. 10-Six Cylinder Compressor-Exploded View
Apparent seal leaks are sometimes the result of
mispositioning of the wobble plate on the compressor
shaft caused by improper procedures during pulley
removal, pounding or dropping on the compressor shaft
or collision impact. Check as shown in Figure 12. f
measurement is greater than shown, replace the shaft
and wobble plate assembly.
Installation
1. Coat the new shaft seal seat "O" ring with clean
Frigidaire 525 viscosity refrigeration oil (or
equivalent) and install in the compressor neck
groove using Tool J-21508 (fig. 13).
NOTE: Refrigeration oil has been specially
dehydrated and therefore has a great affinity
for the moisture in the atmosphere. NEVER
leave the refrigeration oil bottle uncapped
for more than a few moments or oil
contamination will result.
2. Coat the "O" ring and seal face of the new shaft
seal assembly with clean refrigeration oil and
carefully engage the seal assembly onto the locking
tangs of Tool J-9392 (fig. 13). Place shaft Seal
Protector J-22974 over the end of the shaft and
slide the seal down the shaft, turning the tool
clockwise and applying light pressure until the seal
assembly engages the flats on the shaft and is
seated in place. Rotate the tool counter-clockwise
OVERHAUL MANUAL

AIR CONDITIONING COMPRESSOR 1-7
Fig. 11-Removing Seal Seat and " 0 " Ring
slightly (to release it from the seal) and remove
Tool J-9392.
3. Coat the seal face of the new seal seat with clean
refrigeration oil. Grip the seal seat with Tool
J-23128 and push into place with a rotary motion,
so as not to disturb the "O" ring and to also effect a
seal with this "O" ring. Remove Tool J-23128.
4. nstall the new seal seat retainer ring with Tool
J-5403, with the flat face against the seal seat. Press
on the retainer ring until it snaps into place.
Remove Tool J-22974 from the end of the shaft.
5. Leak test the compressor as described under "Leak
Testing the Compressor" in this section. Correct
any leaks found.
6. nstall the new absorbent sleeve by rolling the
material into a cylinder, overlapping the ends, and
slipping the sleeve into the compressor neck with
the overlap toward the top of the compressor. With
a small screw driver or similar instrument, carefully
spread the sleeve until the ends of the sleeve butt at
the top vertical centerline.
7. Position the new metal sleeve retainer so that its
flange face will be against the front end of the
sleeve. Tool J-9395 may be used to install the
retainer. Press and tap with a mallet, setting the
retainer and sleeve into place (retainer recessed
approximately 1/32" from the face of the
compressor neck).
8. Reinstall the clutch hub and drive plate assembly.
Compressor Rear Head and 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.
Fig. 12-Checking or Wobble Plate Position on Sha t
Fig. 13-Replacing Seal and " 0 " Ring
Pressure Relief Valve
When a faulty pressure relief valve, located in the rear
head casting, is encountered, the valve assembly should
be removed after purging the system and a new valve
and gasket installed. The entire system should then be
evacuated and recharged.
SEAL ASSEMBLY
STRAI HT ED E
WIRE AU E
.029" SHOULD " O "
.072" SHOULD "NOT O"
OR SHOULD "JUST O"
ABSORBENT SLEEVE
SLEEVE RETAINER
SEAL SEAT
RETAINER RIN
SEAL SEAT
" RIN
OVERHAUL MANUAL

1-8 AIR CONDITIONING COMPRESSOR
Superheat Switch
The superheat switch is used on passenger cars and "G"
model trucks. f it becomes necessary to replace the
superheat switch, located in the rear head casting, the
switch assembly should be removed only after purging
the system. After the switch has been replaced and a new
"O" ring seal installed, the system should be evacuated
and recharged.
Rear Head, Oil Pump and Valve Assemblies
Removal
1. Remove the compressor from the vehicle, drain
compressor oil into a clean container, clean the
exterior of the compressor case and rear head
casting with a suitable solvent and mount the
compressor, rear head up, in Holding Fixture
J-9396 which should then be mounted securely in a
vise.
2. Remove the four nuts from the shell studs.
3. Remove the rear head. Examine the sealing surface
of the casting webs. f this surface is damaged by
nicks or scratches, the head should be replaced.
