Document NEG1NwMeX97ZokEJQ2nbrm9V8
DIRECT DIAL (407) 244-1165 DIRECT FACSIMILE (407)648-4664 INTERNET E-MAIL CK0LQSQUVW.COM
Maguire, Voorhis & Wells, P.A.
QJ^ttowieyi atJQaco
TWO SOUTH ORANGE PLAZA 2 SOUTH ORANGE AVENUE
ORLANDO, FLORIDA 32801
TELEPHONE (407) 244-1100 FACSIMILE (407) 423-8796
P.O. BOX 633 ORLANDO, FLORIDA 32802
July 17, 1997
Chris N. Kolos
David M. Lipman, Esq. 599 SW 74th Street Suite 304 Miami, FL 33143
Re: Anne M. Tinker, Executrix of the Estate of Timothy W. Tinker, Deceased vs. A.E. Clevite, et ai. Ontario County Index No. 83778.
Dear Mr. Lipman:
My letter of July 2, 1997 was not quite right. Enclosed please find what truly is the final production to be made by Mack Trucks, Inc. in response to paragraphs 7 and 11 of Plaintiff's Request for Production.
If you have any questions regarding the above, please do not hesitate to contact me.
CNK.jo Enclosures
ORLANDO
MELBOURNE
TALLAHASSEE
TOP OF SPRING
- wlOCR
' SPACE
Figure 2-12. Valve Spring
Sli
Figure 2-14. Torquing Sequence
Valve Rocker Arm ana Shaft Assembly
The valve rocker arm features a bushing. When the bushing is installed, the split must locate on the horizontal plane and face the slipper side c: the arm. See Figure 2-15.
Figure 2-13. Installing Valve Keys
Installing Cylinder Heads
New cylinder head gaskets are installed on the cylinder block with "Top" markup. Check cylinder head studs for secureness in the block: also threads for damage that may cause binding of the stud nuts. Fit cylinder heads over studs lowering on to cylinder head gasket carefully to avoid damage. Install cylinder head stud washers and nuts. Torque nuts in sequence shown with a calibrated torque vrencn in progressive steps of 50, 100 and finally 140 lb. ft. (Stud threads oiled). See Figure 2-14.
Install the two water connection flanges, with gaskets, to cylinder head (connecting heads together to permit cooling water circulation through the three cylinder heads), and install thermostat housing (outlet) and gasket to the front head. A blank plate and gasket are used at the rear head.
Figure 2-15. Rocker Arm Assembly
Press the bushing in so that it will come flush with the side of the hub which contacts the rocker arm shaft bracket. Two oil holes must be drilled in the bushing. They must be in alignment with the two oil holes pro vided on top of the arm to feed the slipper and the rocker arm to pushrod adjusting screw with lube oil. Ream bushing I. D. 0.8661 to 0.3669 in., to allow for proper running clearance with a new rocker arm shaft diameteT. Check shaft O.D. at unworn area for size, before reaming new bushings tobeusedwith old shaft. Running clearance, 0.0005 to 0. 0015 in.
!< L
The valve roctcer arm snair is hoilo\v. Two large hoies are drilled thrcugn the shaft, vertically, at locations where the bracketto-cylinder head screws are installed. Four positions on the shaft are drilled through the shaft from one side to the other, on a horizon tal plane. This provides eight oil feed hoies, two for each of four rocker arms. Theyfeed the bushing with lube oil at the 3 and 9 o'clock positions.
The valve rocker arm and shaft assembly must be installed only after the cylinder heads have been properly torqued down.
The valve lifters must be installed wdth the camshaft in place. The pushrods must then be installed. See Figure 2-16.
Figure 2-16. Installing Valve Lifter
The rocker arms, shaft, springs and brackets are assembled and secured at each end with large hex head type plugs. The two bracketto-cvlinder head bolts must also be in place before installing the assembly to the head. The bolts are drilled up through the center, and a feed hole drilled on side of the bolt locates inside the rocker arm shaft, on the assembly, to admit lube oil which originates (under pressure) from a passage directed to the bottom of the tapped hole (in the cylinder head) to feed the bracket bolt.
A heavy paper disc type gasket is used bet ween the brackets and cylinder head to pre vent oil leakage. Before installing new gas kets. remove any part of the old gaskets that may be adhering to the bracket or head to assure solid seating.
Tighten the bolts equally and finally torque to 40 lbs. ft. maximum. See Figure 2-17.
Figure 2-17. Rocker Arm and Shaft Assy.
When the rocker arm and shaft assembly is installed on the engine, carefully check outer rocker arms for possible binding between bracket and hex head plug. Rap opposite end of shaft with hammer to free.
Naturally Aspirated Diesel (END475)
Adjust valve clearance (cold engine setting); inlet valve, 0.014 in. and exhaust valve, 0. 018 in.
Turbocharged Diesel (ENDT475)
Inlet valve, 0. 014 in. and exhaust valve 0.028 in. Squirt engine oil over valve mechanism and at valve stems for initial protection.
NOTE
As soon as engine is running, ob serve to be sure lubricating oil is flowing from all rocner arms.
CYLINDER BLOCK
Description
The cylinder and upper crankcase is an in tegral casting of alloy cast iron. See Fig ure 2-18. It features replaceable wet-type cylinder sleeves flanged at the top to fit in the counterbores on the cylinder block deck. Three O-ring type seals are employed to sealthe lower areas of the sieeve at the water jacket. The O-rings are resistant to oil and heat.
The standard cylinder sieeve I. D. is 4.527. This is the only size available. A worn or scored sleeve must be replaced with a new sleeve because the piston and piston rings are also only available in standard size. Cylinder sleeves may be removed by using puller J -21376 and sleeve puller shoe J 21587. See Figure 2-19.
2-35
:o 1.457 Lr.cn (3 7mm.' is 147. 34 lbs. ;660N). See Figure 2-19.
Figure 2-19.Checking Valve Springs
Position inner and outer valve springs over the inlet and exhaust valve stems and install washers, valve stem keys and caps using a suitable spring compressing tool. See Fig ure 2-20.
\
Figure 2-21 .Cylinder Head Gasket (Note: Fire Ring Formed in Left Gasket)
1. Clean the cylinder block deck thoroughly.
2. Check cylinder sleeve height above the deck. (SeeFigure 2-31.)lnstall new cylinder head gasket on deck.
NOTE
Do not use a sealing compound or soak cyiinder head gasket.
3. Check gasket position. Be sure that all passages are open and not blocked by the gasket. See Figure 2-22.
Figure 2-20.Installing Valve Keys
Installing Cylinder Heads
NOTE
A fire ring is formed in the cyl inder head gasket when the cyl inder head is torqued on the cyl inder block: therefore, a new gasket must be used when instal ling the cylinder head. See Fig ure 2-21.
it
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I
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i
f
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2. Install strainer (6) on bottom plate (4) and insert assembly in rotor cover.
3. Place washer (2) on top of rotor and firmly hand tighten rotor nut (1).
4. Install rotor assembly (Item 4, Figure 2-68) in filter housing. Check rotation - the rotor assembly must rotate easily.
5. Install new O-ring on body cover and attach to filter housing.
6. Firmly hand tighten top"T" handle lock nut.
Oil Cooler
The oil cooler does not normally require any form of maintenance. If leakage is sus pected, the cooler should be pressure test ed. Water side 58 psi (399. 9kPa) oil side 145 psi (999. 7kPa). In case of possible water leakage past the O-ring seals, they must be replaced.
Replacing O-Ring Seals
1. Remove cooler assembly from oil filter (1). See Figure 2-72.
NOTE
Numbers in () refer to Figure 2-72.
2. Remove capscrews (51 and lockwashers (6).
3. Remove end plates (4).
4. Press element out of housing far enough to expose the O-ring seal (3).
5. Remove O-ring seal (3).
6. Reverse oil filter (1) and remove oppo site O-ring seal (3).
7. Place the new O-ring seals (3) in oil for a few minutes.
8. Oil the O-ring seal groove and install new O-ring seal (3) in position.
9. Press core in cooler housing (2) far en ough to expose the opposite O-ring seal (3) groove.
10. Lubricate groove and install ooposite O-ring Seal (3).
11. Center core in housing and secure byinstalling end plates (4), capscrews (5), and washers (6).
Turbocharger Oil Filter
The turbocharger oil filter is provided to in sure only filtered oil is directed to the tur bocharger. See Figure 2-73.
1. Oil FUter
4. End Plate
2. Oil Cooler
5. Capscrews
3. O-Ring Seal
6. Lockwashers
7. Oil Cooler
Mounting Gasket
Figure2-72.Removing Cooler Assembly from Oil Filter
Figure2-73.Turbocharger Oil Filter
This filter is a spin-on disposable unit. It has an adapter with internal oil passages into and from the filter element.
2-91
9. Install impeller lockwasher and nut and secure.
THERMOSTAT
The thermostat is located above and to the right of the injection pump. See Figure 2-91.
Removal
To remove the thermostat, first drain the coolant and then remove the outlet housing. See Figure 2-92.
Figure 2-92.Thermostat Housing Exploded View
TURBOCHARGER
Preliminary
Inspect external and visible internal areas for contamination or damage before install ing the unit on che engine. Check the con dition of the turbine and exhaust manifold mating flanges for uneven surfaces. The
smooch surface is required to assure good gasket clamping for dependable sealing and for longer gasket life.
Make certain that the air cleaner and air tubes are clean, to avoid restricted air flow. New hose connections and dependable clamps should be used and properly secured.
2-99
Insert the proper timing gear cover alignment sleeve m the cover, (J-265S3 for 4.250 i.ncn nominal C-.D. oil seal, and J-24230, with handle J-8092, for 4.00 inch nominal C.D. seal). The sleeve also protects the seal wnen installing the timing gear cover.
Install two suitable guide studs and position the timing gear cover on the engine using a new gasket.
Install two timing gear cover screws,
finger tight.
Then tap the cover
with a soft-faced hammer, using a
straight edge to align the timing
cover with the oil pan rail. See
Figure 2-129.
After timing gear cover has aligned, remove the guide studs. stall the remaining capscrews torque to specifications.
been In and
To adjust the thrust button, rotate the button clockwise until it is snug against the shaft, (camshaft and auxiliary shaft). Then back out the thrust button 1/4 turn and tighten jam nut. The resulting end-play will then be within specifications. See Figure 2-130.
Figure 2-129. Aligning Timing Gear Cover
After thrust buttons have been adjusted, remove the centering sleeve.
2-252
T
Lubricate oil pump drive and driven
back lasn between gears to make
gears and mount the oil pump assembly
certain that gears are not tight.
to engine. See Figure 2-150.
Place new gasket on oil pump inlet
tube flange and assemble to oil pump.
See Figure 2-151.
Figure 2-150. Assembly of Oil Pump to Engine
Assemble the oil pump mounting screws and torque to specifications. Check
Figure 2-151. Assembling Oil Pump Inlet Tube
To assist in readily identifying the different cap and spring combinations, refer to Table 4.
TABLE 4
OIL PRESSURE RELIEF VAVLE CAP AND SPRINGS (In Oil Pump)
TYPE OF FILTERING SYSTEM By-Pass Filter
Full-Flow By-Pass (Pre-ESI)
ESI (With 100 PSI Oil Pressure Gage in Cab)
ESI (With 150 PSI Oil Pressure Gage in Cab)
ESI Plus
RELIEF VALVE CAP *
RELIEF VALVE SPRING
226GB121 572GC11
J226GB122 572GC114
226GB147 572GC114
226GB122 572GC114
226GB122 572GC114
SPRING INSPECTION LIMITS
25.0 lbs.+ 1.8 lbs. at 2-3/4 in.
40.0 lbs._+ 4.0 lbs. at 3-5/64 in.
40.0 lbs.+ 4.0 lbs. at 3-5/64 in.
40.0 lbs.^ 4.0 lbs. at 3-5/64 in.
40.0 Ibs.r 4.0 lbs. at 3-5/64 in.
* The last three digits of the part number (such as "121") are stamped on the end of the cap for identification.
2-259
4.
OIL PAN
Inspect oil pan mounting flange sur face for flatness. Correct as re quired. See Figure 2-152.
Figure 2-152. Checking Oil Pan Mounting Flange for Flatness
Figure 2-153. Original Production Oil Pan (19 Quart Capacity)
ESI Engines
The oil pan capacity was then in creased to 28 quarts for use with the ESI (Extended Service Interval) en gines. See Figure 2-154.
Install new gasket and assemble pan to engine. Assemble capscrews and torque to specifications.
There are three types of oil pans in
use on Mack engines.
Thse are
"Original Production", "ESI Engines",
and "ESI-Plus Engines."
Figure 2-154. Oil Pan for ESI Engines (28 Quart Capacity)
Original Production
Original production engines were built with a 19 quart capacity oil pan. See Figure 2-153.
ESI Plus Engines
Oil pans for ESI-Plus engines have been made deeper and have an addi tional increase in oil capacity to 51 quarts. See Figure 2-155.
CYLINDER HEAD
Figure 2-155. Oil Pan for ESI-Plus Engines (51 Quart Capacity)
NOTE
Because of the low mileage normally incurred with on and off highway type vehic les, and also because of ground clearance problems, the new "ESI-Plus" engines are not used in models such as the DM600 or 800, DMM, RD.RM and MB.
Basic Engine Assembly - Oil Pan Applications
Current Basic Engine Assemblies (for Service) are built with the 28 quart capacity oil pan which is required for ESI engines. When this assembly is used to replace an engine not hav ing ESI features, it is recommended that the ESI retrofit kit be in stalled.
If the original oil filter arrange ment is retained, there are two options:
1. Use the new oil pan and add 9 quarts of oil to provide proper oil level in the 28 quart pan.
2. Use oil pan from replaced engine, (19 quart capacity).
If an "ESI-Plus" engine is being re placed, the 28 quart capacity oil pan on the new assembly must be replaced by a 51 quart capacity oil pan.
