Ford - F 250 - Workshop Manual - 1949 - 1952

1949-50-51 F-SERIES TRUCKS SHOP MANUAL WITH 1952 SUPPLEMENT FORD D I YISION FORD MOTOR COMPANY Copyright © 2011, Forel Publishing Company, LLC, Woodbridge, Virginia All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever without written permission of Forel Publishing Company, LLC. For information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192 1949-52 Ford Truck Shop Manual EAN: 978-1-60371-062-6 ISBN: 1-60371-062-0 Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address: [email protected] Website: http://www.ForelPublishing.com This publication contains material that is reproduced and distributed under a license from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company. Note from the Publisher This product was created from the original Ford Motor Company’s publication. Every effort has been made to use the original scanned images, however, due to the condition of the material; some pages have been modified to remove imperfections. Disclaimer Although every effort was made to ensure the accuracy of this book, no representations or warranties of any kind are made concerning the accuracy, completeness or suitability of the information, either expressed or implied. As a result, the information contained within this book should be used as general information only. The author and Forel Publishing Company, LLC shall have neither liability nor responsibility to any person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by the information contained in this book. Further, the publisher and author are not engaged in rendering legal or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the services of a competent professional should be sought. RD 1949-50-51 F-sERIEs TRUCKS SHOP MANUAL Copyri,ht 1951 FORD MOTOR COM PANY DEARBORN , MICHIGAN AU rilhu rnerved FORD DIYISION FORD FORM 7099-A MOTOR • COMPANY April, 1951 PREFACE This manual combines under one cover complete service information for the 1949-50-51 Ford Trucks. All aspects of the servicing of the parts, assemblies, or systems involved will be found here. Repair men will find step by step procedures plus disassembled views of all of the assemblies used in these models. The diagnostician will find that working procedures for each kind of trouble he will encounter are covered. Maintenance and lubrication data is provided for those interested in this aspect of service. Service Managers and salesmen will find hints of everyday care that they can pass on to their customers. Collision men will find construction detail well illustrated to assist them in collision work. Electrical men will find simply written principles, not only of operation, but of testing as well for each of the electrical units or systems. Upholstery men will find how-to-do-it procedures for their work. Step-by-step procedures for the disassembly, inspection, and repair are presented throughout this manual. In addition, each assembly has been illustrated disassembled, with each of the component parts arranged in the order of assembly or disassembly. In many cases, a glance at these illustrations will tell you all you need to know about how the parts go together. These illustrations carry basic part numbers for each of the parts. These basic numbers plus the model number of the truck will permit you to order parts from any Ford dealer even though you may not have a "Parts Book." In recognition of the specialization that is currently practiced in many service establishments, this manual has been divided into five major divisions. These five parts are as follows: Part ONE-POWER PLANT -has to do with the Ford engines and the various systems that are necessary to their operation. These include fuel system, ignition system, and the cooling system. Part TWO-CHASSIS-starting with the clutch, covers the entire power train (clutch, transmission, drive line, rear axles, etc.) and the running gear (wheels, tires, brakes, springs, suspension, frames, steering gear, and linkages, etc.). Part THREE-ELECTRICAr.~ AND ACCESSORIES-covers all of the electrical systems and units (other than ignition which is covered in Part ONE) and accessories for Ford Truck models. Part FOUR-BODIE.$-contains complete information on the maintenance and repair of all body components, including adjustment and alignment not only of the body proper, but also of doors, hoods, fenders, and shields. Part FIVE-MAINTENANCE, TROUBLE SHOOTING, AND SPECIFICATIONS-has been arranged in the back of the book separately for the convenience of quick service men. In this part, all of the information ordinarily required for quick service men and service salesmen has been combined into three separate chapters. The Table of Contents on the next page shows not only the part break-down as described above, but also the chapters that have been established in each of the five parts. Each chapter has been divided into sections which also are listed in the Table of Contents. Regardless of the aspect of service in which you are interested or the unit of the vehicle in which you may be specializing, a glance at the Table of Contents will quickly direct you to the portion of this manual in which you are interested. If you are interested in maintenance procedures, trouble shooting, or specifications, the information you desire will be found in Part FIVE. Otherwise, it will fall in one of the four other parts. A quick glance at the chapter and section listings under the part involved will direct you to the page desired. Throughout this manual the top of each lefthand, even-numbered page gives the name of the chapter; and the top of each right-hand, oddnumbered page gives the name of the section involved. Thus, regardless of where you open the manual, a glance at the top of the two pages will tell you exactly what subject matter is discussed at that point. No one expects even the most experienced mechanic to remember all details of servicing these trucks and you will find that you will have to occasionally refer to this manual. Keep your manual where it will be readily available for reference at all times. FORD DIVISION FORD MOTOR COMPANY SERVICE DEPARTMENT TABLE OF CONTENTS Page Preface.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Part ONE - POWER PLANT CHAPTER I-GENERAL ENGINE REPAIR Section 4 Connecting Rods, Pistons, Rings, and Section 1 Engine Removal and Installation. . . . . . 5 Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 Valves, Springs, Guides, and Valve Seat 5 Flywheel Repair. . . . . . . . . . . . . . . . . . . .. Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6 Muffler, Inlet Pipe, Outlet Pipe, and 3 Crankshaft, Bearings, and Piston Crossover Pipe (8 cyl. only). . . . . . . .. Assemblies. . . . . . . . . . . . . . . . . . . . . . .. 11 20 CHAPTER II-H-SERIES 6-CYLINDER ENGINE Section 5 Cylinder Front Cover ............... , Section 1 Manifold Replacement .............. , 22 6 Valves and Valve Guides. . . . . . . . . . . .. 2 Cylinder Head Replacement..... . . . . .. 25 7 Camshaft Gear, Camshaft, and Bearings 3 Oil Pan, Oil Pump, and Oil Pressure 8 Flywheel, Crankshaft, and Bearings. . .. Relief Valve. . . . . . . . . . . . . . . . . . . . . .. 26 9 Piston and Connecting Rod Assemblies. 4 Crankshaft Damper. . . . . . . . . . . . . . . . .. 29 30 31 32 35 38 CHAPTER III-M-SERIES 6-CYLINDER ENGINE Section 5 Cylinder Front Cover. . . . . . . . . . . . . . .. Section 1 Manifold Replacement. . . . . . . . . . . . . . .. 40 6 Valves and Valve Guides ............ , 2 Cylinder Head Replacement. . . . . . . . . .. 42 7 Camshaft Gear, Camshaft, and Bearings 3 Oil Pan, Oil Pump, and Oil Pressure 8 Flywheel, Crankshaft, and Bearings. . .. Relief Valve. . . . . . . . . . . . . . . . . . . . . .. 44 9 Piston and Connecting Rod Assemblies. 4 Crankshaft Damper. . . . . . . . . . . . . . . . .. 47 47 48 50 54 56 CHAPTER IV-R-SERIES, 8-CYLINDER ENGINE Section 5 Cylinder Front Cover ............... , Section 1 Manifolds........................... 58 6 Valves and Valve Guides ............ , 2 Cylinder Heads. . . . . . . . . . . . . . . . . . . . .. 60 7 Camshaft Gear, Camshaft, and Bearings 3 Oil Pan, Oil Pump, and Oil Pressure 8 Flywheel, Crankshaft, and Bearings. . .. Relief Valve. . . . . . . . . . . . . . . . . . . . . .. 61 9 Piston and Connecting Rod Assemblies. 4 Crankshaft Pulley. . . . . . . . . . . . . . . . . . .. 64 64 65 66 69 70 CHAPTER V-E-SERIES 8-CYLINDER ENGINE Section 1 Manifolds........................... 74 Section 6 Valves, Valve Guides, Hydraulic Lifters, 2 Cylinder Heads.. . . . . . . . . . . . . . . . . . . .. 75 and Tappets. . . . . . . . . . . . . . . . . . . . .. 3 Oil Pan, Oil Pump, arid Pressure 7 Camshaft Gear, Camshaft, and Bearings Relief Valve ..................... ,. 77 8 Flywheel, Crankshaft, and Bearings.. .. 4 Crankshaft Damper. . . . . . . . . . . . . . . . .. 80 9 Piston and Connecting Rod Assemblies. 5 Cylinder Front Cover ............... , 80 Section 1 2 3 4 5 Ii CHAPTER VI-IGNITION, FUEL, AND Ignition System ..................... 91 Section 7 Distributor Minor Repair and Adjustment ....................... 95 8 Distributor Overhaul. ................ 99 Carburetor Construction, Oper~t;on, 9 and Adjustments .................. 103 10 11 6-Cylinder Carburetor Overhaul (Single Downdraft) ................ 108 12 8-Cylinder Carburetor Overhaul 13 (Dual Downdraft) ................. 112 14 COOLING SYSTEM 8-Cylinder Carburetor Overhaul (Dual Concentric) ................. 6-Cylinder Carburetor Overhaul (Single Updraft) ................... Governors .......... , ............... Fuel Pumps and Vacuum Booster ...... Fuel Tanks and Lines ................ Fans and Belts ...................... Water Pumps ....................... Radiators, Hose, and Thermostats ..... 15 19 81 84 86 89 114 118 120 123 127 128 129 132 Part TWO - CHASSIS CHAPTER I-CLUTCH AND TRANSMISSION Section 1 Clutch.............................. 135 Section 4 4-Speed Transmission ................ 2 Transmission Cleaning, Inspection, 54-Speed Synchro-Silent Transmission. .. 6 5 -Speed Transmissions. . . . . . . . . . . . . . .. and Alignment. . . . . . . . . . . . . . . . . . .. 13R 7 Gearshift Linkage. . . . . . . . . . . . . . . . . . .. 