4. Examine the suction screen in the rear head for any
damage or contamination. Clean or replace the
screen as necessary.
5. Remove and examine the oil pump gears. f either
of the gears shows any wear or damage, replace
both gears.
NOTE: Keep the ends of the two oil pump
gears matched and replace the same end
toward the discharge plate upon reassembly.
6. Remove the rear head-to-shell "O" ring and
discard.
7. With two screw drivers, carefully pry up on the rear
discharge valve plate assembly (fig. 14). Check for
broken reeds or damaged seats and replace entire
assembly if such is found.
CAUTION: Excessive force during this opera
tion may loosen valve reed retainer rivets.
8. Carefully lift off the rear suction reed valve. Valve
must be replaced if any damage is evident.
Fig. 14 -Removing Rear Discharge Valve Plate
Fig. 1 5--Proper Oil Pump Gear Positioning
Installation
1. Carefully replace the suction reed valve and the
rear discharge plate over the dowel pins and ports
in the cylinder assembly. Proper positioning of the
reed plate may be determined by lining up the
proper opening in the plate with the discharge
crossover tube opening.
2. Position the rear head casting to align with the
dowel pins. The two lower mounting pads will be in
alignment with the oil sump in the shell. Rotate the
cylinder assembly back and forth by hand, if
necessary, to permit this alignment. Remove the
rear head from this trial assembly.
3. nstall the inner oil pump gear over the "D" flat on
the shaft and place the outer oil pump gear over the
inner gear. Position the outer gear as follows:
a. Observe the position of the oil sump in the shell.
b. Locate the approximate centerline of this sump.
c. Facing the centerline of the sump and viewing
from the sump side (bottom) of the compressor,
move the OUTER gear toward the right (side
having the oil drain fitting) until it is at
approximately 90 degrees (3 o’clock position)
from the centerline of the oil sump (fig. 15).
4. Coat the head-to-shell "O" ring with clean
refrigeration oil and generously lubricate the area
around the outer edge of the valve plate where the
"O" ring will be placed. Oil also the oil pump
OVERHAUL MANUAL

AIR CONDITIONING COMPRESSOR 1-9
gears, valve reeds and the area where the head
casting web sealing surface will contact the valve
plate.
5. nstall the head-to-shell "O" ring.
6. Be sure that the suction screen is properly
positioned in the rear head, then assemble the rear
head to the compressor shell being careful not to
damage the sealing surface of the head casting
webs.
CAUTION: Be sure head does not bind against
oil pump gears when being installed.
1. nstall new nuts to the threaded shell studs and
tighten to 19-25 ft. lbs. torque.
8. Leak test the compressor as outlined under "Leak
Testing the Compressor" in this section.
9. nstall compressor in the vehicle.
Major Internal Mechanism
The clutch hub and drive plate assembly, drive key,
pulley, and coil housing and shaft seal should be
removed before proceeding with the following compres
sor disassembly.
Removal from Shell
1. Remove the rear head, discharge plate and suction
reed valve from the compressor as outlined under
"Rear Head and Reed Valve Assemblies."
2. Remove the oil inlet tube and "O" ring with Tool
J-5139 as shown in Figure 16.
3. Carefully lay the compressor shell on its side and
slide out interior mechanism and front head
assembly. DO NOT hammer or use undue force to
remove the mechanism; however, gentle taps on the
head casting may aid in removing the assembly.
CAUTION: D N T hammer or tap on the
compressor shaft.
4. Remove front head casting, front discharge valve
plate and suction reed valve from the mechanism.
Examine parts for damage and replace if necessary.
Check particularly for damage to the sealing
surfaces of the front head casting webs.
5. Examine the mechanism for any obvious damage.
6. Remove the suction crossover cover (fig. 17).
7. f desired, the mechanism may be assembled in
Checking Cage J-9397 and operated on a motor test
stand, or by some other suitable means, to observe
sound level and general operation. Tighten cage
nuts evenly to 14-16 ft. lbs. torque.
8. Remove mechanism from the cage.
Disassembly
f the mechanism has sustained major damage, due
possibly to loss of refrigerant and/or oil, it may be
necessary to replace it with a complete service interior
Fig. 17- Removing Suction Crossover Cover
mechanism assembly rather than to replace individual
parts. f further disassembly is considered worthwhile,
proceed as follows:
1. Before disassembling the cylinder and mechanism,
number the pistons and cylinder locations so that
all parts may be replaced in their original location.