Make certain that cylinder head as sembly is in satisfactory condition. (Refer to "Cylinder Head Recondition ing Procedure" on Page 2-225 .)
Assemble the correct type of cylinder
head gasket to engine. The "folded-
steel" type gasket is used with the
"flat-flange" type cylinder liner,
and the "Maxidyne" type is used with
the beaded-flange type liner.
See
Page 2-155.
All gaskets are pre-coated and do not require any type of sealing com pound.
Assemble gasket in cylinder block lo cating gasket over guide pins. Make cerain that surface of gasket marked "Top" is on the top side. With the "Maxidyne" type gasket, carefully fit a new fire ring over the circular bead on each cylinder liner flange. See Figure 2-156.
Figure 2-156. Installing Maxidyne Fire Ring
Position the cylinder heads (com pletely assembled) over the cylinder block, locating the guide holes in the head over the pins in the cylin der block. See Figure 2-157.
If engine has cylinder head studs, check for condition of threads and straightness of shank. Apply a light coat of lubricating oil to threads of studs and install them in cylinder block finger tight, then back off 1/3 turn. Apply a light coat of oil to cylinder head stud washers and nuts and install in position and hand tighten.
2-261
6. Continuing adjusting valve lasn fnr the remaining cylinders, m fir ing order, placing eacn piston at TDC vita respective turning of the engine cr .nkshaft.
NOTE
Engines equipped with the
Mack Dynatara* engine brake
system vill have hydraulic
valve lash adjusters in the
exhaust rocker arms. Adjust
exhaust lash (cold static)
using special exhaust valve
adjusting
tool
MVT-36-6.
When using tool press down
ward with hand on exhaust
valve adjuster so that the
internal clearance in the ad
juster is eliminated. Fail
ure to press down on the ad
juster will result in unsat
isfactory engine performance
and unsatisfactory perform
ance of the engine brake.
The MVT-36-6 Exhaust Valve Adjusting Tool is available from:
Automatic Aids 1618 Willow Avenue La Mott, Philadelphia, Pennsylvania 19126
For a detailed explanation of the en gine brake operation, refer to "Dynatard Engine Brake" section.
CYLINDER HEAD COVER
Check cylinder head covers to make certain that mounting surfaces are flat and clean. Also make certain that gasket surfaces are dry and free from dust.
Apply a thin layer of "Scotch Grip"
3M Co., No. 1711, (or equivalent)
contact-type cement to both cover
counting surface and gasket.
Let
stand for several minutes then assem
ble adhesive side of gasket to
cover.
Allow several minutes for gasket to bond to cover, then assemble covers to engine. Torque capscrews to spec ifications. See Figure 2-167.
NOTE
Use of the adhesive between the cover and the gasket will prevent the gasket from sque ezing out from under the cover.
Cylinder Head Cover (with Mack Dynatard Engine Brake)
There are two types of terminals
assembled to the cylinder head cover.
Type No. 1 has a spring steel strip
(approximately 3/8 inch wide) which
contacts the terminal on the center
valve rocker arm shaft bracket. Type
No. 2 has a circular contactor spring
(approximately
1-5/16
inch
in
diameter).
The circular spring
eliminates the need to position the
contactor in the horizontal plane.
Type No. 1 Assembly (Non-Current)
1. Assemble insulating washers and/or insulating adapter in terminal hole in cylinder head. See Figure 2-168.
2. Position strip on terminal in
cylinder head toward center of engine
so that it will come in contact with
terminal on center valve rocker arm
shaft bracket.
Use Loctite and
torque nut as specified in Figure
2-168.
3. Loosen nuts holding center screw and adjust screw to obtain dimension shown in Figure 2-168.
2-266
1. N'ut
8. Contactor
2. Lock Washer
Spring
3. Terminal Blade 9. Lock Washer
4. Lock Wasner
10. Cylinder Head
5. Plain Washer
Cover 3oss
6. N'ut
11..Adapter(Brass)
7. Screw
12. Insulator
(Nylon)
Figure 2-171. Engine Brake Terminal Parts Arrangement Current
To assemble terminal, proceed as fol lows:
in threads after assembly. (Three Places). 2. Apply Permatex No. 2 to joint between nylon insert and screw.
Figure 2-172. Engine Brake Terminal Assembly Arrangement (End View) Current
VALVE LIFTER COVER
Check valve lifter covers for flat ness. Use new gaskets and assemble front and rear valve lifter covers. See Figure 2-173.
1. Assemble contactor screw with lock washer Tighten nut.
spring to and nut.
2. Install the adapter into the cyl inder head cover boss, using sealant as specified in Figure 2-172.
3. Assemble screw through the adap ter insulator, using sealant. Adjust to dimension as shown in Figure 2-172.
4. Assemble flat washer, lock washer and nut (with sealant) on top side of screw to lock screw at dimension shown in Figure 2-172. Tighten nut.
5. Assemble terminal blade, lock washer, and nut (with sealant), as shown in Figure 2-172. Tighten nut.
2-268
Figure 2-173. Assembling Valve Lifter Covers
NOTE
If any instruction plates are fastened to the original valve lifter cover, make certain that they are replaced when rebuilding engines.
VA*:.
*r54r
.--V '*V *>-
SSSP m
TACHOMETER DRIVE ASSEMBLY
There are two types cf tachometer drive assemblies in use. One assem bly is used solely to drive the tach ometer, while the other is a combina tion fuel transfer pump and tach ometer drive. (The combination drive assembly is covered in the preceding section of this manual.)
Lubricate tachometer shaft and gear. Install tachometer drive assembly in cylinder block, using new gaskets and flat washers under mounting cap screws. Tighten capscrews. See Fig ure 2-185.
Figure 2-184. Combination Fuel Transfer Pump and Tachometer Drive
This unit is assembled at the tach
ometer drive hole location. Lubri
cate shaft and gear. Always use a
new gasket when installing pump. Use
flat washers and capscrews for secur
ing pump to block.
Tighten cap
screws .
Assemble fuel inlet line to transfer pump inlet.
NOTE
For complete details on the two types cf transfer pumps, refer to the "Fuel Section" in this manual.
7-777
EXHAUST. INLET AND WATER MANIFOLDS
Exhaust Manifold
NOTE
After checking exhaust manifold for
restrictions, cracks or wear, assem
ble on cylinder head exhaust manifold
mounting studs, using new gaskets.
Position plain washer and nut locking
tab over studs, and assemble nuts to
studs.
Torque nuts to specifica
tions. See Figure 2-190.
Some installations use a "Patch-Lock" capscrew for mounting the inlet manifolds. With these screws, lockwashers are not required.
On Charge Air Cooling engines, assem
ble rear half of inlet manifold after
charge air cooler header is in posi
tion. Use new gaskets and rubber
hose connection. Tighten capscrews
to specifications.
Tighten hose
clamps.
Figure 2-190. Torquing Exhaust Manifold Stud Nuts
After nuts are torqued, bend locking tab to secure nut. One-half of tab is bent against flat on nut and the other half is bent against side of manifold flange.
Inlet Manifold
Check inlet manifold to make certain flanges are flat and there are no cracks or foreign material in mani fold .
NOTE
On engines equipped with tur bochargers, assemble turbo oil feed line to oil filter adapter before assembling in let manifold.
CAUTION
If turbocharger oil feed check valve is in system on ESI engines, it should be re moved, since field tests in dicate it is not required.
Position lockwasher on capscrew and insert in flange holes. Using new gaskets, assemble manifold to engine. Tighten capscrews to specifications.
Water Manifolds
Non-Charge Air Cooling
Inspect the water manifolds for re
strictions, cracks, and flange wear.
Assemble hose and clamps at center
section of front inlet manifold. Us
ing lockwashers, proper length cap
screws, and new gaskets, assemble
manifold to engine. Assemble rear
water manifold to engine and tighten
all capscrews.
Position hose to
suitable cover front and rear section
for proper clamping area. Tighten
hose clamps.
Charge Air Cooling
On these engines assemble rear sec
tion of water outlet manifold after
charge air cooler manifold is in
position. Use new gaskets and rubber
hose connection. Tighten capscrews
to specifications.
Tighten hose
clamps. See Figure 2-191.
Figure 2-191. Installing Rear Water Outlet Manifold
2-275
lOOLIP.
WATER PUMP
Ma.-'.e certain that oil cooler is :r.
satisfactory condition.
(Refer to
'Cil Cooler Rebuild" Sub-Heading./
Assemble the oil cooler and oil fil ter lube oil fitting to the oil cool er. using a new O-ring gasket. Snug capscrews.
Make certain that water pump is m
satisfactory condition.
(Refer to
Sub-Heading "fater Pump Rebuild".)
Assemble water pump to cylinder block using new gasket. Install capscrews and lockwashers, and torque to speci fications. See Figure 2-193.
Assemble thermostat by-pass tube, hoses, and clamps, at the oil cooler water inlet fitting.
Assemble oil cooler to engine using new gasket between cooler inlet fit ting ana water pump. Snug capscrews. See Figure 2-192.
Figure 2-193. Water Pump Installation
OIL PRESSURE RELIEF VALVE
Refer to Sub-Heading "Lubrication System" for correct oil pressure re lief valve housing.
Align gasket on mounting flange of relief housing to ensure that the proper gasket is used. See Figure 2-194.
Figure 2-192. Assembling Oil Cooler to Engine
Assemble oil cooler oil inlet tube to
cooler, using new O-ring.
Before
fastening inlet tube to cooler, lub
ricate O-ring in oil filter fitting
and insert tube into fitting. Snug
capscrews.
NOTE
The snugged capscrews are tightened when the oil pres sure relief valve housing is assembled to the engine. This will permit alignment of all connecting parts.
n - o ?c
Relief Valve Housing Gasket
CAUTION
Failure to use proper gasket could result in insufficient oil pressure, and cause en gine damage.
THERMOSTAT
Ir.s~a.il new rr.err.cstar seal ir. water outlet fitting using tool J-25637. See Figure 2-205.
the valve snould be locatec m the direction of the arrows. The call checks are located so that c.-.ey are unseated by the direction of coolant flow.
&
Figure 2-205. Installing Thermostat Seal
Using new thermostat and gasket, as semble fitting to water outlet mani fold.
Attach hose from thermostat by-pass tube to water outlet fitting and tighten hose clamps.
figure 2-206 Type II
Coolant Conditioner Adapter
Engines equipped with the 170F. thermostat and no shutterstat (or an optional shutterstat which operates at a lower temperature), have an ex ternal coolant feed line. This sys tem eliminates the inlet check valve that was in the adapter. Instead, the inlet check valve is included with the water inlet fitting which is assembled into the adapter.
COOLANT CONDITIONER
There are two basic types of coolant conditioner arrangements in use.
When assembling adapter to thermostat housing, always use new 0-ring in check valve counterbore. See Figure 2-207 .
I Type I. - Engines equipped with
150?. (or 170 F.) thermostats hav ing a higher opening temperature shutterstat.
Type II. - Engines equipped with a 170F. thermostat and no shutterstat or a lower opening shutterstat.
With this arrangement, two ball check
valves are assembled in the coolant
conditioner adapter. The direction of the coolant flow into the adapter
is indicated by cast arrows s.nown on
top of the adapter.
See Figure
2-206.
Take note of the direction cf the arrows so that check valves can be properly installed. The open end of
Figure 2-207. Assembling Coolant Conditioner Adapter
Before assembling coolant conditioner
to adapter, apply a film of oil to
the sealing gasket.
Tighten con
ditioner one full turn after gasket
contacts adapter.
2-279
OIL COOLER. r.j.3U LD
Oil Cooler Disassemblv
1. Remove water inlet and outlet end caps. See Figures 2-287 and 2-288.
0. Scrape off end cover gaskets. See : igure 2-290 .
Figure 2-290. Scraping End Cover Gasket
4. Remove oil supply line gasket. See Figure 2-291.
Figure 2-288. Removing Water Outlet End Cap
2. Remove bundle from housing. Figure 2-289.
See
5. Remove 0-ring from housing. Figure 2-292 .
See
Figure 2-289 . Removing Bundle
Figure 2-292. Removing 0-Ring 2-303
NOTE
Visually inspect cr.e housing for cracKS which could lead to a leak. If the housing is damaged, replace with new.
6. The oil cooler bundle should be checked for leaks by pressurizing with 80 PSI air pressure and submerg ing in water. If leaks develop, re place bundle with new. See Figure 2293.
Figure 2-295. Installing 0-Ring
3. Spread Perma-Tex gasket sealer on inlet water flange before installing gasket. See Figure 2-296.
Figure 2-293. ffater Testing Bundle
Oil Cooler Assembly
1. Lubricate 0-ring. 294.
See Figure 2-
Figure 2-296. Applying Gasket Sealer to Housing
4. Install gasket on water inlet end of housing. See Figure 2-297.
Figure 2-294. Lubricating 0-Ring
2. Install 0-ring in groove at water outlet end of the oil cooler. See Figure 2-295 .
2-304
5. Spread Perca-Tex gasset sealer on top of gasket. See Figure 2-298.
7. Spread Perma-Tex gasket sealer on bundle end. See Figure 2-301.
Figure 2-298 Applying Gasket Sealer on Gasket
6. Install bundle. Tap last 1/2 inch with a soft-faced hammer to seat bundle past O-ring. See Figures 2299 and 2-300 .
Figure 2-301. Applying Gasket Sealer on Bundle
Figure 2-299. Installing Bundle
Figure 2-302 . Placing Gasket on Bundle
9. Spread Perma-Tex gasket sealer on top of gasket before installing the end cap. See Figure 2-303.
Figure 2-300. Tapping Bundle into Housing
Figure 2-303. Applying Gasket Sealer on Gasket
2-305
13. Install -.-ater inlet end cap. zee Figure 2-304 .
Figure 2-304. Installing Inlet End Cap
11. Torque inlet end cap capscrews to 13 lb.ft. See Figure 2-305.
Figure 2-306. Installing Oil Inlet Plate
2. Install a steel plate with a rub ber gasket on the oil outlet open ing. See Figure 2-307.
Figure 2-305. Torquing Inlet End Cap Capscrews
NOTE
To install the water outlet end cap, spread Perma-Tex gasket sealer on housing flange. Place the gasket on the sealer then put seal on top of the gasket. Install the end cap and torque cap screws tc 13 lb. ft.