3 3 -Speed Transmissions ............... 140 147 149 154 161 CHAPTER II-REAR AXLES AND DRIVE LINES Section 1 Integral Housing Hypoid. . ......... " 163 Section 4 Banjo Ho~sing Spiral Bevel. . . . . . . . . .. 178 2 Split Housing Hypoid. . . . . . . . . . . . . . .. 168 5 Planetary Two-Speed ................. 182 3 Split Housing Spiral Bevel ............ 174 6 Drive Lines. . . . . . . . . . . . . . . . . . . . . . . .. 193 CHAPTER III-RUNNING GEAR Page Section 1 2 3 4 Frames............................. Front Axle .......................... Springs............................. Shock Absorbers ..................... Steering Gear ....................... Steering Connections. . . . . . . . . . . . . . . .. Wheels and Tires .................... Hubs and Bearings ................... 201 203 204 209 Section 1 2 3 4 CHAPTER IV-BRAKES Section 5 Brake Assemblies. . . . . . . . . . . . . . . . . . .. Types, Description, Model Application. 214 6 Brake Drums ........................ Adjustments........................ 217 7 Air Brake System. . . . . . .. ........... Hydraulic System. . . . . . . . . . . . . . . . . . .. 218 8 Parking Brakes ...................... Hydraulic Brake Boosters. . . . . . . . . . . .. 223 231 236 236 249 195 196 198 199 Section 5 6 7 8 Part THREE - ELECTRICAL AND ACCESSORIES CHAPTER I-ELECTRICAL SYSTEMS Section 4 Horns.............................. 276 Section 1 Generating System and Battery ....... 249 5 Instruments ......................... 277 2 Starting System. . . . . . . . . . . . . . . . . . . .. 263 3 Lighting System. . . . . . . . . . . . . . . . . . . .. 269 CHAPTER II-ACCESSORIES Section 1 Radio .............................. 282 Section 3 Windshield Wiper .................... 289 2 Heater............................. 287 Part FOUR - BODIES CHAPTER I-CONSTRUCTION AND MAINTENANCE Section 3 General Body Maintenance. . . . . . . . . .. 296 Section 1 Construction Details ................. 291 2 Door Alignment .................... , 295 CHAPTER II-HARDWARE, GLASS, AND INTERIOR TRIM Section 1 Door Locking Mechanism. . . . . . . . . . . .. 298 Section 4 Windshield and Rear Window. . . . . . . .. 303 2 Window Regulators. . . . . . . . . . . . . . . . .. 300 5 Seats and Interior Trim. . . . . . . . . . . . .. 304 3 Door Glass and Ventilator Assembly ... 301 CHAPTER III-FRONT END SHEET METAL AND RUNNING BOARDS Section 4 Fenders and Running Board. . . . . . . . . .. 316 Section 1 Front End Sheet Metal Replacement. .. 308 5 Cab Replacement. . . . . . . . . . . . . . . . . . .. 317 2 Radiator Grille ...................... 309 6 Platform Body Replacement ......... , 319 3 Hood and Component Parts. . . . . . . . . .. 312 Part FIVE - MAINTENANCE, TROUBLE SHOOTING, AND SPECIFICATIONS CHAPTER I-MAINTENANCE PROCEDURES Section 1 Engine Tune-up ..................... 321 Section 4 Lubrication ......................... 329 5 Preventive Maintenance. . . . . . . . . . . . .. 334 2 Wheel Alignment. . . . . . . . . . . . . . . . . . .. 323 3 Brake Adjustment. . . . . . . . . . . . . . . . . .. 328 CHAPTER II-TROUBLE SHOOTING Section 4 Electrical and Instruments. . . . . . . . . . .. 349 Section 1 Power Plant. . . . . . . . . . . . . . . . . . . . . . . .. 336 5 Accessories.......................... 358 2 Suspension, Stp.ering Gear, and 6 Power Train. . . . . . . . . . . . . . . . . . . . . . . .. 360 Tire Wear. . . . . . . . . . . . . . . . . . . . . . .. 346 3 Brakes............................. 348 Section 1 2 3 4 5 6 7 8 CHAPTER III-SPECIFICATIONS Section 9 Fuel System ........................ , Wheels and Tires. . . . . . . . . . . . . . . . . . .. 361 10 Generating System .................. , Brakes............................. 362 11 St~ng Systerr.. . . . . . . . . . . . . . . . . . .. Wheel Alignment and Steering. . . . . . .. 365 12 IgnItion ............................ Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . .. 366 13 Lights and Horns. . . . . . . . . . . . . . . . . . .. Frame and Springs ................... 367 14 Wiring Diagrams. . . . . . . . . . . . . . . . . . .. Engines............................. 369 15 Tools and Equipment. . . . . . . . . . . . . . .. Clutch and TransmIssIon ............ , 375 Cooling......................... 376 377 378 379 379 380 381 383 Part ONE POWER PLANT Chapter I General Engine Repair 8ecUoa 1 2 3 4 5 6 Pq. Engine Removal and Installation .............................. ......................... Valves, Springs, Guides, and Valve Seat Inserts ................................. .......... Crankshaft, Bearings, and Piston Assemblies .................... . Connecting Rods, Pistons, Rings, ana Pins ...................... . Flywheel Repair ........................................... . Muffler, Inlet Pipe, Outlet Pipe, and Crossover Pipe (8 cyl. only) ... . This Chapter brings together repair procedures that are common to all engines. Instructions for fitting the various engine parts are accompanied by charts that conveniently list the tolerances for all engines. This eliminates searching through the book for specifications. For added convenience, a complete list of specifications is included in the back of the book. 5 9 11 15 19 20 Engine removal and installation procedures are presented first with respect to the body style and then are subdivided according to the engine. This eliminates repetition of preliminary operation procedures and quickly (luides the reader to the procedure for any combination of body style and engine. 1. ENGINE REMOVAL AND INSTALLATION A detailed procedure for removing and installing the engine is given in this section for the various body styles. Ford trucks are classified by a series number trom f'-1 thru F -8 according to their wheelbase and gross weight. The possible combinations of truck series, body style, and engine that may need servicing are listed in Table 1. Removal and installation procedures are given according to the type of truck. The operations common to the removal of any engine are covered immediately follow. ing the heading for a certain type truck. The major headings are "a. Conventional Truck" and "b. Cab-OverEngine." Specific information for each engine is covered under headings "( 1) H or M Series Engine Removal," "(2) H or M Series Engine Installation," "(3) R Series Engine Removal," "( 4) R Series Engine Installation," "(5) E Series Engine Removal," and "(6) E Series Engine Installation." Only the H series engine is used in the parcel delivery truck and it is handled separately under the heading "c. Parcel Delivery." the flexible fuel line, choke wire, throttle linkage, vacuum hose, and starter cable at the starter. (1) H OR M SERIES ENGINE REMOVAL. Disconnect the upper radiator hose at the engine and the lower radiator hose at the radiator. Disconnect the fan shroud from the radiator and lean it against the engine. Remove the radiator, then remove the shroud. Disconnect the ignition switch to coil wire. Disconnect the muffler inlet pipe at the exhaust manifold, and the clutch release bearing spring and rod. Install an engine lift bracket (fig. 1) and take up the load with a hoist. Remove the engine front support bolts. Remove the bolts which secure the transmission to the flywheel housing. Pull the engine away from the transmission and lift Tabl. J-Truck Models Body Style Engine Conventional a. Conventional Truck. Drain the radiator and crankcase. Remove the hood, air cleaner, and battery. Disconnect the heater hoses at the engine. Disconnect the generator wires, temperature sending unit wire, and oil pressure sending unit wire. Disconnect 5 Cab-Over-Engine H F-l to F-6 F-S and F-6 R F-l to F-6 F-5 and F-6 M F-6 F-6 E F-7 andF-8 Parcel Delivery F-3 Chapter I-General Engine Repair 6 the engine from the chassis. Do not allow the engine to strike the grille. (2) H OR M SERIES ENGINE INSTALLATION. To install the engine, lower it into the engine compartment and align it with the flywheel housing. Shift the transmission into Bny gear. Start the transmission main shaft into the clutch disc spline. If the spline grooves do not mesh, turn the crankshaft slowly with a box wrench on the crankshaft damper retaining bolt until the main shaft slides into the clutch disc spline. Install the transmission to flywheel housing bolts and tighten them to 40-50 foot-pounds torque. Install the engine front support bolts. Remove the lift bracket from the engine. Connect the clutch spring and rod, the muffler inlet pipe, and ignition switch to coil wire. Lean the fan shroud over the engine and install the radiator. Fasten the fan shroud to the radiator. Connect the radiator hoses. To complete the engine installation, connect the starter cable, vacuum hose, throttle linkage, choke wire, temperature and pressure sending unit wires, generator wires, Bnd heater hoses. Install the battery, air cleaner, and hood. Fill the cooling system and crankcase according to the prevailing temperature. (3) R SERIES ENGINE REMOVAL. Remove the upper radiator hoses. Remove the fan belt and fan, and the generator belt and generator. Disconnect the lower radiator hoses at the radiator and remove the radiator. Disconnect the ignition switch to coil wire, muffler inlet pipe, and the clutch pedal retracting spring. Remove the road draft tube. Place a support under the transmission to prevent it from dropping out of line when the engine is removed. Insta ll the engine lift hook assembly (fig. 2) and take up the slack in the cables with a hoist. Remove the engine front support bolts. Remove the transmission to flywheel housing bolts. Pull the engine away from the transmission and lift it from the engine compartment. Do not allow the engine to strike the grille. (4) R SERIES ENGINE INSTALLATION. To install the engine, lower it into the engine compartment and align it with the fly wheel ' housing. Shift the transmission into any gear. Start the transmission main shaft into the clutch disc spline. If the spline grooves do not mesh, turn the crankshaft slowly until the main shaft slides into the clutch disc spline. Install the transmission to flywheel housing bolts and tighten to 40-50 foot-pounds torque. Install the engine front support bolts. Remove the engine lift