Pistons and cylinder bores may be identified by
numbering them 1, 2 and 3 with a pencil.
2. Use an old discharge tube to drive discharge tube
out of cylinder (fig. 18): Drive from REAR of
cylinder.
3. Drive the cylinder halves apart and free from the
dowel pins and discharge crossover tube using a
fiber block and mallet (fig. 19). Discard the
discharge crossover tube.
NOTE: Before driving cylinder halves apart,
position wobble plate toward front of
compressor in area of crossover tube.
OVERHAUL MANUAL

1-10 AIR CONDITIONING COMPRESSOR
Fig. 18-Unseating Discharge Crossover Tube
4. Carefully remove the rear half of the cylinder from
the pistons and set the front cylinder half, with the
piston, shaft and wobble plate, in Compressing
Fixture J-9397.
5. Push up on the shaft and, one assembly at a time,
remove pistons, rings, seats and balls placing all
parts in Tray J-9402 in the compartment associated
with the proper end of the piston. Discard all piston
ball seats.
NOTE: The front of the piston may be
identified by a notch in the casting web (fig.
20). The piston compartments in Tray J-9402
have a boss at this notch location to indicate
the front.
6. Remove and inspect all piston rings. Replace all
broken or damaged rings. Damaged pistons must
also be replaced.
7. Examine piston balls. Replace if they show burning
or excessive wear.
8. Remove the rear combination of thrust races and
bearing from the shaft and discard all three pieces.
9. Remove the shaft and wobble plate assembly from
the front half of the cylinder.
10. Remove the front combination of thrust washers
and bearing and discard all three pieces.
11. Examine all surfaces of the wobble plate and, if
satisfactory, reuse. f it shows signs of wear, replace
the shaft and wobble plate as an assembly. Use care
Fig. 19-Separating Cylinder Halves
not to move wobble plate on the shaft. This is
factory set.
12. Examine the front and rear cylinder halves and
replace if cylinder bores are deeply scored or
damaged.
13. Wash all parts to be reused in a suitable cleaner.
Blow dry all parts.
14. f cylinder main bearings are to be replaced, they
may be removed and reinstalled at this time using
Tool J-9432. Drive against the lettered end of the
bearings and from the outside of the cylinder.
Bearing must be not more than 1/8" below surface.
Gauging Procedure
The gauging operations which follow have been worked
out on a simple basis to establish and provide necessary
running clearances. Two gauging procedures are
necessary.
The first gauging operation is made to choose the proper
size ball seats to provide, at each piston, a .0005" to
.0010" total preload between the seats and the wobble
plate at the tightest place through the 360 degree
rotation of the wobble plate. The bronze ball seats are
Fig. 20-Notch Identi ying Front End o Piston
OVERHAUL MANUAL

AIR CONDITIONING COMPRESSOR 1-11
Wobble Plate
No. 1 Piston
Front
Cylinder
Half y Front Thrust Races
3 and Bearing M B
Holding Fixture
H J-9396 H P
| Compressing |
Fixture J-9397
Fig. 21--lnstaliing Piston, Front Ball and Seat and
Rear Ball
provided in .0005" variations including a basic ZERO
seat.
The second gauging operation, performed at the rear
shaft thrust bearing and race pack, is designed to obtain
.0005" to .0015" preload between the hub surfaces of the
wobble 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. Proper selection of thrust races
and ball seats is of extreme importance.
1. Secure from service parts stock:
Four-ZERO thrust races
Three-ZERO ball seats
Two-New thrust bearings
2. Assemble a ZERO thrust race, a new needle thrust
bearing and another ZERO thrust race, in that
order, to the front end of the shaft (A dab of clean
petroleum jelly will hold the bearing-race pack
together and in place on the shaft). Lubricate front
and rear faces of the wobble plate with clean
refrigeration oil.
3. With the front half of the cylinder assembly resting
on Tool J-9397, insert the shaft threaded end
through the front main bearing until the thrust race
assembly rests on the front cylinder hub.
4. Assemble a ZERO thrust race, a new needle
bearing and a second ZERO thrust race in that
order, to the rear of the shaft.