Figure 2-307. Installing Oil Outlet Plate
3. Connect air line and pressurize
to 80 psi.
Submerge in water to
check for leaks. See Figure 2-308.
Pressure Test Oil Cooler Assembly
1. Install a steel plate with a rub ber gasket and an air line fitting on the oil inlet opening. See Figure 2306.
Figure 2-308. Pressure Testing Completed Assembly
2-306
18. Torque- pulley put to ICO lb.: See Figure 2-204 .
CO. Place gusKet on sealer making sure to line up tbe r.oles. See Figure 2-336.
Figure 2-334 . Torquing Pulley Nut
21. Position housing cover assembly over housing. See Figure 2-337.
NOTE
When torquing the pulley nut on the shaft, it is necessary to use a strap wrench to keep the pulley and shaft from turning while tightening the pulley nut.
19. Place gasket sealer on the gasket seating surface of the housing. See Figure 2-335 .
Figure 2-337 . Positioning Housing Cover
22. Coat housing cover capscrew threads with sealing compound and tighten. See Figure 2-338 .
Figure 2-335 . Applying Gasket Sealer 2-312
Figure 2-338. Applying Sealer to Capscrews
1. Air Valve Assembly 2. Tip Turbine Fan 3. Header Plate 4. Inlet Manifold Gasket
5 . Rear Inlet Manifold 9. Water Outlet Tube
6 . Water-to-Air Core 10. Water Inlet Tube
7 . Air-to-Air Core
11. Housing Mounting
8 . Housing
Bracket
Figure 2-357. Exploded Vi ew of Series Charge Air C ooling Arrangement
Series Charge Air Cooling
The two stage, or series, charge air cooling arrangement combines a water:o-air heat exchanger with an air-toair heat exchanger. The combination of these two units lowers the temper ature of the air coming from the tur bocharger to the inlet manifolds by about 180 degrees F. [100 degrees C.] See Figure 2-357.
The coolant for the water-to-air heat exchanger is drawn off the top of the water pump, circulated through the core and returned to the cooling sys tem via the oil cooler end cap. See Figure 2-357.
Assemciv Charge Air Cooling Arrangement 1. 7o install the charge air cooling housing and intake manifold, place two locating guide pins in the cylin der ceaa to help in positioning the manifold- Assemble gasket over guide pins and position manifold over pins. Install mounting capscrews (patchlock) and torque to 35-45 lb.ft. 2. Install the thermostat housing. See Figure 2-381.
Figure 2-383. Clamps Locations
5. Install the coolant conditioner mounting plate and torque capscrews to 12-14 lb.ft. [8.85-10.32 Nm|. See Figure 2-384.
Figure 2-381. Installing Thermostat Housing
3. Install the lower two capscrews in the thermostat housing. Torque to 12-14 lb.ft. See Figure 2-382.
Figure 2-384. Installing Mounting Plate
Figure 2-382. Lower Capscrews Location
6. Install coolant conditioner by hand. Tighten conditioner 3/4 turn after the gasket comes in contact with the mounting plate.
4. Position the hose clamps and tighten. See Figure 2-383.
7. Install the coolant conditioner inlet line. See Figure 2-385.
2-330
12. Connect ar.c tighten the turbo charger oil feed line. See Figure
2-330.
15. Position and tighten the turbine fan bleed line clamps. Figure 2-392.
tip See
Figure 2-390. Connecting Oil Line
13. Install the air-to-air core in the housing. Then install the waterto-air core being careful not to dam age the ends that extend through the housing.
NOTE
Wipe housing or gasket sur faces with talcum powder or Dow Corning 44 silicone grease before installing in housing to prevent gasket sticking.
14. Install the header plate and
capscrews.
Torque capscrews to
23 lb. ft. See Figure 2-391
Figure 2-392. Clamp Locations
16. Series Charge Air Cooling Only Place the water inlet and outlet tubes into the water-to-air core.
17. Series Charge Air Cooling Only Tighten clamps at both ends of the water tubes. See Figure 2-393.
Figure 2-393. Clamp Locations
Figure 2-391. Installing Headplate Capscrews
2-332
18. Position and tighten the turbo charger crossover tube connecting sleeve clamps. See Figure 2-394.
air-to-air heat exchanger
Cleaning the Atr-to-Air Heat Zxchaneer
NOTE
The cleaning procedure and the gasket replacing proce dure is the same for both the air-to-air heat exchanger and the air-to-air portion of the series heat exchanger. This can be done by either one of two cethods.
1. Steam cleaning.
CAUTION
Steam pressure exceeding 40
psi
and/or
temperatures
exceeding 400 degrees F. can
damage core and gaskets.
Figure 2-395. Pulling Gasket
2. Using a razor blade or a sharp knife, cut away the excessive bonding material. See Figure 2-396.
2. Detergent cleaning.
Use a solution of household laundry detergent. Flush through the core several times followed by a rinse with warm water. Use low pressure air to blow ary.
CAUTION
Do NOT under any circum stances use strong caustic solutions such as "Oakite" or acids such as bowl cleaners, hydrochloric acid, etc. as they will corrode the core and damage the gaskets. Al so, do NOT use shop solvents to clean the core as they will damage the gaskets.
Gasket Removal
1. Pull off old gaskets. See Figure 2-395.
Figure 2-396. Cutting Material
NOTE
It is not necessary to remove all the bonding material out of the depressed areas since the new gasket will seal per fectly to the slightly uneven old gasket surface.
3. Remove all loose shavings and cuttings.
2-334
jasket Ir.stai iatice
NOTE
The unit must be clean and dry before installing the new gaskets.
1. Place the unit on a flat work bench with the gasket surface up. (The turbocharger air flow arrow pointing up or down.)
2. Soak a clean rag with alcohol and wipe the old gasket surface and the new gasket to remove all oily resi due.
Figure 2-398. Applying Agent to Gasket
5. Place gasket on core and adjust into place. See Figure 2-399.
3. Run a bead of silicone rubber bonding agent on the corners of the core. See Figure 2-397.
Figure 2-397. Applying Agent to Core
4. Run a bead of silicone rubber bonding agent on the four sides of the new gasket. See Figure 2-398.
Figure 2-399. Placing Gasket
CAUTION
Refer to diagrams on gasket shipping container for proper installation position.
6. Invert the core and repeat steps 3 through 5 for the second gasket.
NOTE
If the end gaskets are damag ed, proceed with steps 7 through 10; otherwise, omit these steps and proceed with step 11.
2-335
Figure 2-402. Placing Gasket
Figure 2-400. Removing End Gasket
8. Soak a clean rag with alcohol and wipe the old gasket surface and the new gasket to remove all oily resi due.
NOTE
Hold the end gaskets in posi tion with string or tape wrapped around the entire unit until the bonding agent takes a set.
11. Check all the gaskets to make sure they have not shifted during handling.
9. Run a bead of silicone rubber bonding agent on the flat side of the new gasket. See Figure 2-401.
NOTE
The gaskets may he adjusted during the first five minutes while the silicone rubber bonding agent is curing.
Figure 2-401. Applying Agent to End Gasket
10. Place new gasket into position. See Figure 2-402.
12. Let the entire unit stand undis turbed for 1 to 1-1/2 hours minimum before installing.
13. Visually inspect the bond after curing to make sure that the gasket is firmly attached all the way around. Gaps that are found should be filled with additional silicone rubber bonding agent. Let cure.
CYLINDER HEAD GASKETS
Two {2) types of cylinder head gas.-:ets are currently being used during engine rebuild. The "folded-steel" type gasket (see Figure 11) is used with the "flat-flange" type cyl inder liner (see Figure 12).
Figure 11. Folded-Steel Type Gasket
FLAT SUBFACE,
Figure 12. Flat-Flange Type Cylinder Liner
Figure 14. Beaded-Type Cylinder Liner (4-7/8 In. Bore)
The "Maxidyne-Type" gasket (consisting of a one-piece composition gasket and three (3) fire rings as shown in Figure 13 must be used with the beaded-type liners as shown in Fig
ures 14 and 15.
NOTE
Before assembly of cylinder head, always check the circular grooves in the head surface di rectly opposite the liner bead. They must be 0. 008 In. deep and absolutely clean to assure a good fire ring seal.
Figure 15. Beaded-Type Cylinder Liner (5 In. Bore-END707 and END711 Engines)
CAUTION Alwavs use new gaskets and fire rings when assembling engines.
2-367
Early engine moceis had by-pass type oii filters. The quantity of oil going through this type of filter is controlled by a meterins orifice. See Figure 65.
M-U 1. Oil Pressure Feed Holes 2. Oil Drain Hole Figure 66. Top View of Oil Filter Pad Cover
1. Metering Orifice 2. Oil Inlet 3. Oil Outlet
Figure 6 5. 3y-Pass Type Filter
Figure 67. Bottom View of Oil Filter Pad Cover
This filter used flexible lines for oil supply to filter and oil recurn to engine. The oil lines are connected to a cover which is as sembled to the oil filter pad on the left-hand side of the engine.
Because of revisions that have been made to the cast contours of the pad on the current cylinder blocks, oil filter pad cover, 368GB29D, and gasket, 590GB1152B, must be used with a by-pass filter installation. See Figures 66, 67, and 63.
JM
Figure 68. Oil Filter Pad Cover Gasket
CAUTION
Failure to use the correct cover and gasket, on current cylinder blocks, will result in low oil pressure and possible engine damage.
If the replaced engine has a full-flow by-pass type of filter, as shown in Figure 69 or a spin-on type filter, as shown in Figure 70, use the adapters or housings from the orig inal engine.
2-382
OIL PRESSURE RELIEF VALVE HOUSING GASKET
Since service gasket kits include different types of gaskets to cover the various oil pressure relief valve housing designs, it is important that the correct gasket be used.
Aithougn these gaskets are similar in ap
pearance, they are not interchangeable. Identification of the correct gasket can be made by comparing with the following illus trations, which are full size. See Figures 73. 74. 75 and 76.
Figure 73. Oil Pressure Relief Valve Housing Gasket 590GB1298B
Gasket Part No.
590GB1298B (See Figure 73)
Application
All ESI and ESI Plus Six Cylinder Engines. Piston Cooled and Non-Piston Cooled
Oil Pressure Relief Valve Housing
766GB269-P1.P2.S:P3 (Non-Piston Cooled
Engines)
766GB51 -PI. P2 & P3 (Piston Cooled
Engines)
2-384
NOTE
The "B" version of the above gasket includes a tab at the bottom right corner, which will indicate at a glance whether the easket is properly installed.
Provisions nave oeen rr.aae or. joui
the case to install buttress screws which fit into the main bearing cap. The buttress screws are used on both sides of ail main bearing caps. They must be removed in order to remove the mam bearing caps.
Block Preparation
1. Check the cylinder block deck surface for warpage. If warpage is excessive be sure that the maximum amount of material removal limit is not exceeded.
Figure 2-9 Cylinder Sleeve Bore Measuring Tool
CAUTION
The piston travel above the cylinder block deck is critical and must be checked during assembly to insure proper clearance of piston with cylinder head and valve.
2. Remove all core plugs and fittings from the cylinder block and remove any accumulation of rust and sludges.
3. Check block for cracks, the condition of threaded holes and the straightness of the mating flanges.
4. Thoroughly inspect the upper edge of the cylinder sleeve counterbore in the block for signs of pitting or errosion. Rework as required. Shims are available to obtain correct sleeve height at reassembly.
5. Blow all passages thoroughly with compressed air.
6. Coat new O-ring with sealant, place on core plugs and install plugs in block.
7. Install all oil gallery plugs and gaskets using Permatex sealant or equivalent to insure positive sealing.
Cylinder Sleeve
The cylinder sleeves are wet type, centrifugal cast iron and are available in standard size. A bead is provided around top of seating flange for using a fire ring type cylinder head gasket. Clean sleeve flanges using a brass wire rotary brush to be sure of effective fire ring sealing. Check cylinder sleeve for out-of-round and taper. Use tool J5347-01 and measure each sleeve I.D. See Figure 2-9. Take readings intwo directions at each of three levels: top, center, and bottom.
Check the sleeve height above the cylinder
block deck. Use gage J26 94 8.
See
Figure 2-10.
Figure 2-10. Checking Sleeve Height Above Block Deck
Honing
If sleeve bore when in place does not exceed out-of-round and taper limit, clean up I.D. with a suitable hone, 150 to 220 grit, to produce a diamond criss-cross pattern surface finish of 25 to 40 micro-inch rms.
Wash liner borewitha solution of household laundry detergent and air blow dry. Wipe liner bore with a clean oii soaked cloth.
Sleeve Rebore
If sleeve exceeds out-of-round and taper limit, the sleeve may be resized using boring bar equipment to receive the next applicable oversize piston. After re-sizing, hone 150 to 220 grit to produce a diamond criss-cross pattern surface finish of 25 to 40 micro-inch rms.
2-407
Figure 2-13.Installing Cylinder Sleeve
Figure 2-14. Installing Camshaft Bushing
CAUTION
If for any reason the sleeve is backed out even as little as 1 '8 inch, it may roll the top seal over the relief edge damaging the seal. Remove sleeve and replace seals.