hook assembly. Connect the clutch pedal retracting spring, muffler inlet pipe, ground strap, and ignition switch to coil wire. Install the radiator and connect the lower radiator hoses. Install the generator and generator belt and the fan and fan belt. Adjust belt tension. Install the radiator hoses. To complete the engine installation, connect the starter cable, vacuum hose, throttle linkage, choke wire, temperature and oil pressure sending unit wires, and heater hoses. Install the road draft tube. Install the battery, air cleaner, and hood.. Fill the cooling system and crankcase according to the prevailing temperatures. (5) E ' SERIES ENGINE REMOVAL. R emove the uI--per radiator hoses. Remove the fan belt and fan and the generator belt and generator. Disconnect the lower radiator hoses at the radiator and remove the radiator. Disconnect the distributor primary wire and the coil to distributor high tension wire. Disconnect the throttle linkage. Loosen the road draft tube clamp at the elbow and remove the road draft tube. Disconnect the muffler inlet cross over pipe and muffler inlet pipe from the exhaust manifolds. Install the engine lift hook assembly (fig. 2) and take up the slack in the cables with a hoist. Remove the engine front support bolts. Support the transmission to prevent it from dropping out of line when the engine is removed. Remove the bolts that secure the flywheel housing to the engine block. Move the engine far enough forward to clear the transmission main shaft, then lift the engine from the chassis. (6) E SERIES ENGINE INSTALLATION. To install the engine, lower it into the engine compartment and align it with the flywheel housing. Shift the trans- INSTAll HOOK PLATES ON O PPOSITE OF ENGINE ~~--To o/_6000·N Engine liffing Eye Too/_6000 · P 1216 fig : '-Engine Lift Bracket for H or M Series Engines 1185 Fig. 2-fngine Liff Hook Assembly for 8-Cylinder fngines Section l-Engine Removal and Installation mission into any gear. This will keep the main shaft from turning. Move the engine toward the transmission until the main shaft enters the clutch disc spline. If the spline gooves do not mesh, turn the crankshaft slowly until the main shaft slides into the clutch disc spline. 7 \,., Install the flywheel housing to engine bolts and torque them to 40-50 foot-pounds. Install the engine front support bolts. Remove the engine lift hook assembly. Connect the muffler inlet pipe and muffler inlet cross over pipe to the exhaust manifolds. Install the road draft tube. Connect the distributor primary wire and the coil to distributor high tension wire. Insta ll the radiator and connect the lower radiator hoses. Install the generator and generator belt and the fan and fan belt. Adjust the belt tension. Install the upper radiator hoses. To complete the engine installation, connect the starter cable, vacuum hose, throttle linkage, choke wire, temperature and pressure sending unit wires, and heater hoses. Install the battery, air cleaner, and hood. Fill the cooling system and c rankcase according to the prevailing temper a tures. b. Cab.Over.Engine. Begin the engine removal operation by draining th e crankcase and cooling system. Remove the hood, air ,.Ieaner and flexible tube, floor pan over the engine, and dash panel. Remove the oil filter lines. Remove either front wheel. Remove the grille assembly (fig. 3). Disconnect the radia tor hoses and remove the radiator support assemb ly with the radiator (fig. 4) . Fig. 4-Removing Radiator (H or M Series Engines] (1) H OR M SERIES ENGINE REMOVAL. Install the engine lift bracket on the cylinder head. Connect a portable floor crane to the lift bracket and take up the engine load (fig. 5). R emove the bolts which secure the transmission to the flywheel housing. Move the engine away from the transmission, lift it high enough to clear the chassis, and carefully maneuver the e ngine out of the engine compartment. Disconnect the generator wires, ignition switch to coil wire, temperature sending unit wire, oil pressure sending unit wire, vacuum hose at the intake m anifold, starter motor cable at the starter, throttle linkage, choke wire, and heater hoses. D isconnect the flexible fuel line, muffler inlet pipe, and clutch release bearing sprin g. Remove the engine front support bolts. \ Fig. 3-C.O.E. Grille Assembly Fig. 5-Lifting the 6-Cylinder Engine 8 Chapter I-General Engine Repair (2) H OR M SERIES ENGINE INSTALLATION. To install the engine, guide it into the engine compartment. Lower the engine and move it back until the transmission main shaft enters the clutch disc spline. Shift the transmission into any gear. This will prevent the main shaft from turning. It the spline grooves do not mesh, slowly turn the crankshaft until the main shaft slides mto the clutch disc spline. Install the transmission to flywheel housing bolts and torque them to 40-50 foot-pounds. Lower the engine to the front supports and install the front support bolts. Disconnect the crane and remove the engine lift bracket. To complete the engine installation, connect the muffler inlet pipe, clutch release bearing spring, and flexible fuel line. Connect th~ choke wire, throttle linkage, starter cable, vacuum hose, oil pressure sending unit wire, temperature sending unit wire, generator wires, ignition switch to coil wire, and heater hoses. Install the radiator and connect the radiator hoses. Install and secure the grille assembly. Install the front wheel. Install the dash panel, floor pan, air cleaner and flexible tube, and hood. Fill the crankcase and cooling system according to the prevailing temperatures. (3) R SERIES ENGINE REMOVAL. Remove the generator, carburetor, crankcase inlet pipe and fuel pump. Install the engine lift hook assembly and take up the slack in the cables with a portable floor crane. Remove the bolts which secure the transmission to the flywheel housing. Move the engine away from the transmission. Lift it high enough to clear the chassis and carefully maneuver the engine from the engine compartment. (4) R SERIES ENGINE INSTALLATION. To install the engine, guide it into the engine compartment. Lower the engine and move it back until the transmission main shaft enters the clutch disc spline. Shift the transmission into gear to prevent the main shaft from turning. If the spline grooves do not mesh, slowly turn the crankshaft until the main shaft slides into the clutch disc spline. Install the transmission to flywheel housing bolts and torque them to 40-50 foot-pounds. Lower the engine to the front supports and install the front support bolts. Disconnect the crane and remove the engine lift hook assembly. Install the fuel pump, crankcase inlet pipe carburetor, and generator. To complete the engine installation, connect the muffler inlet pipe. clutch release bearing spring, and flexible fuel line. Connect the choke wire, throttle linkage, starter cable, vacuum hose, oil pressure sending unit wire, temperature sending unit wire, generator wires, ignition switch to coil wire, and heater hoses. Install the radiator and connect the radiator hoses. Install and secure the grille assembly. Install the front wheel, dash panel, floor pan, air cleaner and flexible tube, and hood. Fill the crankcase and cooling system according to the prevailing temperature. c. Parcel Delivery. Drain the crankcase and cooling system. Remove the hood and radiator support bar. Disconnect the upper radiator hose. Remove the fan shrOUd from the radiator and lean the shroud against the engine. Disconnect the lower radiator hose, remove the radiator support assembly with the radiator, and remove the fan shroud. Remove the engine compartment rear cover. Open the engine compartment front cover and attach the hook at the left corner near the hinge to keep it open. Remove the weatherstrip retaining panel at the rear edge of the engine compartment rear cover. Remove the air cleaner and flexible tube. Disconnect the generator wires, ignition switch to coil wire, temperature sending unit wire, oil pressure sending unit wire, vacuum hose at the intake manifold, starting motor cable at the starter, throttle linkage, choke wire, and heater hoses. Disconnect the flexible fuel line, muffler inlet pipe, clutch release bearing spring, and hand brake cable where it is clipped to the transmission. Fasten the engine lift bracket to the cylinder head. Project' the portable floor crane through the righthand door. Connect the crane chain to the lift bracket and take up the engine weight. Remove the engine front support bolts. Remove the bolts that secure the transmission to the flywheel housing. Move the engine far enough forward to clear the transmission main shaft. Lift the engine and carefully maneuver it through the door (fig. 6). To install the engine, guide it through the right-hand Fig. 6-Removing Parce' Delivery Engine Section l-Engine Removol and Installation door and lower it into the engine compartment. Do not allow the engine to strike any part of the body or chassis. Shift the transmission into any gear. This will prev.nt the main shaft from turning. Align the engine with the transmission and move it back until the transmission main shaft starts into the clutch disc spline. If the spline grooves do not mesh, slowly tUrn the crankshaft with a box wrench on the crankshaft damper bolt until the main shaft slides into the clutch disc spline. Install the transmission to flywheel housing bolts and torque them to 40-50 foot-pounds. Lower the engine to the front supports and install the front support bolts. Disconnect the crane and remove the engine lift bracket. Connect the hand brake cable to the transmission. 9 Connect the clutch release bearing spring, mufHer inlet pipe, fuel line, starter cable, and heater hoses. Connect the generator wires, ignition switch to coil wire, temperature sending unit wire, oil pressure sending unit wire, vacuum hose,_ throttle linkage, and choke wire. Install the air cleaner and flexible tube. Install the weatherstrip retaining panel, lower the engine front compartment cover, and install the engine rear compartment cover. Lay the fan shroud over the engine. Install the radiator support assembly with the radiator and connect the lower radiator hose. Fasten the fan shroud to the radiator. Connect the upper radiator hooe. Install the radiator support bar and hood. Fill the crankcase and cooling system according to the prevailing temperature. 