5. Apply a light smear of clean petroleum jelly to the
ball pockets of each of the three pistons.
6. Place the balls in the piston pockets. The petroleum
jelly will hold the balls in place.
7. Apply a light smear of petroleum jelly to the cavity
Fig. 22--Assembling Cylinder Halves
of three new ZERO ball seats and place one seat
over each front piston ball. There should now be a
ball and seat in the front ball pocket of each piston
and a ball only in the rear ball pocket.
NOTE: Do not assemble any of the piston
rings at this time.
8. Rotate the shaft and wobble plate until the high
point of the wobble plate is directly over the
cylinder bore previously designated as No. 1. Lift
up slightly on the shaft and wobble plate assembly,
insert the front (notched) end of the No. 1 piston
into the cylinder bore, and at the same time, place
the front ball and seat and the rear ball only over
the wobble plate (fig. 21). Hold front thrust bearing
pack tight against wobble plate hub while lifting
shaft.
9. Repeat this operation with pistons No. 2 and No. 3.
10. Align the rear head casting with bores, suction
passage, discharge crossover holes, and dowel pins.
Tap into place, using a plastic block and mallet (fig.
22).
11. Place the cylinder assembly in the checking cage
with the front of the compressor shaft pointing up,
positioning the discharge tube opening between the
cage bolts. This will provide access for the feeler
gauge. Assemble the cage and tighten all nuts
evenly to 14-16 ft. lbs. torque.
12. Use a leaf type feeler gauge and a suitable spring
scale to check clearance between the REAR ball
and the wobble plate (fig. 23) of the No. 1 piston.
Use a suitable combination of feeler gauge leaves
until 4 to 8 oz. of force is required to pull gauge
from between the ball and the plate.
NOTE: Use undamaged feeler gauges gener
ously lubricated with clean refrigeration oil.
Support the spring scale so that only the
OVERHAUL MANUAL

1-12 AIR CONDITIONING COMPRESSOR
actual force required to pull the feeler gauge
free is measured.
Rotate the shaft approximately 120 degrees and
again check with a feeler gauge between the parts.
Rotate the shaft another 120 degrees and make a
third check. From this total of three feeler gauge
checks, use the M N MUM reading to select a
numbered seat to correspond to the feeler gauge
reading (i.e., if minimum reading was .019, use a
No. 19 seat. f reading was .0195, use a No. 19-1/2
seat). Place this seat in the parts tray in the
Fig. 2 3 -Checking Clearance Between Rear Ball and
Wobble Plate
Fig. 2 4 -Checking Clearance Between Rear Thrust
Bearing and Outer Thrust Race
compartment corresponding to the rear ball position
of the No. 1 piston.
13. Repeat the operation described in Step 12 for
pistons No. 2 and No. 3.
14. The next gauging operation is to determine the
space between the REAR thrust bearing and the
upper (outer) rear thrust race. Use a suitable
combination of feeler gauge leaves so that 4 to 8 oz.
of force is required to pull gauge free (fig. 24).
Select a numbered thrust race to correspond to this
feeler gauge reading and place this race in parts
tray in the rear thrust race compartment.
15. Loosen the nuts and ring from the checking cage.
16. Drive the cylinder halves apart, using a fiber block
and mallet.
17. Carefully remove the rear half of the cylinder and
set the front half (including the pistons, shaft and
wobble plate assembly) on Fixture J-9397.
18. Carefully remove one piston at a time from the
wobble plate and the front half of the cylinder.
Transfer each piston, ball and seat to its proper
place in the parts tray along with the numbered
rear seat chosen in Steps 12 and 13 above.
CAUTION: When the balls and seat are
removed from the piston, be sure that they are
placed in the proper parts tray pocket so as not
to lose the relationship of the balls and seats to
the proper end of the piston.
19. Remove the rear outer (upper) ZERO thrust race
from the compressor shaft and replace it with the
numbered thrust race (determined in Step 14
above) from parts tray.
NOTE: This ZERO thrust race may be put
aside for reuse in future gauging and/or
rebuild operations.
20. The gauging operations are now complete.
Assembly
After properly performing the gauging procedure and
choosing the correct ball seats and thrust races as
outlined under "Gauging Procedures," the cylinder
assembly may be reassembled. Be sure to install all new
seals and "O" rings. All are included in the compressor
seal service kit.