8. Secure cylinder sleeve in pairs using keeper washer and capscrew at center cylinder head capscrew hole until pistons, rings and cylinder heads are installed.
Expand the front oil gallery plug to offer resistance upon entering bore. The front oil gallery plug is further secured by installing the camshaft thrust washer which partially covers the plug. Patchlock countersunk Allenhead capscrews are used to secure the thrust washer in place. It is imperative that the mating
surfaces be clean and new Patchlock screws are used. See Figure 2-15.
Camshaft Bushings
There are two camshaft bushing widths. The front camshaft bushing is the wider bushing; the remaining bushings are of a narrower width. All bushings are located at set distances measured from the forward machined surface of the camshaft thrust washer recess to the forward edge of subsequent bushings. Use special tool kit J-21428 to install or remove bushings. Coat outer surface of the bushings with engine oil before installation. The oil supply hole in the bushing should be located to the right as viewed from above and standing to the rear of the engine. The camshaft bushing interlocking split should be installed upward. See Figure 2-14.
Figure 2-15.Installing Camshaft Thrust Washer
NOTE
The rear camshaft bushing can be removed, using special tool J-21385, without removing the flywheel housing.
Apply a coat of Permatex to the rear oil gallery plug and gasket and install in rear oil gallery. See Figure 2-16.
2-409
4. Remove front bearing retainer and drive front bearing and spacer from housing out through the front.
5. Reverse housing and drive rear bearing from housing out through the rear. Inspection
1. Inspect the water pump drive gear for wear pattern and condition of teeth.
2. Inspect and check shaft for journal wear and condition of internal spline.
3. Inspect and check condition of the bearings. Assembly
1. Install front bearing (double row ball bearing) in housing from the front.
2. Install retaining ring, tapered side outward, in housing groove.
3. Start water pump drive gear and shaft assembly into the bearing bore. Do not completely install.
4. Rotate gear and tap with a soft face hammer until gear rotates concentric with the bearing. 5. Press gear and shaft assembly into bearing until it bottoms on shoulder on shaft. 6. Invert housing and gear and install spacer. 7. Install rear bearing with seal side outward in housing. 8. Clamp assembly m a suitable clamping fixture to hold gear and install water pump drive shaft screw. Tighten to recommended torque. 50 lb. ft. 9. Install O-ring in the groove on outer periphery of the housing. 10. Lubricate O-ring seal generously and install drive assembly in cylinder block recess with flat side of housing toward camshaft gear.
NOTE
It is important to generously lubricate O-ring seal before installing in block. This will prevent the O-ring from rolling on upper surface and restricting oil supply to the water pump bearings.
11. Install '.hree water pump housing capscrews securing assemciy in position. Tighten to recommended torque. 26 lb. ft.
TIMING GEAR COVER
Inspection
Inspect timing gear cover for dents, condition of threaded holes and straightness of flanges. Installation
1. Install crankshaft front oil seal into the cover using tool J-21375. 2. Install the adjustable camshaft thrust button from the inside and position the washer and jam nut on the outside of the cover. 3. Adjust camshaft thrust button to its retracted position. 4. Install six guide studs. Two guide studs are used at the lowest point, highest point and one adjacent to the water pump drive and the final stud adjacent to the drive provision directly opposite the water pump drive. 5. Install the timing gear gasket over guide studs. 6. Install the timing gear cover over the guide studs and push cover into position. 7. Install all cover capscrews loosely.
8. Install water pump drive alignment tool J-21382 and crankshaft oil seal alignment tool J-21381. Torque all capscrews.
CRANKSHAFT VIBRATION DAMPER AND HUB
Inspection
1. Inspect crankshaft vibration damper hub for scoring, condition of flange, threaded holes and keyway. 2. Inspect the vibration damper for general condition, mounting threaded holes and housing.
Installation
1. Position crankshaft keyway UP and install key.
2. Heat crankshaft vibration damper hub in hot oil to 250 degrees F.
3. Align crankshaft hub on key and install hub. See Figure 2-49.
2-427
_;u. sk(a>t :
MUl
2. Inspect and check the bolt hoies for elongation and baffle for security.
3. Inspect and check drain hole for condition of threads.
Installation
1. Position gasket on oil pan and position oil pan on cylinder block.
2. Install and tighten oil pan retaining capscrews evenly to prevent oil leakage.
AUXILIARY DRIVE ASSEMBLY NON-CURRENT (Figure 2-50) Prior to following:
Engine
ENDT(B)865 ENDT(B)865C ENDT(B)866 ENDT(B)866C
Serial Number
TB865 5F 9380 T865C 5M 5045 T866 5F 8981 T866C 5M 4357
* Not required on Current Production Engines
Figure 2-49. Vibration Damper and Hub Arrangement
4. Install hub washer and retaining screws. Torque screws.
5. Install vibration damper, spacer and timing disc on crankshaft hub: the holes will only line up one way.
6. Install retaining capscrews securing assembly.
NOTE
When all parts are assembled on the crankshaft, keyway up, the scribe mark on the damper rim must be up. The TDC mark must align with the timing indicator 30 degrees to the left of the engine centeriine.
OIL PAN
Inspection
1. Inspect oil pan for dents, cracks and condition of flange.
Figure 2-50. Auxiliary Drive Assembly
Description
The auxiliary drive is a complete unit sub-assembly located between the cylinder heads on the front of the engine. The auxiliary drive consists of a drive housing, idler shaft and gear assembly and drive shaft. It is gear driven from the camshaft.
DRIVE HOUSING Description
The auxiliary drive housing is an alloy casting and supports the drives for the injection pump, air compressor, tachometer drive and hydraulic steering pump.
Installation
1. Time auxiliary drive :o camshaft gear. Install both push rods ir. No. 6 cylinder location. Bar engine over until movement is felt in both push rods simultaneously and the timing indicator pointer indicates TDC for No. 1 and 6 cylinders. The single punch mark on the camshaft gear will be in the upright position.
2. Install O-ring in oil passage port at right hand front top edge of cylinder biock.
3. Apply a bead of 243SX32 gasket compound or equivalent to mating surfaces of the auxiliary drive housing.
4. Place auxiliary housing assembly on top of the block carefully.
NOTE
Be sure timing gear cover gasket is properly positioned and the single timing mark on the camshaft gear alignes with the single timing mark on the auxiliary drive gear.
5. Install ail nine capscrews and washers hand tight.
6. Torque the two lower timing gear cover to auxiliary housing capscrews.
7. Torque all auxiliary housing to cylinder block capscrews.
8. Release the torque on the two timing gear cover to auxiliary housing capscrews then retorque the same capscrews.
NOTE
This procedure will align auxiliary housing to front face of the cylinder block and permit block surface to butt fully to mating surface of auxiliary housing.
9. Check cacklasn between camshaft gear and auxiliary cr.ve gear. If backlash is not within limits, loosen auxiliary housing capscrews and reposition r.ousing by tapping with a soft faced maiie:. Retorque capscrews and recheck backlash.
NOTE
Care must be taken at this time to have a_i pipe plugs in the auxiliary drive oii gallery passages. Access to these plugs becomes increasingly difficult at later assembly points.
VALVE LIFTER COVERS
The center valve lifter cover is a steel stamping and requires a new gasket at assembly. The rear valve lifter cover is cast aluminum. At assembly apply a bead of gasket compound 243SX32 to the cover and cylinder biock mating area.
INJECTION PUMP
Installation
1. Bar engine over in the normal direction of rotation until the No. 1 cylinder piston is at TDC, as indicated by the timing indicator, and the timing marks on the auxiliary drive shaft gear aligns with the timing mark on the auxiliary drive idler. The pin hole location will be a; the five o'clock position and the coupling tangs are at 12 degrees 36 minutes off the horizontal. See Figure 48.
2. Bar engine back approximately 40 degrees.
3. Bar engine over in the normal direction of rotation until timing indicator reads the B.T.C. setting as specified on the injection pump name plate. In this position the tangs on the drive coupling will be approximately horizontal and the drive coupling pin hole will be approximately at the 4:30 o'clock position. The gear marks will be approximately 15 degrees 30 minutes to the right. See Figure 2-55.
2-431
NOTE
End piay is controLe a by the drive shaft thrust washers. Check the following if the er.c play does not fall within the correct specifica tion. MaJke corrections as re quired.
1. Worn thrust washers. 2. Worn thrust journals. 3. Shaft bushings not properly
installed.
Figure 2-79. Auxiliary Drive Gear
13. Install auxiliary drive gear retaining ring. See Figure 2-80.
INSTALLATION
1. Thoroughly clean the auxiliary housing mounting surface on the engine block and remove the exposed portion of the timing gear cover gasket.
2. Carefully cut a new timing gear cover gasket to the exact size of the removed portion and install on the timing gear cover using a good grade gasket sealer.
NOTE
Apply an extra bead of gasket sealer where the new gasket meets the old gasket.
3. Install a new O-ring seal in the engine block to auxiliary oil supply port.
4. Apply a bead of Silastic to the mounting surface of the block. Use extreme care not to allow the Silastic to enter /block the oil supply port. See Figure 2-81.
Figure 2-80. Installing Retaining Ring
14. Place the auxiliary housing on end and check end play with a dial indicator.
Figure 2-81. Applying Silastic 5. Install the auxiliary nousing on the engine
block.
2-441
CYLINDER head installation
NOTE
New cylinder head gaskets and fire rings must be installed each time cylinder heads are removed.
1. Clean the cylinder block deck thoroughly.
2. Install new cylinder head gasket on deck. Position of gasket is determined by guide pins in the upper deck.
NOTE
Do not use a sealing compound or soak cylinder head gaskets. They are all pre-coated;
3. Install new fire ring carefully fitted over circular bead on cylinder sleeve flange. See Figure 2-102.
6. Install cylinder nead or. oiock. 7. Install fourteen cylinder head capscrews. 8. Torque capscrews on each head progressively in steps of 50 to 100 to 175. and finally to 225 lb. ft. in sequence as shown. See Figure 2-103.
'aun
Figure 2-103. Cylinder Head Tightening Sequence
Figure 2-102. Cylinder Head Installation
4. Clean the surface of the cylinder head and ciruclar groove for the fire ring.
5. Carefully position the cylinder head assembly over the cylinder block deck aligning the guide pins in the block with the guide hoies in cylinder head.
PUSH RODS
Description
The push rods for the intake and exhaust valve rocker arms are tubular steel with spherical ends. Engines not fitted with the Dynatard engine brake feature identical 1 '2 inch O. D. x 14-17/64 11 push rods; however, when the engine is fitted with the Dynatard engine brake system the exhaust valve rocker arm push rod is a solid steel rod 5/8 inch 0.D. x 14 inches long.
Inspection
1. Inspect and check the push rods for length and straightness. Replace any that are bent.
2. Inspect and check the spherical surfaces for wear and tightness to tube.
Installation
Apply a light coat of lubricating oil to the spherical ends and install the push rods in the valve lifters.
2-449
4. Continue adjusting '.jive .ash for the remaining cylinder pistons _n taring order placing each cylinder piston at TDC with respective 1/4 turns of the engine crankshaft.
5. Properly secure aduustine screw locknut after each cylinder piston valve lash adjustment.
INLET MANIFOLD
Inspection
1. Inspect and chec* the inlet manifolds for restrictions.
2. Inspect and check mounting flanges for erosion, cracks and straightness.
Installation
1. Place r.ew gaskets between the inlet manifold and cylinder head.
2. Install right and left hand inlet manifolds and lifting eyes. Secure to cylinder head by installing attaching capscrews and tighten to the recommended torque.
3. Place a new inlet manifold fitting gasket on the top of each inlet manifold and install inlet manifold inlet fitting.
4. Install tee fitting and complete inlet manifold assembly.
WATER OUTLET MANIFOLD
Inspection
1. Inspect water outlet manifold for restrictions.
2. Inspect and check mounting flanges for cracks and straightness.
Installation
1. Place new gasket between right bank and left bank water manifold and the mating cylinder heads.
2. Install and tighten attaching capscrews to the proper torque.
3. Install thermostats in the right and left bank water manifolds.
4. Install thermostat gaskets, water outlet fittings, thermostat seals and water outlet by-pass elbows.
5. Secure assembly to the water manifold by installing the attaching capscrews.
EXHAUST MANIFOLD
Inspection
1. Inspect and check the exhaust manifold for restrictions.
2. Inspect and check the mounting flanges for erosion, cracks and straightness.
Installation
1. Place new gaskets between exhaust manifold and cylinder head.
2. Install and tighten the attaching capscrews and washers to the proper torque.
CYLINDER HEAD COVERS
Inspection
1. Inspect and check the cylinder head covers for cleanliness, cents and straightness of flange.
2. Inspect and check b reamer m cover, u applicable, to be sure it is not plugged.
Installation
1. Cement a new gasket to the mounting flange of the cylinder head cover.
2. Position the cylinder head cover over rocker arms.
3. Install and torque cover retaining capscrews.
TURBOCHARGER
Description
The turbocharger is an exhaust gas driven air compressor. See Figure2-10&The purpose of the turbocharger is to increase the supply of air to the cylinders and thus bum more fuel which in tum produces more power.
flows around me turbine housing and radially inward causing the turbine wheel to rotate. The exhaust gas is then discharged through the center of the turbine housing into the exhaust pipe.
The bearing housing contains the through-shaft, bearings, seals, and oil passages.
The bearings are of the floating sleeve type and are pressure lubricated from the engine oil supply system. Piston ring type oil seals are used at each end of the shaft to effectively seal off the oil.
The compressor housing contains the compressor wheel and air enters at the center of the compressor wheel and flows radially outward intothe compressor wheel and flows radially outward into the compressor housing. The air leaves through a tangential outlet on the outside of the compressor housing and is ducted to the inlet manifold.