2. VALVES, SPRINGS, GUIDES, AND VALVE SEAT INSERTS Removal and disasse mbly procedures for valves and guides in a specific engine are covered in the chapter on that particular engine. Cleaning, testing, inspection, and repair operations common to all valves, guides, a nd seats, are given in this section under headings which are descriptive of the parts cove red. a. Valves, Springs, and Valve Guides. The procedure given below constitutes the essential steps for a valve grinding operation when the valves have been removed from the engine. This procedure in· eludes cleaning, inspection, spring testing, and refacing valves and valve seats. Valve clearances are set at the time of valve installation and are discussed for each engine in the chapter on that particular engine. Valve operation is dependent on the clearance be· tween the valve stem and valve guide. Excessive clearance or bellmouthed valve guide ends cause noisy valve operation. Insufficient clearance may cause the valve to stick open resulting in rough engine operation and valve failure. with lacquer thinner. On rotating type valves clean the valve caps thoroughly. NOTE : Foreign particle. between Ihe valve "em and cap may prevent the valve from rotating and caU8e the valve to fail. (2) INSPECTION. Check the valves for burned ar warped heads. Measure the stem diameter and replace the valve if the diameter is less than 0.341 inch. Measure the valve guide inside diameter to determine ,valve to guide clearance. Figure 7 illustrates the method of measuring the valve guidE:. with the telescope gauge and micrometer. Replace the guide if the clearance is greater than the tolerance shown in Table 2 for each engine. Tight guides can be relieved by burnishing (fig. 8). Replace the guide if either end is bellmouthed. Replace warped, burned, pitted, or worn valves. (3) SPRING TESTING. Test the Valve Springs ( fig. 9) for compression. Replace springs if they are not within the limits given in Table 3. (1) CLEANING. Wash all parts of the valve assembly in solvent. Scrape carbon and lead deposits from head and stem of valve. Remove varnish from the stem Tabl. 2-Valve Stem Clearance Specifications Engine Valve Stem to Guide Clearance ( Inches) R 0.0015-0.0035 HorM 0.0010-0.0031 E 0.0022-0.0037 Fig. 7-Checking Valve Guid. Wear Chapter I-General Engine Repair 10 TobIe 3-5pr;ng Test Sp ecification s Compression ( Pounds ) Y ea r Test J.ength R 1949-1950 2.1 3 37-40 R 1951 1.89 40-42 HandM 1949-1951 2.11 47-50 E 1949-1951 1.6R 63-69 Enginfl -valve 1pring - 65 I 3- _ _ - (4) REFACING VALVES. Remove all carbon from the valve head and stem. Grind the face of the valve at 45 0 angle as shown in fig. 10. If the valve head is less than '132 inch thick at the outer edge replace the valve. (5) REFACING VALVE SEATS. Clean seats thoroughly with a wire brush to prevent carbon from becoming embedded in the grinding wheel during the refacing operation. Keep grinding dust from entering the engine. R emove only enough stock to clean up pits and other depressions. NOTE: Worn valve guides nlust be replaced be/ore re/acing val've seats. After regrinding the valve seats, the width of the seat must not exceed V16 inch measured across the face of the seat as shown in fig. 11. Tf the valve seat is too wide, remove just enough stock from the top or bottom of the va lve seat to reduce the width to approximately %6 inch. This can be done by using a 30 degree angle grinder to remove stock from the bottom of the valve seat, a nd a 60 degree angle grinder to remove stock from the top of the valve seat. The valve seat should not exceed 0.005 inch run out. Check the valve seat run out with a dia l indicator (fig. 12). Lap the seat a nd valve together with a fine lapping compound to finish the operation. Fig . 8-Burnishing Val v e Guide ~ 1037 Fig . 9-Checkin g Valve Spring b. Valve Seat Inserts. Some R series engines are equippe d with valve seat inserts for both intake and exhaust valves, others use inserts in the exhaust val ve ports only, and some have no inserts at all. The H , M, and E se ries engines have inserts in the exhaust valve port only. Valve seat inserts are pressed into the counter bore in the cylinder block valve port (fig. 13). (1) REMOVAL. Remove the insert by driving a we dge under the insert and prying it out. (2) INSTALLATIUN. Chill the inserts with dry ice be fore inserting them in the cylinder block. Tap them with a soft faced hamme r until they seat firmly in the recess. After installing the valve seat inserts, grind them concentric to the valve guides. Fig . 10-Grinding Valve Face 11 Section 2-Valves, Springs, Guides, and Valve Seat Inserts VAL SEAT EXHAUST VALV E SEAT IN SERT_6057 VALVE PORT COUNTER BORE Fig. JJ-Correct Valve Seat Width ........ 1038 F Fig. J3-Volve Seat Insert 3. CRANKSHAIT, BEARINGS, AND PISTON ASSEMRLlES The crankshaft is supported in three main bearings in the 8-cylinder engines a nd four main bearings in the 6-cylinder engines. The center bearings are placed so that two crankshaft throws are located between any two main bearings. This a rra ngem ent provides a rigid support for the crankshaft and a llows the bearing load to be distributed. a. Camshaft. The cra nkshaft is made o f cast a lloy steel with integral counterweights and is dynamically a nd statically bala nced. Oil di strib ution h oles are drilled through the shaft for main bearing and connec ti ng rod lub rication. F igure 14 shows these oil passages in a cutaway view of the R series engine cranksh a ft. ( 1) CLEANING AND INSPECTION. W ash the crankshaft in solvent. Blowout the oil passages with compressed air. R emove the sludge trap plugs and clean out t he traps. Press in new plugs. Examine the shaft for evidence of crac ks. Check t he dowel pins in the fl ange for looseness. Remove any nicks on the ends of the pins with a file. CAUTION: Do n ot file th.e body diameter of th.e dowel pins. (2) CRANKSHAFT JOURNAL MEASURE· MENT. M easure each crankshaft journal diameter at a minimum of four places to determi ne the size, whether or not it is out of round, and whether or not it h as taper. If any of the journals are out of round more t h a n 0.0015 inch or if tape r of more tha n 0.001 in ch exists, they sho uld be machined. J ournals that are worn evenly and have less than 0.001 inch taper or a 0.0015 inch out · of round condition will not require machining if the availa ble b eari ngs wi ll provide not more than 0.002 inch clearance for the main bearing, or not more than 0.003 inch clearance for the crankpin b earings. M a nufacturer 's crankshaft journ a l diameters for each en gi ne a re given in Table 4. SLUDGE TRAPS (DRILLED IN JOURNAL- I NDIVIDUAL O IL PASSAGES FROM SLUDGE TRAP TO EACH ROI:) BEARING-PRESSED-IN HO LLOW PLUGS SEAL OPENINGS.) Fig. 12-Checking Valve Seat Runout 1523 Fig . '4-Crankshaft Oil Passag.es (R Series EnginesJ 12 Chapter I- General Engine Repair (3) GRINDING CRANKSHAFT JOURNALS . Calc ulate the correct undersize from the crankshaft dimension given above. EXAMPLE : 1/ Ih e main bearing jo urnal on an E Series Engine crankshaft will " clean up" /) el o re it is f(rou Ilcl to 2.499 -0.010 = 2.489 inc/, es diam· ete r, finish it to 'hat diamete r and ins/all 0.010 undersize bearings . Undersize bearings are available in 0.002, 0.0 10, 0.020, and 0.030 inch sizes for Hand M series engines and 0.002, 0.010, 0.020, 0.030, and 0.040 inch sizes for R and E series engines. NOTE : On lat e lllodel E series engines a series oj selecti ve fit bearings are used instead 0/ t/, e 0.002 in ch undenize bearing. Always reproduce the same radii that existed originally 10 the corners of the pin or journal. T oo small a radius may result in crankshaft failure, whitt: too large a radius w11l result in bearing failure. After grinding, polish the pin or journal with No. 320 grit emery cloth and engine oil. Crocus cloth tnay also be used. b. Main and Connecting Rod Bearings. Steel backed copper-lead insert bearings are used in the main bearing supports and connecting rods. These Fig . 'S-Bearing Scratched bv D,n Table 4-Crankshofl Journal Specifications lDiame ter ( Inches) Engine Main Journal Front and Center R ear Crankpin E 2.8735-2.8740 2.8730-2.8735 2.3995-2.4000 R 2.4982-2.4990 2.4982-2.4990 2.1382-2. 1390 HorM 2.8732-2.8740 2.8732-2.8740 2.2980-2.2988 bearings are held in place with inde ntations on the end of the insert which locate in machined notches in the cyl inder block and connecting rod caps when installed. Care should be used in fitting bearings SInce the crankshaft carries the entire engine load. Lubrication must be maintained or the bearings will wear out rapidly with possible damage to the crankshaft journals. Be sure the oil holes in the bearing line up with those in the bearing bore. Crankshaft end thrust is controlled by the rear main bearing flange. Bearing inserts are precision manufactured and are ordered by size to re-establish the manufacturer's tolerance when the engine is overhauled. Main bearing inserts th at are scratched. show fatigue pockets, or have the overlay wiped out, should be replaced. Fig. 16-Fatigue Failure 0' Bearing Se~tion 3-Crankshaft, Bearings, and Piston Assemblies 13 RADII RIDE Fig . '7-8earing Failure Due to lack 01 Oil A bearing that has only light sc ratches may be reused providing the clearances are satisfactory. Scratched bearings are shown in fig. 15. Fatigue fai lure can be recognized by the breaking away of the bearing overlay material (fig. 16). Figure 17 shows two bearings with the overlay wiped out. Excessive wear on one side of the bearing half (fig. 18 ) indicates a tapered bearing journal. The journal should be reground to the next undersize to remove the taper and undersize bearings should then be installed. Similarly excessive wear at the center or end of the bearing around the circumference (fig. 19) indicates high spots on the bearing journal which should be corrected before the engine is rebuilt. Fig. J 9-Bearing Showing Radii Ride cause of the bearing bore being too large, or by the bearing not having sufficient "crush." Grooved or scored main bearing or crank pin journals will cause bearing failure and should be machined if possible; otherwise the crankshaft should be replaced. Light scores or scratches can be removed with a hone, then polished with No. 320 grit polishing paper. ( 1) FITTING MAiN BEARINGS (PLASTIGAGE METHOD). Remove the bearing cap and wipe the oil from the bearing and journal. Bright sections across the back of the bearing (fig. 20) indicate the bearings have been loose in the bore either because of an undersize outside diameter, beaVERlA Y GONE 1161 Fig. J B-Bearing Failure Due to Tapered Journal Fig . 