Assembly procedure is as follows:
1. Support the front half of the cylinder assembly on
Fixture J-9397 and install the shaft and wobble
plate, threaded end down, with its front bearing
race pack (ZERO race, bearing and ZERO race)
and its rear bearing race pack (ZERO race, bearing,
numbered race) if this was not already done at the
end of the "Gauging Procedure."
2. Assemble a piston ring, scraper groove toward the
center of the piston, to each end of the three
pistons.
Wobble Plate Rear Ball
Feeler Gages
Spring Scale
(Pull Scale
parallel to
slope o
Wobble Plate)
Feeler Gages
Spring Scale
Rear Thrust Race
Thrust Bearing
OVERHAUL MANUAL

AIR CONDITIONING COMPRESSOR 1-13
3. Apply a light smear of petroleum jelly to the
numbered ball seats chosen in the gauging
procedure and install all balls and seats (if removed
in Step 18 of the gauging procedure) in their proper
place in the piston.
4. Rotate the wobble plate so that the high point is
above cylinder bore No. 1. Carefully assemble
piston No. 1, complete with ball and ZERO seat on
the front and ball and numbered seat on the rear,
over the wobble plate. Hold front thrust bearing
pack tight against wobble plate hub while lifting
hub. Compress and enter the piston ring into the
front cylinder half.
5. Repeat this operation for pistons No. 2 and No. 3.
6. Assemble one end of a service discharge crossover
tube into the hole in the front cylinder half.
7. Rotate the shaft to position the pistons in a stair
step arrangement, then carefully place the rear
cylinder half over the shaft and start the pistons
into the cylinder bores.
8. Compress the piston ring on each piston to permit
its entrance into the cylinder.
9. When all three pistons and rings are in their
respective cylinders, align the end of the discharge
crossover tube with the hole in the rear half of the
cylinder.
NOTE: Be sure the flattened portion of this
tube faces the inside of the compressor to
allow for wobble plate clearance.
10. When all parts are in proper alignment, tap with a
fiber block and mallet to seat the rear half of the
cylinder over the locating dowel pins. f necessary,
clamp the cylinder in Fixture J-9397 to complete
drawing the cylinder halves together.
11. Generously lubricate all moving parts with clean
refrigeration oil and check for free rotation of the
parts.
NOTE: t may be desirable to clamp the
cylinder assembly in compressing Fixture
J-9397 and check on the motor test stand for
proper operation before proceeding further.
f any improper operation is observed, the
mechanism should be regauged to insure
proper operation. Complete the assembly
procedure when correct operation is obtained.
12. Replace the suction crossover cover as shown in
Figure 25. Compress the cover (as shown) to start it
into the slot, and then press it in until flush on both
ends.
Installation Into Shell
1. Support the cylinder on Fixture J-21352 with the
threaded end of the shaft up.
2. Assemble the two dowel pins in the front cylinder if
they are not already in place.
NOTE: A rod drilled 1/4 in. deep to the O.D.
of the dowel pins will aid in installing.
3. nstall the discharge crossover tube front "O" ring
and spacer (fig. 26).
4. Aligning the dowel pin holes, discharge crossover
and oil return slot, assemble the suction reed valve
to the front end of the cylinder.
5. Assemble the front discharge valve plate, aligning
the holes with the dowel pins and proper opening in
the head.
Fig. 2 5-1nstalling Suction Crossover Cover
NOTE: The front discharge plate has a
Fig. 2 6 -Installing Discharge Crossover Tube Front
"O " Ring and Spacer
OVERHAUL MANUAL

1-14 AIR CONDITIONING COMPRESSOR
Fig. 27-lnstalling Shell Over Internal Mechanism
larger diameter hole in the center than the
rear discharge plate.
6. Check the sealing surface of the compressor front
head casting webs and replace the entire casting if
there is any evidence of damage. Discard the "O"
ring.
7. Coat the valve plate with clean refrigeration oil.
Rotate the front head casting until it is properly
positioned over the discharge reed retainers and
dowel pins, then set it in place (being careful not to
damage the sealing surfaces) and seat it over
dowels with light mallet taps.
NOTE: Dowel pin and hole location can be
marked with pencil to aid in locating proper
position.