Checks Before Removal
If turbocharger malfunction is suspected, make the following checks before removal of turbocharger from the engine.
1. Start engine and check for unusual noise or vibration from turbocharger. This will idicate out-of-balance, rubbing or damage to compressor or turbine wheels.
2. Check for leaks in the air system from
Figure 2-106. Exhaust Driven Turbocharger
turbocharger to intake manifold and from intake manifold to cylinder block. Be sure all
bolts, clamps and connections are tight and
gaskets are not blown and are in proper
location.
The turbocharger consists of three main parts;
the turbine housing, the bearing housing and
3. Check air cleaner and air intake system,
the compressor housing. The turbine housing
from the air cleaner to turbocharger, for
is located at one end of the bearing housing
restrictions to air flow or leaks.
and the compressor housing is located at the
other end. A common shaft connects, the
4. Check exhaust system from cylinder block
turbine wheel and compressor wheel.
to turbocharger for exhaust leaks. Be sure all
bolts, clamps and connections are tight and
The turbine end of the turbocharger uses
gaskets are not blown and are in proper
exhaust gas energy normally discharged to the
location.
atmosphere. The exhaust gas enters the
turbocharger through the flange connection
5. Check exhaust system from turbocharger
3-
on the exhaust manifold. The exhaust gas
to outlet for restrictions.
4?
2-453
.Reassembly
Install oil seal ring in groove in housing and position bearing and shaft assembly in housing. Place housing assembly onasuitable press, using a bucking bar through the plug hole to back up shaft and bearing assem bly, and Dress fan pulley on shaft. See Fig ure 2-107. Install bearing retainer using suitable pliers. Be sure retainer is properly seated in groove. Pack grease compart ment 1/3 full with Alvania No. 3 water insoluble lithium soap petroleum grease or equivalent. Install plug.
Installation
1. Press a new oil seal in support housing.
2. Install a new gasket and position sup port housing over auxiliary shaft extension and secure with capscrews. Be sure oil seal is properly positioned over shaft be fore tightening capscrews.
3. Place key in slot of auxiliary shaft ex tension and align and Install driving pulley.
4. Secure with bolt and washer.
5. Position fan pulley housing in support housing and secure loosely with capscrews and washers. Install adjustment nut "D" loosely on stud. See Figure 2-107
6. Install the two fan belts. Make adjust ment with nut "D" until the fan belts are properly tensioned. Refer to Fan Belts for procedure. Tighten lock plate screws.
Extension Driven Type Disassembly
Remove fan belt and fan. Remove housing retaining capscrews and remove housing.
NOTE
One capscrew cannot be completely removed due to interference with puiley hub.
Place housing on a suitable adapter scrap auxiliary drive extension) in vise and re move fan hub retaining lock nut and wash er. Remove fan hub using a suitable puller in threaded holes of inner hub. Remove key from shaft. Remove bearing retainer snap ring using pliers.
Place housing, rear side down, on adapter and press shaft from housing. Invert hous ing and press front bearing from hous ing. Remove grease compartment vent. Wash parts in suitable solvent and air blow dry.
Inspect all parts and replace as required.
Reassembly
1. Install front (large) bearing in housing, shielded side of bearing facing outward.
2. Install Tru-arc bearing retainer ring with taper facing out. Bottom retainer ring in groove.
3. Install short key at flange end of fan driveshaft.
4. Install fiber coupling on shaft with face inside of coupling seating against shaft flange. Install coupling spacer washer against coupling.
5. Install rear (small) bearing on shaft against coupling with sealed side toward coupling.
6. Install bearing spacer on shaft.
7. Pack housing 1/3 full with Alvania No. 3 water insoluble lithium soap petroleum grease or equivalent.
8. Place fan drive housing nose down on press base and install shaft with coupling, bearing and spacer in housing and through large bearing. Press shaft assembly into housing using suitable plug. See Figure 2-109.
2-456
11. Place nousing assembly on a suitable adaptor in vise and install hub retaining washer and locknut. See Figure 2-111.
12. Install grease vent. (Install auxiliary drivesnaft extension, if removed).
Figure 2-109. Installing Fan Drive Shaft V-8 Series
9. Invert housing on press stand and sup port coupling end of shaft on press base. Install long housing capscrew and lockwasher before installing fan drive pulley.
10. Install long key in shaft, align, and using a suitable tool to engage inner part of hub, press hub on shaft. See Figure 2-110
Figure 2-111. Installing Hub Retaining Washer and Locknut
Installation
1. Place new gasket on housing and install housing, grease vent at top, aligning coupling with auxiliary driveshaft extension.
2. Assemble fan to hub. Be sure bolts are proper length, 3/8-16 x 7/8 inch.
Figure 2-110. Installing Fan Drive Hub
CAUTION
Longer bolts will engage inner member and cancel out vibration absorbing effect of elastic insu lator and shorten service life of fan drive assembly.
3. Install fan belt. Refer to Fan Belts for proper tensioning.
2-457
Oil Pun:? Inlet Tube
Piston Cooling Tubes
Figure 119. Installing Oil Pump Inlet Tube
Assemble gaskets, capscrews, and washers to oil pump inlet tube fit ting flange and mount to oil pump. See Figure 119.
Oil Pump Outlet Tube
Figure 121. Piston Cooling Cross-Over Tube (Front)
Assemble "0"-ring over end of tube
and into flange counterbore.
See
Figure 121.
Lubricate "0''-rings.
(Coating ''0"-ring which fits in coun
terbore with a little grease will aid
in holding it in place.)
Assemble screw and washer in flange end and mount to cylinder block. Tighten screws to specifications.
Figure 120. Installing Oil Pump Outlet Tube
Assemble oil pump outlet tube fitting
at cylinder block and hold in
position by installing capscrews and
washers.
Do not tighten until
complete assembly is completed.
Assemble "0"-ring to oil pump outlet
tube.
See Figure 120.
Lubricate
"0"-ring and insert tube into fit
ting at cylinder block. Mount to oil
pump using capscrews and washers.
Torque all screws to specifications.
NOTE
Gaskets are not used between fitting and block and between fitting and oil pump.
Figure 122. Piston Cooling Cross-Over Tube (Rear)
Assemble "0"-rings into flange coun terbore at both ends of tube. See Figure 122. Use a light coating of grease in "0"-rings to aid in holding them in place.
Position cross-over tube on cylinder block.
2-541
TIMING GEAR COVER AND OIL PAN
Inspection
Inspect tiie timing gear cover mounting surface for flatness of flanges and condition of threaded holes.
Timing Gear Cover Installation
1. Timing Gear Cover Alignment Tool (at Water Pump Location
2. Water Pump Locating Pin 3. Timing Gear Cover Alignment
Tool (at Crankshaft Location) 4. Timing Indicator 5. Timing Indicator Mounting Pins 6. Alternator Drive Cover Stud 7. Camshaft Thrust Screw 8. Camshaft Thrust Screw Nut 9. Camshaft Thrust Screw Nut
Washer Figure 124. Timing Gear Cover
Installation Install the adjustable camshaft thrust screw from the inside of the timing cover. Position washer and nut on outside of cover and adjust thrust screw to the retracted posi tion. See Items 7, 8 and 9 in Figure 124.
Thread alternator drive cover stud into timing gear cover. Apply Loctlte 271 before installing stud. See Item 6 in Figure 124. Then install gasket, cover and tighten capscrews and nut.
Install water pump locating pin in cover. Height of pin above mounting surface should be 0.250 - 0.200 inch es. See Item 2 in Figure 124.
Place timing indicator over locating holes in timing gear cover and drive pins into holes to secure indicator. See Items 4 and 5 in Figure 124.
Install six guide studs in the cyl inder block. Two guide studs are used at the lowest point, two at the high est point, and one adjacent to the water pump drive location and the final stud on the side opposite the water pump drive location.
Install the timing gear cover gasket over the guide studs.
Install timing gear cover over guide studs and push cover into position.
Install all cover capscrews loosely.
Install timing gear cover alignment tool J-29287, at water pump location. See Item 1 in Figure 124.
Install timing gear cover alignment tool J-29288, over crankshaft stub end. See Item 3 in Figure 124.
Make certain that timing gear cover lower edge is aligned with the oil pan mounting surface on the cylinder block.
After timing gear cover is properly aligned, remove the guide studs. In stall the remaining capscrews and torque to 42 lb. ft.
The timing gear cover gasket will
extend below the cover and the block
by approximately 1/8 inch.
This
excess gasket material should be
trimmed flush with the cover and
block.
2-543
Check capscrew holes for elongation.
cylinder block.
Check drain hole for condition of threads.
If oil pan is satisfactory, position new gasket on oil pan and assemble to
Install and tighten oil pan retaining capscrews evenly and to specifica tions. This will prevent distortion of mounting flange and possible leak age problems.
2-545
NOTE
If the auxiliary housing is being installed on a block that does not have a new tim ing gear cover gasket, pro ceed as follows:
1. Before installing auxil iary housing on the engine block, remove the exposed portion of the timing gear cover gasket.
2. Carefully cut a new timing gear cover gasket to the ex act size as the removed por tion and install on the tim ing gear cover using a good grade gasket sealer.
3. Apply an extra bead of gasket sealer where the new gasket meets the old gasket.
Install the auxiliary housing on the cylinder block. Assemble the auxil iary housing to cylinder block cap screws and lockwashers. Make certain that the front face of the auxiliary drive housing is in line with the front face of the cylinder block within 0.005 inches. Snug capscrews, but do not tighten.
Assemble capscrews through timing
gear cover and into auxiliary drive
housing. Tighten capscrews to speci
fications.
Then tighten auxiliary
drive housing mounting capscrews.
NOTE
Disregard timing marks that
appear on the auxiliary drive shaft gear. Timing of the auxiliary drive shaft gear to the camshaft is not required for assembly of this short drive auxiliary housing.
Check the backlash between the auxil
iary drive shaft gear to camshaft
gear.
Should be 0.0037 to 0.0088
inches.
2-564
Engine Breather
Assemble four breather tube studs to valve lifter cover using Loctite 271. See Figure 185, Items 3 and 12.
Assemble breather cover and filter in valve lifter cover. See Figure 185, Items 10 and 11.
Assemble new gasket over studs, and fasten breather tube with plain wash ers and nuts. See Figure 185. Items 1, 2, 4, and 5.
Oil Filler Tube (or Cover Plate)
Thread oil filler tube flange stud (or cover plate stud) to valve lifter cover, using Loctite 271. Apply FIPG compound to counting surface on cover. Assemble flange (or cover) to valve lifter cover and tighten the mounting stud nut and capscrew.
2-566
1. Fan Pulley 2. Fan Pulley Screw 3. Fan Pulley Screw Washer 4. Fan Pulley Key 5. Auxiliary Drive Shaft Seal
(at Fan Drive Housing)
.6 Fan Drive Housing Screw
7. Fan Drive Housing Screw Washer
.8 Timing Gear Cover .9. Fan Drive Housing Gasket
10 Fan Drive Housing
.11 Auxiliary Drive Shaft
Figure 186. Fan Drive Arrangement
The fan drive is mounted on the front end of the auxiliary drive shaft. See Figure 186.
Inspection
Using new gasket assemble fan drive housing to timing gear cover with capscrews and washers. See Figure 187.
Inspect fan drive housing to make certain that counting flange is flat and free of defects.
Figure 188. Aligning Fan Drive Housing
Before tightening fan drive housing
screws, install alignment tool J29304
in seal counterbore.
See Figure
188.
2-567
Cylinder Head Gaske: Installation
Cylinder Head Installation
Figure 256. Assembling Fire Ring
Assemble fire ring over shoulder on cylinder sleeve. See Figure 256.
Figure 258. Lubricating Cylinder Head Capscrew Threads
Position cylinder heads over cylinder block, locating guide holes in head over pins in block. Lubricate cap screw threads. See Figure 258. .
Figure 257. Assembling Cylinder Head Gasket
Assemble gasket ca cylinder block. Locating gasket over guide pins and making certain that fire ring is within gasket opening. Surface of gasket marked "TOP" should be on the top side. See Figure 257.
A11 gaskets are pre-coated and do not require any type of sealing com pound .
Figure 259. Lubricating Underside of Capscrew Head and Washer
Lubricate underside of capscrew and washer. See Figure 259.
Assemble all capscrews in cylinder head.
Snug capscrews lightly.
2-595
INLET, EXHAUST AND WATER MANIFOLDS
1. Inlet Manifold 2. Water Outlet Manifold
Figure 269. Inlet and Water Manifolds
An integral gasket is used for the water and air manifold. See Figure 269. Assemble screws and washers to the inlet, and the water outlet manifold. Position gasket over screws and as semble manifolds to cylinder head. Tighten all screws.
Water Manifold Crossover Tube
Figure 271. Assembly of Crossover Tube Shield
Assemble shields over hoses with slots in shields pointing towards middle of engine. See Figure 271. Assemble inner hose clamps over shields, clamping the hoses and the shield to crossover tube.
"-Mi.'
1. Crossover Tube Shield 2. Crossover Tube Hose Clamp 3. Crossover Hose 4. Crossover Tube 5. Water Manifold
Figure 270. Water Manifold Crossover Tube
Slide hoses and clamps over crossover tube. See Figure 270.
Place crossover tube between water
manifold and slide hose over water
manifold.
Tighten hose clamp at
water manifold.
Figure 272. Positioning Crossover Tube Shield
Shields are used over the crossover tube hoses to protect them from the heat given off by the turbocharger. Position shields to provide maximum hose coverage. Cut out in shield should be as close to engine as poss ible, and still not interfering with adjacent parts. See Figure 272.
2-599
'A'hen the check valve is properly installed, the open end will be at the .noun 11 r.g surface, and the ball check will be towards the center of the aaapter. See Figure 279.