20-Bearing Showing Bright Spots Because of Improper Seating Chapter I-General Engine Repair 14 NOTE: Keep the other bearing caps tight while checking the /it of a bearing. Place a piece of Plastigage the full width of the bearing on the bearing insert. Install the bearing cap and torque the retaining bolts. Leave the cap tight for approximately one minute and then remove it. CAUTION: Do not turn the crank.haft while the Plastil/age is between the bearing and the crank. haft jou.rnal. Remuve the bearing cap. Without moving the plastic, check its width (at the widest point) with the graduations on the Plastigage container as shown in fig. 21. If the bearing clearance is not over 0.002 inch, the bearing insert is satisfactory. If the clearance is greater than 0.002 inch, install another standard bearing with thicker wall or a 0.002 inch undersi ze bearing and recheck the clearance. NOTE: In the later model "E" series engines, use the selective fit series of standard bearings 10 oblain correct .:learance. When the 0.002 inch undersize bearing is used and the clearance is excessive, grind the crankshaft main bearing journals for use with the next undersize bearing insert. (2) FITTING MAIN BEARINGS (SHIM METHOD). Place a 0.002 inch brass shim '/2 inch wide by 1 inch long between the bearing insert in the cap and the crankshaft journal. Coat the shim lightly with engine oil. Tighten the main bearing cap bolts. Turn the crankshaft one inch in either direction. If the crankshaft is . locked with the 0.002 inch shim, and is free without the shim, the bearing insert used is satisfactory. If the crankshaft can be moved freely with the 0.002 inch shim, install another standard bearing with thicker wall or a 0.002 inch undersize bearing insert and repeat the above check. If the crankshaft still turns ,aslly, excessive clearance is indicated and the crankshaft should be reground to the next undersize bearing insert size. NOTE: Rotate the crankshaft to be sure thaI the bearing i, not too tight. (3) FITTING CONNECTING ROD BEARINGS (PLASTIGAGE METHOD). Place a piece of Plastigage plastic the length of the cap in the bearing cap. Install and tighten the cap. NOTE: Do not turn the crank.halt with the Pla.ti· gage in place. Remove the bearing cap and use the Plastigage scale to measure the width of the Hattened piece of plastic at the widest point. If the reading is not over 0.003 inch, standard size connecting rod bearings should be used; if it is over 0.003 inch, install a 0.002 inch undersize bearing and recheck the clearance. When use of the 0.002 inch undersize bearing results in excessive clearance, grind the crankshaft and install undersize bearing inserts. (4) FITTING CONNECTING ROD BEARINGS (SHIM METHOD). Place a 0.003 inch brass shim V2 flattened Plaslic .002 " ClEARANCE GRADUATED CONTAINER fig. 2J-Measuring Flattened Plastigage 1181 1047 Fig. 22-Checking Crankshaft End Clearance 15 Section 3-Crankshaft, Bearings, and Piston Assemblies inch wide by 1 inch long in the bearing cap with a new standard insert and install the cap. Tighten the nuts. Attempt to move the connecting rod endwise on the crank pin by hand and then by a light tap of a hammer. Remove the shim and repeat the above test. If connecting rod did not move by hand, but moved by tap of hammer in the previous test and moved freely with shim removed, the standard bearing as installed should be used. If rod could be moved by hand when used with the shim, install the 0.002 inch undersize bearing and repeat the above test. After determining that the correct bearing insert has been fitted, tighten connecting rod bearing cap nuts. Then rotate the shaft to be sure the bearing is not too tight. (5) CHECKING CRANKSHAFT END CLEAR- fable 5-,Crankshaft End Play Specifications Engine Crankshaft End Play (Inches) H.M.orE 0.004-0.006 R 0.002-0.006 ANCE. Before you install new rear main bearing in- serts the crankshaft end play should be checked. To check the crankshaft end play, pry the crankshaft toward the rear of the engine. Place a dial indicator against the forward side of the rear counterweight. Set the dial to zero and then pry the shaft forward (fig. 22). If the dial indicator shows excessive end play (Table 5), the rear main bearing insert should be replaced with a new insert to take up the end clearance. 4. CONNECTING RODS, PISTONS, RINGS, AND PINS Procedures in this section cover all operations necessary to fit an engine with new piston rings. Piston cleaning and inspection, cylinder bore inspection and reboring, fitting pistons, and fitting piston rings are discussed under the heading "a. Piston and Rings." Inspection and fitting of piston pins is covered under CYLINDER WAll CYLINDER WAll TAPER .CAST IRON SECTION STEel UI==iiiiI~SECTION INNER RING EXPANDER TYPE COMPRESSION RING SNAP COMPRESSION RING CYLINDER WAll STEEL SECTION COMPRESSION RING CYLINDER WAll INNER RING+-~~ INNER RING LJm=~Cl--STEEl SlOTIED CAST IRON Oil RING SNAP OIL RING EXPANDER TYPE OIL RING lEVELED INSIDE DIAMETER SNAP COMPRESSION RING STEEL SECTION OIL RING COUNTERIORED INSIDE DIAMETER SNAP COMPRESSION RING Fig. 23-Piston Ring Types SECTION 1087 16 Chapter I-General Engine Repair the heading "b. Piston Pins." Connecting rod inspection is covered under the heading lie. Connecting Rods." a. Pistons and Rings. Pistons and rings seal the combustion gases from the crankcase and control the amount of oil left on the cylinder wall for lubrication. Worn or improperly in~ stalled rings will cause engine oil contamination, excessive oil consumption, fouled spark plugs, and poor engine performance. Three types of piston rings sets are used in servicing Ford engines. They are: a "snap" type or standard ring set; an dexpander" type ring set; and a "steel section" type ring set. Figure 23 shows the various compression and oil control rings included in these ring sets. The standard or snap type ring is designed for use in a new engine block or whenever a block is reba red and new pistons installed. Under these conditions the block would neither be out-of-round nor have a taper. A light honing with a No. 280 grit hone is recommended in either case. Under a tapered condition the standard type oil rings are not flexible enough to provide sufficient wiping action on the cylinder wall. Oil is then allowed past the rings and oil consumption increases. To remedy this situation the expander type ring is used in cylinder bores where the taper does not exceed 0.006 inch or whenever an oil consumption condition is encountered. Ring pressure is maintained by an expander under the oil ring. Hone the cylinder bores before installing the expander type ring. When the cylinder bore taper is greater than 0.006 inch but less than 0.015 inch, the expander type ring is not adequate to seal the combustion chamber from the crankcase. Under this condition the steel section type ring is used. The oil ring is installed with a steel ring on both top and bottom in addition to the expander under the ring. Honing is not necessary when the steel section type ring. is used. (1) CLEANING AND INSPECTION. Remove all carbon from the piston with a scraper or carbon brush. Clean the piston ring grooves with a ring groove cleaner (fig. 24). Clean the carbon from the oil return holes in the oil ring grooves by running a drill through the holes. Be sure the drill is the same size as the hole. Inspect pistons for fractures at the ring lands, skirt, and pin bosses. Replace pistons showing signs of wavy ring lands, fractures, or damage from detonation. Spongy eroded areas around the top edge of the piston, usually on the side opposite the valves, are caused by detonation. In some instances holes are also burned through the top of the piston. (2) INSPECT CYLINDER BLOCK. Make a thor- ough cheek for cracks. Minute cracks can be located simply and quickly with the following procedure: Coot the cylinder wall with a mixture of 25 percent kerosene and 75 percent light engine oil. Wipe the wall dry, then apply a light coat of zinc oxide powder dissolved in wood alcohol. The cracks will show as discolored lines on the zinc oxide coating. Inspect the cylinder bore for scratches or scuffing. Check for bulging at the top of the cylinder bore. Replace any leaking expansion plugs (indicated by rust around the plug). Use a sealing compound under the new plug. Check tbe cylinder bore using a telescope gauge and outside micrometers, cylinder gauge, or inside micrometers. Measure and record as "A," "B," "C," and "0 " the dimensions shown in fig. 25. Compare "A" with liB" and "C" with "0 " to determine the amount of taper in the bore. If the taper is greater than 0.015 inch, the cylinder must be rebored. Compare IIA" with "C" and ''H'' with "0" to determine how much the cylinder is out of round. If the bore is more than 0.003 inch out of round it must be rebored. (3) BORING CYLINDER BLOCK. To assure maximum performance and balance of the reciprocating parts of the engine, all cylinders must be bored to the same size even though only one cylinder requires reboring and the others are within tolerance. Manufacturers recommendations on how to use boring equip. ment should be followed and the work performed only by experienced personnel. Bore the most badly worn cylinder first to determine the proper oversize. If the cylinders will not clean up at 0.060 inch oversize, the block must be replaced. When reboring the cylinders allow 0.0015 inch stock for honing when fitting pistons. Use a number 220 to 280 grit hone for this operation. CAUTION: Thoroughly clean the block to remove all particle. of abra.ive after the honing operation. Fig . 