8. Apply clean refrigeration oil to a new "O" ring and
"O" ring groove at the lower edge of the front head
casting and carefully assemble the "O" ring in the
groove.
9. Coat the inside machined surfaces of the compres
sor shell with refrigeration oil.
10. Locate the oil intake tube hole in the rear discharge
plate. Line up the oil sump with this hole location
and slide the shell down over the mechanism while
supporting the mechanism on Fixture J-21352 (fig.
27).
NOTE: Raise the front head slightly to
facilitate shell installation and to reduce the
possibility of damaging the "O" ring.
11. Place Compressor Support Bracket J-9396 in a vise
and, carefully inverting the compressor shell with
the mechanism inside, mount the front compressor
flange on the support bracket.
12. Place a new "O" ring in the oil intake tube hole
applying clean refrigeration oil to the oil intake
tube hole and the "O" ring. Rotating the
compressor mechanism to line up with the hole in
the compressor oil sump baffle, install the pickup
tube. Be sure that the "O" ring and intake tube are
properly seated.
13. Assemble the dowel pins into the rear cylinder.
14. nstall the discharge crossover tube rear "O" ring
and spacer.
15. Replace the rear suction reed valve, rear discharge
valve plate, oil pump gears, rear head and head
nuts as outlined previously under "Rear Head and
Reed Assemblies—nstallation."
16. nstall a new shaft seal assembly kit as outlined
under "Shaft Seal Assembly- nstallation."
17. Reinstall the coil housing, pulley and bearing
assembly and hub and drive plate assembly as
outlined earlier in this section.
Leak Testing The Compressor
Whenever service operations are performed on the
compressor shaft seal assembly or on the interior
mechanism, use the following procedure to leak test the
reassembled compressor:
1. nstall "O" rings and Cover Plate J-9527 over the
suction and discharge ports of the compressor head.
2. Check and add oil to the compressor as outlined
under "Checking Compressor Oil Charge" in the
Chassis Service Manual.
3. Temporarily install the shaft nut. With the
compressor in the horizontal operating position (oil
sump down), rotate the compressor shaft several
times in the normal direction of rotation.
4. Hook up a Refrigerant-12 container and charging
line (using Adapter J-5420) to cover plate fitting
over the suction port, charge the compressor up to
can pressure, and leak test compressor with a leak
detector.
5. Turn off the refrigerant container valve. Transfer
gauge line and adapter to cover plate fitting over
the discharge port and repeat the procedure
outlined in Step 4.
6. Correct any leaks present.
OVERHAUL MANUAL

AIR CONDITIONING COMPRESSOR 1-15
SPECIAL TOOLS
1. J 8393 Charging Station 12. J-5403 No. 21 Snap Ring Pliers 23. J-9481
2. J-24095 Oil Inducer 13. J-6453 No. 26 Snap Ring Pliers
2A. J 9393 Super Heat Switch 14. J-9396 Compressor Holding 24. J-8092
Remover Fixture 25. J-21352
3. J-5453 Goggles 15. J-9397 Compressing Fixture
4. J-9459 90 Degree Gauge Line 16. J-9403 Clutch Hub Holding Tool 26. J-5139
Adapter 17. J 9399 9/16" Thin Wall
5. J-5420 Gauge Line Adapter Socket 27. J-9432
6. J-6084 Leak Detector 18. J-9401 Hub and Drive Plate 28. J-9553
7. J-8433 Puller Assembly Remover
8. J-9395 Puller Pilot 19. J-9480 Hub and Drive Plate 29. J-21508
9. J-23595 Re rigerant Can Valve Assembly Installer
(Side-Tap) 20. J 9392 Seal Remover 30. J-22974
10. J-6271 Re rigerant Can Valve 21. J-23128 Seal Seat Remover 31. J-9527
(Top-Tap) 22. J-9398 Pulley Bearing Remover 32. J-9402
11. J-5421 Pocket Thermometers (2)
Pulley and Bearing
Installer
Handle
Internal Assembly
Support Block
Oil Pickup Tube
Remover
Needle Bearing Installer
Seal Seat " 0 ” Ring
Remover
Seal Seat "O " Ring
Installer
Sha t Seal Protector
Pressure Test Connector
Parts Tray
Fig. 28-Air Conditioning Special Tools
OVERHAUL MANUAL