CAUTION'
If check valve assembled, no flow through tioner.
is improperly coolant -ill
the condi
Figure 281. Assembling Rear Exhaust Manifold
Position new gaskets in place, and assemble exhaust manifolds to engine using capscrews, washers and locks.
Figure 280. Installing Inlet Check Valve Fitting
NOTE
When assembling the rear ex haust manifolds, the long boss should be on the upper side. See Figure 281.
Install the inlet check valve in the adapter. See Figure 280. This valve can only be assembled one way since one side has a 1/8 NDT thread which is assembled to the adapter. The other end has a 1/2 - 24 straight thread.
Install feed line from water pump to inlet check valve fitting.
Assemble exhaust manifold to turbo charger tee fitting on flywheel housing. Assemble exhaust fittings and sleeves at rear of engine. Use new gasket between fitting and rear exhaust manifold.
Conditioner Installation and Removal
Apply film of oil to sealing gasket. Install conditioner and turn one full turn after gasket contacts base, (check for leaks when engine is started) To remove, use tool J24783 or equivalent.
After manifold, fittings, and sleeves are aligned at the rear of the en gine, tighten the capscrews at the turbocharger fitting on the flywheel housing.
2-602
Assemble drain tube to turbocharger, tstr.g new gasket. Assemble screws one lock washers. Tighten screws to specifications.
CAUTION
The flange on the drain tube is mounted at an angle to provide clearance between the bellows and the turbocharger mounting flange. See Figure 333. Failure to mount the tube properly will result in an interference between the bellows and flange, causing bellows to wear and possibly result in oil leakage.
Assemble flexible hose to oil feed
fitting at cylinder head. Assemble
turbocharger oil inlet tube to turbo
charger using new gasket.
Install
washers and screws and tighten to
specifications. Assemble 90 degree
elbow fitting to inlet tube. See
Figure 331, Item 9. Assemble flex
ible hose to fitting. See Figure
Item 1. Tighten all connections.
Assemble from turbocharger mounting
studs to tee fitting.
See Figure
331, Item 4.
Position new gasket over mounting studs. See Figure 331, Item 5.
Figure 335. Inlet Manifold Crossover Fitting.
After turbocharger is assembled, sition crossover fitting between let manifolds. See Figure 335. semble fitting with new gaskets. stall capscrews and washers tighten to specifications.
po in As In and
Figure 334. Assembling Turbo Oil Drain Hose Into Cylinder 31ock
Assemble 0-Ring seal to turbo drain tube. See Figure 332, Item 4. At the same time position turbocharger mounting flange over studs in tee fittings. See Figure 331. Assemble washers and cuts to studs, and rigaten to specifications.
2-620
:r.sta11 new O-ring seal at rear side of housing. See Figure 337. Lubri cate surface of O-ring with clean lubricating oil.
Assemble gaskets and water inlet fit
ting and rear bracket to oil cooler
assembly.
Assemble screws and
tighten to specifications. See Fig
ure 339.
Oil Filter PressureRelief Valve
1. Oil Inlet Port 2. Notch in Bundle Flange
Figure 338. Installation of Bundle into Housing
Assemble new gasket to flanged end of bundle and insert bundle into oil cooler housing. The notch in the bundle flange must be assembled in line with the oil inlet in oil cool er. See Figure 338.
NOTE
Use correct gasket between bundle flange and housing. This is an elastomer coated gasket, and is black in color. Failure to use cor rect gasket could result in oil leakage in this area.
After gasket and bundle are in posi tion, push bundle into housing, past O-ring.
151-37
1. Oil Filter Adapter (Rear) 2. Oil Filter Adapter Pressure
Relief Plunger 3. Oil Filter Adapter Pressure
Relief Plunger Spring 4. Oil Filter Adapter Pressure
Relief Cap 5. Oil Filter Adapter Pressure
Relief Cap Washer
Figure 340. Oil Pressure Relief Valve Arrangement
Check plunger and spring to make cer tain they are in satisfactory condi tion. Install plunger, spring, wash er, and cap, in adapter. See Figure 340. Torque cap to 100 lb. ft.
NOTE
Figure 339. Oil Cooler Assembly with Water Inlet Fitting and Rear Bracket
The oil filter pressure re lief valve opens when the pressure restriction across the element exceeds 42 to 50 psi. Oil then by-passes the filters and goes directly in to the nun oil gallery.
2-622
f;-' ' i*
it
* -
?
p~;
a--k'. -
CLUTCH REMOVAL
1. Mark clutch cover and flywheel with a center-punch before removing clutch to facilitate reinstalling clutch in same posi tion.
2. Use three spring retention tools (J26450 for CL-28, 40 and 50 series. J26451 for CL-47 series) or retaining cups as shown in Figure 4-1, when removing a clutch as sembly from the flywheel.
RETAINING CUP
SPAING CUP
11.0. (CL-28 ft SO SERIES)
i i.o.(cu-o schies) 9
J _t
.//
rar-- - 'I//, .-----------------------------
n-ni Figure 4-1. Retaining Cups
To use spring retention tools, bottom screws in tapped holes in pressure plate. Set tool nuts up snugly against tool bracket. Tighten tool nuts evenly to relieve spring tension on pressure plate. Not used on CL-58 Series.
3. Remove two clutch-to-flywheel cap screws with lockwashers at the ten o'clock and two o'clock positions of the flywheel and install two long headless guide studs to support the clutch assembly during re moval of the remaining attaching capscrews.
4. After removal of all capscrew fasten ers, carefully remove heavy clutch and disc assembly from flywheel counterbore and place on bench. Be careful not to drop driven disc assembly which is now free. Also remove the temporary guide studs from flywheel.
CLUTCH INSTALLATION
1. Using spring retention tools, bottom screws in tapped holes in pressure plate. Set tool nuts up snugly against tool brack et. Not used on CL-58 Series.
NOTE
Three retaining cups and screws are used to hold a new clutch as sembly together until it is in stalled on the flywheel. Spring cups are pressed into the clutch cover hence the retaining cups are necessary to prevent spring cups loosening and slipping out of the cover during handling. Re taining cups and screws must be removed after the clutch is as sembled to the flywheel. A tag is attached tonewclutches (CL-28, 40 and 50 Series) calling attention to this fact and cups and screws are painted red for ready identi fication.
2. Engage splined end of clutch disc align ing mandrel or a spare main driving pinion with hub splines of driven disc from rear of long hub side. Then position driven disc assembly in flywheel so that spigot end of shaft engages inner race of clutch pilot bearing mounted in flywheel. This arrangement positions the disc assembly in proper alignment until clutch is com pletely assembled and secured in flywheel.
3. Install two long guide studs in the ten and two o'clock positions in flywheel rim. Mount clutch assembly on guide studs and push unit into flywheel bore until clutch cover flange enters counterbored pilot pro vided. Be careful not to disturb disc aligning mandrel.
4. Lubricate and install cover-to-flywheel capscrews with their lockwashers. Tighten capscrews a few turns at a time so that cover will not be misaligned and forced into flywheel pilot by the tightening of the cap screws. Remove the two guide studs and re place with capscrews and their lock wash ers. Remove aligning mandrel.
CL-28 and 40 SERIES
Description
CL-28, -40 Series assemblies are single plate, dry disc pusher type clutches. They consist of a pressure plate, a cover, and a driven disc which is splined to the trans mission main driving pinion shaft. When
4-3
engaged, the driven disc is damped between the pressure plate and the flywheel by the pressure of coil springs which are mounted in cups on the cover. Drive is transmitted to the pressure plate by pressure piate lugs which fit in the cover openings. Six re lease levers have ball pivots and are linked to the pressure plate by eyebolts. The in ner ends of the levers are held by the notched release thrust washer. See Figure 4-2.
17
1. Clutch Spring
Washer
(outer)
Fulcrum Adjust
2. Clutch Spring (in
ment Nut
ner, where used) 14. Lock Nut
3. Release Bearing 15. Eyebolt
4. Release Collar 16. Eyebolt Pin
5. Thrust Washer 17. Cover Plate
6. Release Lever 18. Pressure Plate
1 . Lever Spring 19. Flywheel
3. Spring Washer 20. Pilot Bearing
9. Lever Pivot
21. Driven Disc
10. Lever Bushing
Assembly
11. Eyebolt Ful
22. Driven Disc
crum
Facings
Figure 4-2. Sectional View of CL-28, 40 Series Clutch
-t .i
Disassembly
1. Before disassembly of the various parts, mark these parts with a center-punch, so that at reassembly, they can be reassembled in their original positions. This is neces sary in order not to disturb the dynamic balance of the clutch.
2. Before removing the three spring re tention tools, compress clutch release lever springs, remove washer pins, then remove washers and release lever springs. Pry off snap ring from thrust washer. Remove eyebolt nuts, fulcrums, and clutch release levers.
CAUTION :
If retaining cups are used instead of tool (J26450) , clamp the cover in a press before removing the cups. This is necessary be cause the screw used does not have sufficient thread length to com pletely release the spring load before coming out of the pressure plate.
3. While holding spring retention tool screws, back off tool nuts alternately mak ing one turn at a time. When spring is entirely relieved, back out the three tool screws.
4. Remove clutch cover and springs. If heat-insulating washers are removed from pressure plate spring pockets, retain them for reassembly. The eyebolts need not be removed unless inspection reveals distor tion or loose fit on pins.
Inspection and Repair
1. Remove all traces of dirt and oil with a suitable safety solvent. Inspect parts care fully for cracks, distortion or excessive wear as described in the following steps.
2. If cover is cracked or distorted, re place. Tack-weld loose spring cups (on covers having this construction) replace worn or loose bail-fulcrums. Replace loose or bent pin rivets.
2. Equally space three steel blocks 3/3 inch thick, on bed of arbor or drill press.
3. Place clutch with pressure plate side down, on blocks. (This is done in order to raise dutch to permit disassembly).
4. Place a block of wood, such as a two by four, across cover plate in a position that does not interfere with tips of release levers, as shown in Figure 4-10. Compress clutch assembly slightly, removing lever adjusting screw locknuts.
2. Check cover plate for distortion, ex cessive wear at indentations which register between drive bosses on pressure plate, and for stripped threads in holes accommodating release lever adjusting screws. If the above mentioned conditions are apparent, replacement of cover plate is required.
3. Replace springs if cracked or defective. Check all springs on a spring tester. Re place all that do not meet specifications.
4. Replace release levers that are badly worn on tips (this is an indication of a stick ing release bearing), worn threads on lever adjusting screws and nuts, or where bind ing appears to be present, which retards free back and forth movement.
NOTE
Release levers are serviced as a subassembly only, and consist of lever, adjusting screw, roller, rol ler block, lever spring and spring retaining pin.
Figure 4-10. Compressing Clutch
5. Turn each lever adjusting screw down (clockwise), a few turns with a screw driver, releasing spring tension a small amount. Repeat operation until all lever adjusting screws are entirely free of cover plate. Release remaining spring tension, and lift cover plate off pressure springs.
6. Pressure springs may now be removed. After extracting cotter pins and lever pins, remove release levers.
Inspection and Repair
1. Clean all parts thoroughly with a suita ble safety solvent. Inspect carefully for excessive wear, distortion, or cracks as described in the following steps.
5. If pressure plate shows signs of scor ing, excessive wear at lever pin holes, inside of drive bosses, heat checking, or if warped more than 0. 020 inch, plate must be refaced or replaced. (When refacing pressure plate, remove only sufficient metal to obtain a smooth flat surface.) When pressure plate thickness becomes less than 1.141 inch, replacement is nec essary.
6. If flywheel is warped or heat checked and surface is refinished, maintain the 1.188 inch dimension between disc surface and bolting face for proper release lever adjustment. No more than 0. 070 inch maxi mum may be removed by grinding.
7. Inspect driven disc assembly for cracks, loose rivets, worn splines, warped or dished condition. If cracked, or hub splines are worn excessively, replace disc assembly.
If facings are worn down nearly even with countersunk, facing-retaining rivet heads and provided assembly is in otherwise good condition, it may be rebuilt.
3. Pilot bearing should be removed, clean ed and checked each time clutch or engine is removed. Discard bearing if balls or races are chipped or scored. After in spection, hand-pack bearing with clutch pilot bearing grease and install bearing in flywheel. Tap into place with shielded side toward clutch.
Use only the recommended pilot bearings specified. These bearings will function without premature failure where slight misalignment exists between engine and transmission.
After bearing is properly installed, pack the entire cavity in back of the bearing with the same specified clutch pilot grease.
2. Place pressure springs in position on pressure piate. as shown in Figure 4-12.
CAUTION
To prevent damage to the bearing seal when the transmission is as sembled to the engine, the space occupied by the main driving pinion pilot must not be filled with grease. See Figure 4-11.
CRANKSHAFT
FLYWHEEL
CLUTCH P'LOT SALL BEARING ISNAP-RING TYPE! WITH BUILT-IN GREASE SEAL
HANO-PACK CAVITY EXACTLY AS SHOWN AFTER BALL BEARING NSTALLATION. CENTRAL AREA MUST BE CLEAR OF GREASE
BEARING SNAP-RING COUNTERBORE
Figure 4-11. Cut-away View of Clutch Pilot BearingGrease Reservoir Correctly
Packed
Reassembly
1. Mount release lever assemblies on pressure plate. Set pressure plate as sembly on three equally spaced steel blocks 3/8 inch thick, on bed of arbor or drill press, plate side down.
Figure 4-12. Assembling Clutch
3. Lay cover plate over springs, being sure that all springs are seated on bosses of pressure plate, and around indentations on inside of cover.
4. If pressure plate was refaced, it will be necessary at assembly, to add shims under each pressure spring equal to total metal removed.