24-Cleaning Pislon Ring Grooves 17 Section 4-Connecting Rods, Pistons, Rings, and Pins Table 6-Pis'on Fitting Specifications Engine R H Piston T y~ Piston T ype: - M and E 7HA OHA 49T New Piston in New Bore Gauge Thickness (Inches) Pounds Pull 0.003 6-12 0.002 3-12 0.003 6-12 0.0015 3-12 0.0015 5-10 New Piston in Used Bore Gauge Thickness {Inches} Pounds Pull 0.003 6-12 0.002 3-12 0.003 6-12 0.0015 3-12 0.0020 5-10 Used Piston in Used Bore Gauge Thickness (Inches) Pounds Pull 0.003 6-12 0.003 3-12 0.004 6-12 0.003 3-12 0.003 5-10 (4) FITTING PISTONS. Proper assembly tolerances of pistons are required if sa tisfactory engine operation is to be obtained. Cylinder bores must be checked for taper and out-of-round condition before fitting a piston. To install a piston with ne w rings in a used bore, the high polish on the cylinder bore must be removed to allow the new rings to seat without scuffing. This is done by running a hone through the cylinder bore. Clean the cylinder thoroughly to remove the hone dust. To fit a new piston in a new bore, aUaen a tension scale to the end of a feeler ribbon 1/2 inch wide and having the correct feeler ribbon thickness as given in Table 6. Position the feeler ribbon on the thrust side of the cylinder (right-hand side of cylinder bore as viewed from the driver's seat). Invert the piston, " C" AND " 0 " MEASUREMENTS MADE ACROSS ENGINE "A" AND " B" MEASUREMENTS MADE PARAllEl TO ENGINE AXIS 00 FR O NT REAR BBA then push the piston into the cylinder bore until the skirL is about '/2 inch below the top of the block. Keep the piston pin bore parallel with the camshaft. Pull out the feeler gauge and at the same time note the reading (fig. 26). The pull limits for new pistons and used pistons in new or used bores is given in Table 6. (5) FITTING PISTON RINGS. Insert the ring in the cylinder bore. Invert a piston and use it to push the ring about half way down into the bore. This will also square the ring with the bore. Measure the ring gap. It should be 0.007 to 0.047 inch in a worn cylinder. If the gap is smaller than 0.007 inch, file the ends of the ring until the correct clearance is obtained. If the ring gap exceeds 0.047 inch install the next oversize ring. Be sure to identify the rings so they will be installed in the same cylinder in which they were fitted. Check the ring groove clearance on the proper piston for the cylinder as shown in fig. 27. The rings should have the clearance shown in Table 7. To relieve rings with less than the minimum allow- \LOC~EASUREMENTS -.1 TOP OF " A" AND "C MADE BELOW RIDGE OR AT THi TOP OF RING TRAVEL ,I MEASUREMENTS " B" AND " D" MADE AT BOnOM OF RING TR AVEl Fig. 25-Cylinder Bore Measurements 1176 Fig. 26-Fi"ing Pis'on '0 Cylinder Bore 18 Chapter I-General Engine Repair Table 7-Ring Groove Clearance Specifications Engine H M R E Rings 8MTH Piston 8EQ Piston Upper Compression 0.0015-0.0030 0.0015 -0.0030 0.0015-0.0030 0.0015-0.0030 0.0020-0.0040 Lower Compression 0.0010-0 .0025 0.0010-0.0025 0.0010-0.0025 0.0010-0.0025 0.0015-0.0030 Oil Rings 0.0010-0.0025 0.0010-0 .0030 0.0010-Q.0030 0.0010-0.0025 0.0015-0.0030 able clearance, place a piece of emery cloth on a fiat surface and rub the ring on the emery cloth in a circular motion. Rotate the ring while rubbing to maintain uniform ring thickness. If several rings are found to have greater than the mllximum allowable clearance, the piston should be replaced. NOTE: When the steel section OHA ring sets are not available for H &eries engines, the steel section 7HA ring. may be used on the OHA piston by installing the oil ring expander in the third groove rath e r than in the fourth groor;e as specified on the THA pistons. h. Piston Pins. Ford engines use hollow piston pins held in the piston by wire retainers at both ends of the pin. Piston pins are available in 0.001 and 0.002 inch oversizes for use when a standard pin fits too loosely. (70 ' F.). Table 8 gives the proper piston pin fit for each engine. If oversize piston pins are used, or if the piston pins are too tight, use an expansion type piston pin reamer. Place the reamer in a vise and revolve the piston around the reamer (fig. 28) . Set the reamer to the size of the piston pin bore, then expand the reamer slightly and trial ream the bore '/8 inch deep in the piston. Use a pilot sleeve of the nearest size to maintain alignment of the piston pin bores. Check the reamed hole size using a new piston pin as a gauge. If the bore is too small, finish reaming the hole, then turn the piston around and ream the other hole. Expand the reamer slightly and make another trial cut, then repeat the procedure outlined until the desired pin fit is obtained. Table 8-Piston Pin Fit Specincations (1) INSPECTION. Replace piston pins showing signs of fractures or etching. Worn piston pins or pins that fit loosely in the piston or rod bushing should be replaced. Replace all piston pin retainers. Engine Clearance in Piston (Inches) Clearance in Connecting Rod Bushing (Inches) (2) FITTING PISTON PINS. Check the piston pin H 0.0001-0.0003 0.0001-0.0003 fit in the piston pin bore at normal room temperature R 0.0001-0.0003 0.0001-0.0003 E 0.0001-0.0005 0.0001-0.0002 M 0.0001-0.0002 0.0001-0.0003 Fig. 27-Checking Ring Groove Clearance Fig. 28-Reaming Piston Pin Holes Section 4-Connecting Rods, Pistons, Rings, ond Pins 19 Check each piston pin bore which has been reamed with the pin to be used in that particular bore. Use a new piston pin to check the piston pin bush- ~_+- __ PISTON PIN - - = inE; in the connecting rod for wear. If the new pin fa lls through the bore by its own weight, ream the bore for the next oversize pin (fig. 29), or replace the bushing. c. Connecting Rods. Connecting rods with damaged threads, nicked studs, deep nicks, signs of fractures, scored bore, or with the bore out of round more than 0.0002 inch should be replaced. Connecting Rod Aligner Connecting rods with twists or bends sho uld be replaced. Check every connecting rod for alignment on a fixture after fitting the piston pins (fig. 30) . F;~ . 30-Checking Connecting Rod Alignment 5. FLYWHEEL REPAIR Flywheel repair consists of refacing the clutch fri ction surface or replacing the starter ring gear. a. Inspection. Flywheels that have a burned or scored friction face surface should be replaced or machined. Check the flywheel runout by positioning a dial indicator on the outer edge of the surface contacted by the clutch plate (fig. 31) . If the runout exceeds 0.005 inch total indi~ator reading, remove the flywheel and turn it 180 0 , then replace it and again check the runout. If the runout is still in excess of 0.005 inch, machine or replace the flywheel. Fig. 29-Reaming Connecting Rod Bushing h. Refacing. If it is necessary to remove more than 0.045 inch from the original thickness of the flywheel to obtain a smooth surface, it should be replaced. c. Ring Gear Replacement. To replace a ring gear, drill a 1 %2 inch hole nearly through the ring gear on the engine side of the gear, a nd cut the re maining portion with a chisel. Heat the new ring evenly to 360 °F., and place it in position on the flywhee l and allow it to cool. Check the ring gear runout. The runout must not exceed 0.010 inch. Fig. 3J-Checking Flywheel Runoul Chapter I-General Engine Repair 20 fig. 32-8-Cylinder Exhaust System 6. MUFFLER, INLET PIPE, OUTLET PIPE, AND CROSSOVER PIPE (8.CYLINDER ONLY) The procedures given here cover the removal and installation of each part in the exhaust system. Figure 32 shows the 8-cylinder exhaust system. The 6-cylinder parcel delivery exhaust system shown in fig. 33 is typical of all 6-cylinder trucks. a. Muffler Replacement. Loosen the inlet and outlet pipe clamps. Remove the outlet pipe. Remove the muffler from the inlet pipe. To install, connect the muffler to the inlet pipe. Connect the outlet pipe to the muffler and tighten both clamps. h. Muffler Outlet Pipe Replacement. Loosen the muffler outlet pipe clamp and remove the outlet pipe from the muffler. To install, connect the outlet pipe to the muffler and tighten the outlet pipe clamp. fig. 33-6-Cylinder Exhaust System Section 6-Muffler, Inlet Pipe, Outlet Pipe, and Crossover Pipe (8-Cylinder only) c. Muffler Inlet Pipe Replacement. Loosen the crossover pipe clamp and muffler inlet pipe clamp. Disconnect the inlet pipe from the right hand exhaust manifold. Remove the inlet pipe from the muffler. To install, connect the tnlet pipe to the muffler. Connect the inlet pipe to the right hand ~xhaust manifold. Tighten the cross-over pipe clamp and muffler inlet pipe clamp. 21 d. Crossover Pipe Replacement (S.Cylinder Only). Loosen the crossover pipe clamp. Disconnect the crossover pipe from the left hand exhaust manifold. Remove the cross-over pipe from the inlet pipe. To install, connect the cross-over pipe to the inlet pipe. Connect the cross-over pipe to the left hand exhaust manifold. Tighten the cross-over pipe clamp. SERVICE LETTER REFERENCE Letter No. Date Subject Changes Information on Page No. t---- -- --- Part ONE POWER PLANT Chapter II SKtion 1 2 3 4 5 6 7 8 9 H-Series-6-Cy/inder Engine Pare Manifold Replacement ........ . .... .. . .. ... . .... ... .. . .... . . . .. . . . ...........• •. ....... Cylinder Head Replacement .... ... . .. .. . . . ..... .. .. .. .. .. . . . . . . . ... . . .. . .. . .• . . . .. ... .. Oil Pan, Oil Pump, and Oil Pressure Relief Valve . .................. . . . ...... . .... . ... • . . ... Crankshaft Damper ... ..... . . .... .. .. .. . ....... ..... .. . .. . .. . .... .. .. ....... ..... .. ... . Cylinder Front Cover . ..... ..... .. ... .. ..... .•. .... . .. ... ..... .. . .. .... .. . ..• ..... . .... Valves and Valve Guides ............. . . . . . . . .• . .. . ... .. ... .. .. ......... . . .. . .. .... . . . .. Camshaft Gear, Camshaft, and Bearings . ... . . ...• . . . .. . .... . ..... ... . . ... . ..... .. .... .. .. . Flywheel, Crankshaft, and Bearings ......... • .... • ............ . .•......... ... ....... .. .... Piston and Connecting Rod Assemblies ................. . ................... . .. . ......... . . The material presented in this chapter covers the H-Series 6-cylinder engine illustrated in figs. 1 and 2. This engine is a 9S-horsepower L-hea<:i engine with a 3.3 inch cylinder bore and a 4.4 inch piston stroke. The piston displacement is 226 cubic inches. Complete removal and installation information covering all of the component parts of the engine are included in this chapter. Procedures for disassembly. cleaning, inspection, repair, and assembly of the differ- 22 25 26 29 30 31 32 35 38 ent units of this engine are also given here. General overhaul procedures for the H-Series engine are given in the chapter on general engine repair. The procedures and operations described and illustrated in this chapter ca n only be used for working on this engine. Always install new gaskets when any installation is made where gaskets have been previously removed. A com plete engine overhaul gasket kit illustrated in fig. 3 is available for engine overhaul. 1. MANIFOLD REPLACEMENT oped cracks. The exhaust control valve (fig. 4) may sti ck and need replacement. Manifold replacement procedures are covered under the headings liS. Conventional Truck," "b. Cab-Over Engine," and "c. Parcel Delivery." A chamber is built into the intake manifold center section where the carburetor and exhaust manifold are attached. An exhaust : ontrol va lve, located in the exhaust manifold, directs exhaust gases into this chamber when the engine is cold to provide faster engine warm-up. NOTE: Do nol re move manifold. when hoI. Th ey may warp and make reassembly difficult. Replace manifolds that are warped or have devel- 1013 Fig. 2-H-Series 6-Cylinder Engine (Sectional View) Fig . i -H-Series 6-Cylinder Engine ('I.. Front ViewJ 22 23 Section l-Manifold Replacement 33925-S-® 34847.S-~ 357692'S-~ ,.<,.' . GASKET - 9447 b( 3381 1703 Fig. 5-/ntake Manifold (Conventional Truck! Fig. 3-Engine Overhaul Gasket Kit a. Conventional Truck. Remove the air cleaner. Disconnect the distributor vacuum line, choke wire, and fuel line at the carburetor. Disconnect the governor lines. Disconnect the accelerator linkage at both sides of the bell crank and at the carburetor. Remove the carburetor and governor. Disconnect the windshield wiper hose. Remove the screw holding the manifold air baffle assembly to the cylinder head. Remove the top nut from the engine right front support bracket and remove the intake manifold baffle assembly. Disconnect the muffler inlet pipe from the exhaust manifold. Remove the manifold hold down nuts and lift both the intake and exhaust manifolds and gaskets from the block. Remove the nuts holding manifolds together and separate the manifolds. Disassembled views of the intake and exhaust manifolds used on H-Series engines are shown in figs. 5 and 6 respectively. Before reassembling and installing the manifolds, make sure all gasket surfaces are free from old gasket material and projections that may affect sealing. To install the manifolds, fasten them together and tighten the nuts to 30-35 foot-pounds torque. Place the manifolds on the engine block with new manifold gaskets (fig. 7). Tighten the nuts to 25-30 foot-pounds torque. Start at the center and work toward the ends to avoid manifold distortion. Install the carburetor and governor. Connect the windshield wiper hose. Connect the accelerator. Connect the choke wire, fuel line, and distributor vacuum line to the carburetor. Connect the governor lines. Fasten the manifold air baffle assembly to the cylinder head. Install the top nut on the engine front support bracket. Connect the muffler inlet pipe to the exhaust manifold. Connect the heater hose and install the air cleaner. b. Cab-Over-Engine. Remove the engine cover and dash panel to gain access to the engine from inside the cab. Disconnect the air cleaner flexible tube at the carburetor. Disconnect the distributor vacuum line, choke wire, and fuel line GASKET - 9t14 ~Jt.I---R:1I512.S '---3.31114-5 1211 Fig . 4-Manifolds Showing Exhaust Control Valve 24 Chapter II-H-Series-6-Cylinder Engine at the carburetor. Disconnect the windshield wiper hose and governor lines. Remove the carburetor and governor. Remove the screw that secures the manifold air baflle assembly to the cylinder head. Remove the top nut from the engine right-hand front support bracket and remove the manifold air baffle assembly. Disconnect the muffler inlet pipe from the exhaust manifold. Remove the manfold hold down nuts and washers. Remove the bolt securing the right-hand front support bracket to the frame. Tilt the engine toward the lefthand side of tne engine compartment to allow sufficient clearance for removing the manifolds. Lift both the intake and exhaust manifolds and gaskets from the block. Remove the nuts that hold the manifolds together and separate the manifolds. The exhaust manifold used in cab-over-engine trucks is shown in fig. 8 with the exhaust control valve removed and disassembled. Figure 9 illustrates the intake manifold. Before reassembling and installing the manifolds, make sure all gasket surfaces are free from old gasket material and projections that may affect sealing. To install the manifolds, fasten them together and tighten the nuts to 30-35 foot-pounds torque. With the engine tilted toward the left-hand side of the engine compartment, place new manifold gaskets (fig. 7) on the studs and install the manifolds on the block. Tighten the manifold retaining nuts to 25-30 foot-pounds torque. Start at the center and work toward the ends to avoid manifold distortion when tightening the nuts. Return the engine to its proper position and install the engine support to frame bolt. Paort No. 1 GA.9-4U MANIFOlD GASKET taT , ~ " fig. 8-Exhaust Manifold ICab-Over-Engine) Connect the muffler inlet pipe. Install the manifold air baffle assembly and secure it to the cylinder head and engine support bracket. Install the governor and carburetor. Connect the windshield wiper hose, governor lines, fuel line, choke wire, distributor vacuum line, and air clea ner flex ible tube. Install the dash panel and engine cover. c. Parcel Delivery. Remove the engine compartment rear cover. Lift the engine compartment front cover and fasten it open with the hook provided at the left-hand corner near the hinge. Disconnect the air cleaner flexible tube, distributor vacuum line, choke wire, and fuel line at the carburetor. Disconnect the windshield wiper hose. Remove the carburetor. Remove the screw that secures the manifold air baflle assembly to the cylinder head. Remove the top nut from the engine right-hand front support bracket and remove the air baffle assembly. Disconnect the muffler inlet pipe from the exhaust manifold. Remove the manifold retaining nuts and washers and lift the manifolds from the block. Remove the nuts that hold the manifolds together and separate the manifolds. The parcel delivery truck is equipped with the same type intake and exhaust manifolds as used on cab-overengine trucks (figs. 8 and 9). (~ ~GASKET_9435 GASKET - 9448 GASKET_ ~~J41"/' S 1657 fig. 7-Manifold Gasket Set fig. 9-I"take Manifold (Cab-Over-Engine) 25 Section l-Manifold Replacement Before reassembling and installing the manifolds, make sure all gasket surfaces are free from old gasket material and projections that may affect sealing. To install the manifolds, fasten them together and tighten the nuts to 30-35 foot-pounds torque. Place new manifold gaskets (fig. 7) on the block and install the manifolds. Tighten the manifold retaining nuts to 2530 foot-pounds torque. Start at the center a nd work toward the e nds to avoid manifold distortion when tightening the nuts. Connect the muffler inlet pipe. Install the manifold air baffle assembly and secure it to the cylinder head and engine support bracket. Install the carburetor. Connect the windshield wiper hose, fuel line, choke wire, distributor vacuum line, and air cleaner flexible tube. Lower the engine compartment front cover and install the engine compa rtment rea r cover. 2. CYLINDER HEAD REPLACEMENT Cylinder heads are cast from the same high grade iron as is used for the cylinder block. Expansion and contraction due to temperature variations is the same for both head and block lessening the possibility of cylinder head distortion. NOTE: The lHA-6050 cylinder head i. interchange· able with either the 7HA·6050 or the OHA·6050 cylinder head. Cylinder heads must be repl aced when cracks develop or distortion prevents adequate sealing at the gasket surface. Replacement procedures are covered under headings "a. Conventional Truck," "b. Cab-Over-Engine." a nd "c. P arcel Delivery." a. Conventional Truck. Drain the cooling system. Remove the air clea ner. Disconnect the upper radiator hose at the cylinder head. Disconnect the cylinder head temperature unit sending wire. Remove the screw from the distributor vac uum line clamp on the forward left corner of the cylinder head. Disconnect the ignition wires from the spark plugs and remove the plugs. Remove the two screws from the coil bracket and let the bracket hang from the distributor. Disconnect the heater hose. Remove the screw from the manifold air baffle assembly on the right-hand side of the cylinder head. Remove the cylinder head bolts, then remove the cylinder head. Before installing a cylinder head, clean the carbon deposits from the combustion chambers and check to see that all water passages are open. Gasket surfaces must be free of old gasket material and projections at bolt holes that may affect sealing. Install a new cylinder head gasket (fig. 10) with the cut off corner at the left front corner of the block. NOTE: If the ga.ket i. installed imprope rly, water will leak exte rnally at the left rear corner of the engine between cylinder head and block. Do not enlarge any gasket holes or overheating oj the rear cylinders m.ay r esult. Place the cylinder head in position on the block, being careful not to damage the gasket. Before insta lling the cylinder head bolts, coat the bolt threads with a light coat of water resistant sealer. Insert the cylinder head bolts and tighten them to 65-70 foot-pounds torque in the sequence shown in fig. 11. Fasten the manifold air baffle