5. Compress assembly slowly, aligning lever adjusting screws with threaded holes in cover plate. (The indentations inside cover, should enter the spaces between drive bosses on pressure plate freely.) With screwdriver, thread ends of adjust ing screws into cover evenly, until screws protrude about 1/2 inch. Hold assembly compressed, while placing locknuts in posi tion, but do not tighten.
6. To facilitate installation on flywheel, place wood blocks approximately 3/8 inch thick, between the tops of release levers and inner rim of cover plate. (Be sure these stay in position as all tension is released).
7. Insert the three spring retention tools (J26451), through cover and bottom in tapped holes in pressure plate (center hole of each five series in cover). With pres-
4-9
0. .vaue nciaing spring i-cisiiiiju coai
screws, back off tool nuts alternately, mak ing one turn at a time. When spring is entirely relieved, back out the three tool screws.
4. Remove clutch cover and springs. If heat-insulating washers are removed from pressure plate spring pockets, retain them for reassembly. The eyebolts need not be removed, unless inspection reveals distor tion or loose fit on pins.
Inspection and Repair
1. Remove all traces of dirt and oil with a suitable safety solvent. Inspect parts care fully for cracks, distortion or excessive wear as described in the following steps.
2. if cover is cracked or distorted, re place. Tack-weld loose spring cups (on covers having this construction) replace worn or loose ball-fulcrums. Replace loose or bent release lever spring pins.
3. Replace springs if cracked or defec tive. Check all springs on a spring tester. Replace all that do not meet specifications.
4. Replace thrust washer if worn, bent or defective.
5. Replace worn release levers, springs and ball seats. Check levers with a straight edge and 11/16 inch ball (J26453) as il lustrated, in Figure 4-14 and if bent so that dimension (1) is more 11/32 inch when measured at a point where distance (2) is 2-1/2 inch, replace the lever.
Figure 4-14. Checking Release Lever for Bend
6. If pressure and intermediate plates are scored, heat checked, or warped more than 0.020 inch, they must be replaced or re faced. Remove only enough metal to ob tain a smooth flat surface. Finish with a light cut and polish with emery cloth. When thickness (1) becomes less than the worn limit given in specifications, the plate must
ce replaced, .uedaui e uuier spring pccK-
et as shown in Figure 4-15. Measuring at inner pocket is not accurate if pressure plate is dished. If cleft lugs are worn, cracked or distorted, replace the plate. The intermediate plate features a double set of drive slots for increased service life. At clutch installations after rebuild, it is re commended that the set with less wear be used. Replace eyebolts if they are dis torted, have worn threads or keywavs.
Figure 4-15. Pressure Plate Thickness Dimension
7. If flywheel is warped or heat checked and surface is refinished, maintain the 2.797 inch dimension between disc sur face and bolting face for proper release lever adjustment. See Figure 4-16. No more than 0.070 inch maximum may be removed by grinding.
Figure 4-16. Flywheel Rubbing Surfaceto-Clutch Cover Bolting Surface Dimension
Intermediate plate drive pins should be inspected for abnormal wear.
When pins have been removed to permit flywheel machining, or require replace ment, squareness between flywheel friction and pin drive faces must be maintained at installation. A positioning tool 'will assist in establishing necessary alignment.
Suitable for this purpose, will be a slotted steel block 4 inches long, 2-1/2 inches wide and 1-1/2 inches thick. One 2-1/2 inches x 4 inches face should be ground for maximum flatness, as it will constitute the major working surface. A 3/16 inch x 45 degree chamfer along all edges of this face will tend to prevent burrs that would affect accuracy. See Figure 4-17.
4-11
i 16 x 45' chamfer.
wheel. Tap into place with shielded side toward clutch and snap ring seated in coun terbore.
All current .Mack-made engine flywheels have been manufactured by boring the clutch pilot bearing hole straight-through and counterboring a recess to provide proper positioning for the snap ring type pilot bearings now in use. Old bearings without a snap ring cannot be used in new throughbored flywheels.
Figure 4-17. Drive Pin Positioning Tool
Midway between ends of the 4 inch length, a 0. 627 to 0. 628 inch wide slot 1-t inch deep should be machined through the 1-1/2 inch thickness. The slot must be exactly square with the ground face for it will determine flywheel to drive pin head alignment. A half -inch drift pin clearance hole, drilled from the side opposite, and intersecting with, the slot will complete the tool. Hole centerline should be 7/8 inch from the ground face, so that driving force will be centered over the head. Magnetizing the block will minimize movement during driv ing and lessen possibility of marring fly wheel face.
In use, the threaded portion of the pin is inserted in the flywheel hole. The position ing tool slot is placed over the drive head, with the ground surface held flat against the flywheel friction face. The pin is then driven until fully seated.
8. Inspect driven disc assembly for cracks, loose rivets, worn splines, warped or dished condition. If cracked, or hub splines are worn excessively, replace disc assembly. If facings are worn down nearly even with countersunk facing-retaining rivet heads and assembly is in otherwise good condition, it may be rebuilt.
9. Pilot bearing shouldbe removed, clean ed and checked each time clutch or engine is removed. Discard bearing if balls or races are chipped or scored. After inspec tion, hand-pack bearing with clutch pilot bearing grease and install bearing in fly
4-12
CAUTION
Do not install anew snap ring bear ing in an old flywheel without re moving the snap ring and dis carding. In old flywheels without the counterbore, the snap ring would position the bearing too far rearward, which would result in early bearing failure and consider able damage to costly components. Use only the recommended snap ring type bearings specified. These bearings will function with out premature failure where slight misalignment exists between en gine and transmission.
After bearing is properly installed, pack the entire cavity in back of the bearing with the same specified clutch pilot grease.
CAUTION
To prevent damage to the bearing seal when the transmission is as sembled to the engine, the space occupied by the main driving pinion pilot must not be filled with grease. See Figure 4-18.
Before assembling the clutch, a positive wear check should be made to insure that it will provide maximum disc wear. This check will uncover any interference that might prevent full release lever travel and allow corrections to be made before the clutch is assembled.
Place the pressure plate assembly and cov er (without springs) into position as shown in Figure 4-19, making sure that shims of the correct thickness (0. 250) are inserted
Figure 4-22. Removing Lever Adjusting Nut Lock Plates
main spring insulator washers from pres sure plate bosses.
NOTE
i
Do not remove the six lever anti I rattle springs from the cover un I less replacement is necessary.
4. Lay pressure plate on bench and with a soft metal drift, drive hardened lever pins out of pressure plate drive lugs to free re lease levers. With a pair of pliers, remove cotter pin from each lever yoke clevis pin and then press out each yoke clevis pin by hand.
CAUTION
When removing levers from pres
I
I
sure plate drive lugs and lever
yoke, be very careful not to lose
I any of the small uncaged needle
II rollers.
I
3. Release Lever 12. Thrust Washer
Inspection and Repair
Pin Clamp
4. Needle Bearings 13. Lever Thrust
Remove all traces of dirt and oil with a
5. Release Lever
Washer Ring
suitable safety solvent. Inspectparts care
Yoke
14. Pressure Plate
fully for cracks, distortion or excessive
6. Yoke Leaf
15. Helical, Main
wear as described in the following steps.
Spring
Spring
7. Lever Adjust 16. Heat Insulator
1. Replace springs if cracked or defective.
ing Nut
Ring
Check all springs on a spring tester. Re
8. Adjusting Nut 17. Driven Disc
place all that do not meet specifications.
Lock Plate
Assembly
9. Lock Plate Lock 18. Facing Rivet
2. If pressure plate is scored, heat check
Screw
19. Driven Disc
ed, or warped more than 0. 025 inch, it must
I 10. Yoke Clevis Pin Facings
be replaced or refaced. Remove only enough
metal to obtain a smooth flat surface. No
Figure 4-21. Sectional View of CL-58
more than 0. 070 inch maximum may be re
I
Series Clutch
moved by grinding.
4-15
3. Inspect clutch release lever tips and clevis pin holes for excessive wear. Make sure levers are not bent. Replace where necessary.
4. Inspect release lever yokes for con dition of threads. Slight thread damage may be cleaned up with a three-cornered Swiss file. Replace lever yokes if clevis pin holes are elongated.
5. Check clevis pins and lever pins for wear. Replace if wear is excessive. Check lever slotted thrust washer ring for exces sive wear. Replace if slots are excessive ly worn.
6. Check lever needle roller bearings for wear. If flats are such that rollers slide rather than roll, replace rollers.
7. Inspect driven disc assembly for cracks, loose rivets, worn splines, warped or dished condition. If cracked, or hub splines are worn excessively, replace disc assembly.
If facings are worn down nearly even with countersunk facing-retaining rivet heads and provided assembly is in otherwise good condition, it may be rebuilt.
8. If flywheel is warped or heat checked and surface is refinished, maintain dimen sions shown in Figure 4-23 between disc surface and bolting face for proper release lever adjustment. No more than 0. 070 inch maximum may be removed by grinding.
tion, hand-pack bearing with clutch pilot bearing grease specified and install bear ing in flywheel. Tap into place with shield ed side toward clutch and snap ring seated in counterbore.
Use only the recommended snap ring type bearings. These bearings will function with out premature failure where slight mis alignment exists between engine and trans mission.
After bearing is properly installed, pack the entire cavity in back of the bearing with the same specified clutch pilot grease.
CAUTION
To prevent damage to the bearing seal when the transmission is as sembled to the engine, the space occupied by the main driving pinion pilot must not be filled with grease. See Figure 4-24.
PLYWNEEL
fSNAR-RlNG TYPE! WITH built-in crease seal
NANO-RACK CAVITY exactly AS Sqwn APTER BALL SEARING NSTALLATiQS. CENTRAL AREA MUST BE CLEAR CP GREASE
bearing Snap-ring CQUNTER60RC
Figure 4-23. Flywheel Rubbing Surfaceto-Clutch Cover Bolting Surface Dimension
9. Pilot bearing should be removed, clean ed and checked each time clutch or engine is removed. Discard bearing if balls or races are chipped or scored. After inspec-
A AC
Figure 4-24. Cut-away View of Clutch Pilot Bearing Grease Reservoir Correctly
Packed
Reassembly
1. Apply a light coat of clutch lever grease on the loose needle bearings and install rollers in each pin hole of levers. When bearings are installed, apply additional grease to each assembled bearing group.
2. Spread a thin coat of lever grease on the two rubbing flats of each lever and on all yoke rubbing surfaces. Center lever
13
1. Pressure Plate 2. Return Spring 3. Pivot Pin 4. Spring Clip 5. Lever 6. Adjusting Ring
7. Snap Ring 8. Release Sleeve Ring 9. Release Sleeve Retainer
10. Spring Pivot
11. Pressure Spring 12. Flywheel Ring 13. Adjusting Ring Lock
14. Bolt & Lock Washer Assy 15. Release Bearing & Bearing Assy 16. Driven Rear Disc 17. Intermediate Plate 18. Driven Front Disc
Figure 4-33. Exploded View AS-1550 Series Clutch Assembly
Removal and Disassembly
A suitable "sling" or transmission jack should be used to properly support and main tain the engine/transmission alignment when removing or installing a transmission on an engine. DO NOT let the rear end of the transmission drop down and hang unsupported in the splined hubs of the clutch discs to avoid bendingor distorting the friction discs. Disconnect the external linkage from the clutch release arm to permit the release yoke to turn up and pull free of the release bearing thrust pads.
1. Prior to actual clutch removal, assemble a clutch disc aligning tool to the driven disc and release bearing assembly.
It is important that two 3/4 inch blocks of wood as shown in Figures 4-34 and 4-35 be inserted between the clutch release bearing housing and clutch flywheel ring as the clutch mounting bolts are loosened around the fly wheel. These blocks will relieve the heavy internal spring load, preventing cocking and bending within the clutch and insure easy re moval of remaining mounting bolts.
2. When all bolts have been removed, slide clutch assembly back and off using caution to keep aligning tool in place to retain discs and intermediate plate.
3. Carefully remove aligning tool, rear disc, intermediate plate and front disc.
4-30
Remaining Clutch Life Chart - "o
Figure 4-43. Removing Retainer Clip
Inspection and Repair Clean all parts thoroughly with a suitable safety solvent.
Many clutches are replacedas a preventative maintenance item at low mileage during re pairs of the transmission or engine. Before the Clutch Assembly is replaced, the unit should be inspected for the following items:
REMAINING CLUTCH LIFE
163.7*
Driven Discs
Inspect disc assembly for cracks, loose ri vets, worn splines, warped or dished condi tion. Re-straighten if dished or warped beyond 0.015 inch maximum runout. Re place if hub is cracked, or splines are worn excessively.
1. Heat cracks in the pressure plate. 2. Excessive wear in all drive slots. 3. Broken springs. 4. Dry or damaged release bearing. 5. Broken intermediate plate. 6. Excessive driven disc hub spline wear. 7. Burned facings. 8. Excessive wear on drive pins or inter
mediate plate slots.
If the preceding inspection shows clutch parts to be in good condition, use the fol lowing chart to determine the approximate remaining clutch life (by measuring the thickness of the rear driven disc assembly).
Replace facings if they are glazed, scored, worn down to rivet heads, burned, or if
contaminated with grease or oil.
The driven discs use high-quality asbestos facings riveted to the steel disc. They may be furnished as rigid type disc or damper type. Used discs can be reworked in the field by drilling out the rivets to remove old facings. Use the correct size drill when re moving old rivets to avoid enlarging holes in disc. Use proper facings and a star set an vil to reline used discs.
Find thickness of rear disc on column to left follow curve on right, then drop this point down to read percent of clutch life re maining.
Ceramic friction material, a combination of metal and ceramic, is used in producing round or trapezoidal buttons which are riveted to steel discs. These clutch
4-33
discs, available with either rigid or damper hubs, offer many advantages for heavy-duty applications. Reworking these discs in the field is not recommended because the ceram ic buttons must be assembled and ground to hold thickness as well as squareness with splines.
Super-duty discs have six trapezoidal cer amic buttons and are available with rigid or damper hubs. These discs are thinner than standard discs while the intermediate plate is thicker. This combination of more ceramic buttons and thicker intermediate plate provides longer life and increased torque capacity.
A super-duty kit consisting of two driven discs and an intermediate plate is available for converting a standard Angle-Spring clutch into a super - duty clutch. It Is very im portant that the kit be installed as a unit and that Its components never be intermixed with standard components.
Flywheel Ring
Inspect the flywheel ring for cracks. Re place if cracks are visible. Check slots for indentation caused by wear of pressure plate driving lugs. See Specification Chart for slot limits.
Inspect bolt circle face and pilot for nicks and burrs due to removal or handling. Re move burrs with file to insure proper seat ing and squareness when clutch is mounted to flywheel.
pressure plate. Smooth and flat pressure plate surfaces must be used for satisfactory clutch life.
Check drive lugs for wear per Specification Chart.
Intermediate Plate
Inspect friction surfaces of intermediate plate for heat checks, scoring or distortion. If friction surface is badly scored, heat checked, warped or dished in excess of 0.010 inch, resurface or replace with new intermediate plate. Smooth and flat inter mediate plate surfaces must be used for sat isfactory clutch life. Inspect driving slots of intermediate plate for wear per Specifi cation Chart.
Release Levers
Inspect levers for excessive wear at points of contactwith pressure plate, release sleeve retainer, and pivot pin. If levers are bent or worn, replace with new levers. It is good preventive maintenance to replace levers during clutch rebuild.
Release Sleeve Retainer
Inspect for wear in lever groove and internal splines. Refer to specifications for driving slot clearance between flywheel ring drive slots and release sleeve retainer drive lugs.
Adjusting Ring
Check pivot pin holes for wear. Clearance may not exceed 0.010 inch between pin and hole. Inspect for cracks; replace if cracks are visible.
Pressure Plate
Inspect fulcrum for wear. If wear exceeds 0.015 inch, remachine. See Specification Chart for maximum rework.
Inspect friction surface of pressure plate for scoring, burning, heat checking or distor tion. If friction surface is badly scored, heat checked, warped or dished in excess of 0.010 inch, resurface or replace with new
Spring Pivots
Inspect for cracks; if visible, replace.
Release Sleeve Sub-Assembly
Check bushing for excessive wear. Check bearing diameter for tight fit. Refer to Specifications Chart and replace if nece ssary.
Release Bearing and Sleeve Assembly
It is recommended that the release bearing and sleeve assembly be replaced as a unit at the time of clutch rebuild. Assemblies are available as service replacement items.
Disc Brakes
No manual adjustment required. Brakes adjust automatically during braking oper ation. The square-cut piston seal is dis torted when pressure is applied to piston. When braking pressure is released, the seal returns to its normal condition and pulls the piston away from the lining. This action, plus some slight rotor lateral runout ("wob ble"), considerednormal, provides adequate running clearance.
Disassembly and Assembly
When brakes are relined or disassembled for other repairs, all parts should be in spected for wear and worn parts should be replaced as required.
Cam Brakes - (See Figure 6-37)
Disassembly
1. Remove shoe return spring.
2. Remove lock rings, retainers, and felts from brake shoe anchor pins.
3. Cut lock wire and remove anchor pin lock screws.
4. Remove anchor pins and shoe assemblies.
5. Remove brake shoe roller retaining clip (or screw) and remove roller.
6. Remove slack adjuster lock ring and spacing washers.
7. Remove camshaft, washer, and felt seal (if used ).
8. Remove nylon bushings if replacement is necessary. Use suitable tool for both re moval and installation of bushing. See Figure 8-44.
NOTE
On brakes where lip type seals are used, these will have to be removed and replaced if nylon bushings are replaced.
Figure 8-44. Bushing Removal and Installation Tool
8-44
Assembly
1. Install new nyion bushings, if required, using suitable tool. (Install new lip type seal if used.)
2. Install brake shoe rollers and retainers. Make certain rollers are of proper size. See instructions relative to brake shoe "Cam Roll-Over."
3. Install camshaft, washer, and felt seals, (if used.)
4. Position brake shoe assembly over spi der and tap anchor pin into position with brass punch, "flat" in line with lock screw hole.
5. Install lock screws, tighten securely and thread with lockwire.
6. Position felts, retainers, and lock rings on anchor pins.
7. Install shoe return spring. New springs should be used with each brake reline. Ten sion loss occurs from normal use and heat buildup. New springs will ensure that shoes are returned to fully relaxed position, and not in contact with drum, which would cause premature wear.
8. Assemble slack adjuster on splined end of camshaft; using spacers and washers on each side of adjuster to obtain. 030-. 060 end play.
Wedge Brakes - 'See Figure 8-39)
Disassembly
1. Remove shoe return springs. Use brake spring pliers. (Do Not use screwdriver.)
2. Remove brake shoe assembly.
3. Remove plunger guide screws and gaskets from plunger housing. If brake is automatic adjusting, remove hollow capscrew, gaskets, spring and adjusting pawl. It may be neces sary to use a magnet to remove the adjusting pawl.
4. Using a suitable screwdriver, pry the seals loose and remove anchor (solid) plungers. adjusting plungers, adjusting sleeves (actuators) and adjusting bolts.
5. Thoroughly inspect and clean all parts including the housing plunger and seal bores and shoe rest pads. DO NOT solvent clean any rubber parts (plunger seals or gaskets).
Figure 8-50. Removing Caliper
NOTE
It is not necessary to remove the hydraulic line when replacing shoe and liningassemblies. How ever, do not let the caliper hang on the hydraulic line. Lay the caliper on the suspension.
Inspecting Caliper
1. Check the inside of caliper for hydraulic fluid leak. If evidence of fluid leak is noted, the caliper should be overhauled.
2. Wipe the inside of the caliper, clean and check the dust boots for cuts, cracks or other damage. If damage is noted the caliper should be overhauled. See Figure 8-53.
Removing Shoe and Lining Assembly
1. Remove the inner shoe and lining assem bly from the anchor plate.
2. Remove outer shoe and lining hold-down spring, pin and cup. See Figure 8-51.
Figure 8-53. Inspecting Boots for Cracks and Cuts.
Figure 8-51. Removing Spring, Pin, andCup.
3. Remove outer shoe and lining assembly. See Figure 8-52.
Assembly
Installing Shoe and Lining Assemblies
1. Install new inner shoe and lining as sembly into anchor plate.
2. Push the pistons to the bottom of the pis ton bore. This is doneby takinga small block of wood and placing it over the pistons and boots. With a "C" clamp, push the pistons to the bottom of the piston bores.
3. This will provide clearance for the caliper to fit over the hub and rotor when new shoe and linings are installed. See Figure 8-54.
8-48
Figure 8-54. Pushing Pistons back into Caliper.
4. Install outer shoe and lining-into caliper and install shoe hold-down spring and pin. See Figure 8-55.
Figure 8-55. Installing Outer Shoe and Lining Assembly.
5. Install caliper assembly over the hub and rotor and position into grooves in anchor plate. 6. Install the caliper hold-down assemblies and tighten bolts to 40 lb. ft. torque. See Figure 8-49. 7. Add brake fluid to bring level to 1/4 inch from top of reservoir. 8. If any hydraulic fluid lines have been dis connected, bleed the hydraulic brake system. Pump the brake pedal several times to make sure brake shoes are adjusted. 9. Install the front wheels and lower vehicle. Caliper Overhaul Always use denatured alcohol or brake fluid to clean caliper parts.
CAUTION Do not use mineral base cleaning solvents such as gasoline, kero
sene. carbon tetrachloride, ace tone or paint thinner to ciean the caiiper. It will cause rubber parts to become soft and swollen in extremely short time.
1. Remove caiiper assembly as previously described in this section.
2. Disconnect the hydraulic hose and cap or tape the fitting to prevent dirt from entering the hydraulic line. 3. Check the brake hose for worn spots, cracks or other signs of deterioration. Dis card the hose if damaged. 4. Drain brake fluid from caliper.
5. Thoroughly clean the exterior of caliper. 6. Place a small block of wood under cal iper piston.(Approximately 2 inches thick) Pad the exterior of the caliper with a clean shop towel. Remove the piston by directing air into the caliper fluid inlet. See Figure 8-56.
CAUTION
Use just enough air pressure to ease the pistons out of bore. If the pistons are blown out, even with padding provided, it may be damaged.
Do not place your fingers in front of the piston in an attempt to catch or protect it when apply ing compressed air. This could result in serious injury.
Figure 8-56. Removing Pistons from Caliper Bore.
7. Remove and discard the piston boots.
8-49
19. Install new shoe and lining assemblies, and caliper as previously described.
20. Connect the brake hose to the caliper.
23. Always check the hub and rotor braking surface for deep scores, cracks, and heat checks. See Figure 8-61.
21. Bleed the system. Allow the caliper to fill with brake fluid. After all air bubbles have escaped and fluid runs clear from bleeder, close the bleeder screw. Replenish the brake fluid in the hydraulic fluid reservoir.
22. "Pump'' the brake pedal several times to actuate the piston seals and position the shoe and lining assemblies.
23. Checkforfluid leakage at all connections under maximum pressure. Refill fluid res ervoir as necessary.
24. Install front wheels and lower vehicle.
Figure 8-61. Checking Rotor Surface
26. Always check hub and rotor lateral run out ("wobble"). Lateral runout must not ex ceed 0.008 Inch.
8-51
leading to the bottom oi the container. The air then rises tnrougn the alconoi and passes into the line to the compressor, carrying alcohol in the form of vapor with it. The alcohol, thus introduced into the air system acts as an anti-freeze.
Figure 8-82. Alcohol Evaporator Preventive Maintenance Every 1, 000 Miles or as Determined by Act ual Usage' Check alcohol level and if necessary replenish with 188 proof methanol alcohol. In cold weather, alcohol level should be at least 2/3 full.
NOTE If aicohoI is not being consumed, it indicates the evaporator is in operative andshouldbe inspected. Every Mack C and D Inspection Remove strainer if present in bottom of evap orator body and clean thoroughly in solvent. Every Mack C and D Inspection
Disassembly evaporator unit and clean thoroughly. Inspect all parts for cracks and be sure evaporator tube is not clogged with dirt. Replace all gaskets and rubber parts. Inspection When the compressor is compressing air, air bubbles should be passing through the alcohol. If air bubbles are not present when the compressor is compressing air. then the alcohol evaporator is not functioning properly.
Cheat to be sure all connections are tight. Cheat condition of filler cap gasket and cover gastcet.
RELINING & RECONDITIONING
Drum-Type Brakes
After supporting the axle on stands, cage the springs in the spring brake chambers. Re move the tires, wheels, and drums as an assembly, and inspection drums for heat checks, cracks, distortion or other damage.
Close inspection of all worn brake parts may lead to clues for corrective action to improve lining life and future drum damage.
Scored Drum
Only the tops of the ridges will contact brake lining. Since a small percentage of the brake lining is required to do all the work, hard pedal and fade will result. A scored drum must be reconditioned in a lathe. See Figure 8-83.
Hard Spots
Hard spots are "islands" of steel in the cast iron surface. They result from a change in metallurgy caused by the heat of braking. Hard spots must be ground out or brake perform ance will be poor and erratic. See Figure 8-84.
Bell-Mouthed Drum
If a drum is bell-mouthed or flared,
full lining to drum contact cannot be
achieved.
Fade and noise can be
expected. A bell-mouthed drum must
be trued in a lathe in order to pro
cure full lining to drum contact.
See Figure 8-85.
8-65
Figure 8-85. Bell Mouthed Drum.
Heat checking and discoloration, if only superficial, can be corrected by resurfacing the drum, otherwise replace drum.
Drums having more than . 010" out of round, or any of the conditions described above should be resurfaced. Use only those drums which produce a satisfactory surface finish.
CAUTION
Drum manufacturer and state vehicle inspection laws (where applicable) govern the amount of drum diameter increase allowed when resurfacing. Most drums are stampedby manufacturers as to maximum oversize allowable.
Excessive removal of drum mat erial could result in drum failure or unsatisfactory brake perform ance and is illegal in some states.
NOTE
When reconditioning brakes, it is important that the brake assem blies on each side of the same axle be serviced in exactly the same manner. This will avoid unequal braking performance. (Drums on the same axle should be resurfacedwithin. 010 of each other.
Cam Roll-Over
Increasing the drum diameter will permit the cam to rotate beyond its maximum lift when the lining becomes worn. To prevent cam "Roll-Over," oversize roller cam fol lowers are available.
Standard (1.250" O. D.)
Standard rollers are used when installing standard linings with standard drums. "X" lining (1/16 oversize) with 1/16 oversize drums, and 'XX" lining (1/8 oversize) with 1/8 overside drums.
1/8" Oversize (1.375")
1/8" oversize rollers are to be used with the installation of standard linings with worn or trueddrums which are 1/32" oversize. 1/8" oversize rollers should be installed and the liners circle ground a few thousandths less than drum diameter.
1/4" Oversize (1.500")
Where "X" linings have been installed with 1/16" c"ersize drums and standard rollers, these rollers should be removed and 1/4" oversize installed before the lining becomes worn to a point where the brake cam is no longer effective with the standard rollers.
1/2" Oversize (1.750")
Where "XX"linings and 1/8" oversize drums have been used, the standard rollers should be removed when the linings become approx imately 50% worn and 1/2" oversize rollers installed.
Brake Linings
Linings must be the correct material for a specific application, and the same type lining should be used for each wheel on the same axle.
Handle lining carefully to prevent grease, oil. or any other type of contamination to come in contact with lining surface.
8-66
I