assembly to the cylinder head. Connect the heater hose. Fasten the distributor vacuum line clamp to the cylinder head. Connect the temperature unit sending wire. Install the spark plugs. Torque the plugs to 24-30 foot-pounds. Position the coil bracket and install the two holding screws. Connect the ignition secondary wires to the spark plugs. Connect the radiator hose. Fill the cooling system according to the prevailing temperature. Operate the engine for five minutes, stop the engine, and check the coolant level in the radiator. b. Cab.Over.Engine. Drain the cooling system. Disconnect the upper radiator hose at the cylinder head. Remove the engine compartment cover. Disconnect the cylinder head temperature sending unit wire. Remove the screw from 1132 Fig. IO-Cylinder Head Gasket 'n.talfatlon Fig . II-Cylinder Head Bolt Tightening Sequ.n,. Chapter II-H-Series-6-Cylinder Engine 26 the manifold air baffle assembly on the right-hand side of the cylinder head. Disconnect the ignition wires from the spark plugs and remove the plugs. Remove the two screws from the coil bracket and let the bracket hang from the distributor. Disconnect the heater hose. Remove the cylinder head bolts, then remove the cylinder head. Before installing a cylinder head, clean the carbon deposits from the combustion chambers and check to see that all water passages are open. Gasket surfaces must be free of old gasket material and projections at bolt holes that may affect sealing. Install a new cylinder head gasket (fig. 10) with the cut off corner at the left front corner of the block. NOTE: If the ga.ket b in.talled improperly, water will leak externally at the left rear corner of the engine between the cylinder head and block. Do not enlarge any ga.ket hole, or overheating of the rear cylinder. may re.ult. Place the cylinder head in position on the block, being careful not to damage the gasket. Before installing the cylinder head bolts, coat the bolt threads with a light coat of water resistant sealer. Insert the cylinder head bolts and tighten them to 65-70 foot-pounds torque in the sequence shown in fig. 11. Connect the heater hose. Fasten the coil bracket and manifold air baffle assembly to the cylinder' head. Install the spark plugs and tighten them to 24-30 foot-pounds torque. Connect the ignition wires to the spark plugs. Connect the temperature sending unit wire. Connect the radiator hose. Install the engine compartment cover. Fill the cooling system according to the prevailing temperature. Operate the engine for five minutes, stop the engine, and check the coolant level in the radiator. c. Parcel Delivery. Drain the cooling system. Open the engine compart- ment rear cover. Open the engine compartment frOllt cover and fasten it open with the hook provided at the left-hand corner near the hinge. Disconnect the upper radiator hose at the cylinder head. Disconnect the temperature sending unit wire. -Remove the screw from the manifold air baffle assembly on the right-hand side of the cylinder head. Disconnect the ignition wires from the spark plugs and remove the plugs. Remove the two screws from the coil bracket and let the bracket hang from the distributor. Disconnect the beater hose. Re-. move the cylinder head bolts, then remove the cylinder head. Before installing a cylinder head, clean the carbon deposits from the combustion chambers and check to see that all water passages are open. Gasket surfaces must be free of old gasket material and projections at bolt holes that may affect sealing. Install a new cylinder head gasket (fig. 10) with the cut-off corner at the left front corner of the block. NOTE: If the gasket i. in.talled improperly, water will leak externally at the left rear corner of the engine between the cylinder head and block. Do not enlarge any ga.ket hole, or overheating of the rear cylinders may re.ult. Place the cylinder head in position on the block, being careful not to damage the gasket. Before installing the cylinder head bolts, coat the bolt threads with a light coat of water resistant sealer. Insert the cylinder head bolts and tighten them to 65-70 foot-pounds torque in the sequence shown in fig. 11. Connect the heater hose. Fasten the coil bracket and manifold air baffle assembly to the cylinder head. Install the spark plugs and tighten them to 24-30 foot-pounds torque. Connect the ignition wires to the spark plugs. Connect the radiator hose. Close the engine compartment covers. Fill the cooling system according to the prevailing temperature. Operate the engine for five minutes, stop the engine, and check the coolant level in the radiator. 3. OIL PAN., OIL PUMP, AND PRESSURE RELIEF VALVE Procedures in this section cover removal, cleaning, inspection, installation of the oil pan, reconditioning the oil pump, and replacement of oil seals and oil pressure relief valve. a. Oil Pan. An oil pan cleanout plate is provided on the bottom of the oil pan. The oil pump screen assembly can be cleaned when the cleanout plate is removed. Figure 12 illustrates the pan, cleanout plate, gaskets, oil seals, and screen assembly. ( 1) REMOVAL. Raise the front end of the truck and set it on safety jacks. Drain the crankcase. Remove the splash pan. Disconnect the starter cable and remove the starter. Disconnect the ventilation pipe bracket. Remove the screws that hold the oil pan to the engine rear plate. Remove the screws that hold the oil pan to the engine block and the front cover plate. Remove the oil pan from the engine. (2) CLEANING. Use a solvent to remove the sludge and dirt from both the inside and outside of the oil pan. Scrape the old gasket ftange. Clean the oil pump inlet screen. (3) INSPECTION. Inspect the oil pan for any external damage such as cracks or warped gasket surfaces. Inspect the drain plug threads for damage that may cause leakage. Check the oil pump screen and inlet tube 27 Section 3-0il Pan, Oil Pump, and Pressure Rel ief Valve PACKING-6701 )G .< PACKING 6702 ~ GASKET -6698~ '""""REINFORCEMENT -6642 Oil PAN _ 6675 @ = P L A TE_S645 1157 GASKET- 6734-o : : : - - 34846-S ____ ~ ~ 33798-S PlUG_6730~ Fig . 14-/n.talling Oil Seal Packing 1022 Fig. 12-0il Pan and Related Parts assembly for restrictions in the passages. R epai r any damage or replace the pan if repairs cannot be made. (4) OIL SEAL REPLACEMENT. Remove the oil packing and thoroughly clean the packing retainer grooves. Soak the packing (fig. 13) in SAE 20 oil for two hours before installation. Install the short packing in the front retainer groove and the long packing in the rear retainer groove. "Roll-in" the packing with a round bar (fig. 14) to make sure the packing meets the gasket evenly. (5) INSTALLATION. Spread a thin film of grease on the oil pan gasket surface to hold the gasket in place during installation. Install a new gasket (fig. 13 ) on the pan. Lift the pan into place and install the screws that hold the oil pan to the block and front cover plate. Torque the screws to 15-18 foot-pounds torque. rear plate. Torque screws to 10- 15 foot-pounds torque_ Install the drain plug. Connect the ventilation pipe bracket. Install the starter and connect the starter cable. Install the splash pan. R e move the jacks from under the front end. Fill the c ra nkcase wit h proper quantity and grade of oil according to the prevailing te mpera ture. h. Oil Pump. The rotor type oil pump is used on the H-Series engine and is externally mounted. In order to remove the oil pump with the engine in , the chassis, it is necessary to raise the front of the engine so that the pump will clear the frame side rail when it is pulled out. NOTE: T h e oil pump and cam.haft gear back la.h should be 0.0003-0.005 inch_ 72432 - S~ O il PUMP NOTE: A.lignment of th e oil pan can be .implified by tem,porarily installing two studs in opposite co rneT! DRIVEN GEAR 6652 - ~ .,.. " of the block to g uide the pan into place. Install the screws that hold the oil pan to the engine 6619 I!:'" " PACKING -6707 '"""'->SIDE GASKET \ "" "" (\, \J ~ )-,,,,,~~,,, COVER 6616 \\ GASKET-67 10 1144 Fig . 13-Engin. Oil Pan Gasket S.t /-21531-S Fig . 1S-Rotor Type Oil Pump 1081 28 Chapter II-H-Series-6-Cylinder Engine --_'.""'0 ROTOR 1082 Fig. J6-Measuring Clearance Between Oil Pump Rotors Fig. 18-0il Pump Rofors Before removing the oil pump, check the back lash between the oil pump driven gear and the camshaft gear. This can be done by moving the distributor rotor and checking the distributor shaft free play. The rotor free play should be less than 1/. inch at the tip of the Outer rotor outside diameter should not be less than 2.2 46 inches. rotor. (I) REMOVAL. Disconnect the right hand e ngine front support. Disconect the radiator hose. R aise the engine so the pump will clear the frame when removed. Remove the screws that hold the pump to the block and remove the pump. (2) DISASSEMBLY. A disassembled rotor type pump is illustrated in fig. IS. Remove the cover plate. Remove the Quter rotor. Remove the pin from the oil pump driven gear. R emove the gear. Remove the inner rotor and shaft. (3) CLEANING. Remove any dirt and sludge formation from the pump parts. Clean all parts with a suitable NOTE : If rotors are worn beyond the specified limit., replace th em with Oil Pump Rotor and Shaft Kit number 7HA-6650 (fig. 19). Check the cover plate for wear as shown in fig. 20. If the clearance exceeds 0.001 inch, replace the plate. With the rotors assembled in the housing, place a straight edge over the rotors and pump body. Measure the clearance between the pump body and the straight edge. Replace the pump body if clearance is less than 0.00 I to 0.003 il1ch. Measure the pump shaft end playas shown in fig. 21. End play should be 0.008-0.012 inch. (5) ASSEMBLY. Install the inner rotor and the shaft in the housing. Press the oil pump driven gear on the shaft until there is a shaft end play of 0.0080.012 inch. solvent. (4) INSPECTION. Visually check all parts for breakage. Measure the clearance between the rotors as shown in fig. 16. Clearance should be 0.006-0.010 inch between the rotors. Measure the outer rotor to body clearance as shown in fig. 17. Clearance shoUld be 0.005-0.010 inch. Make rotor measurements as illustrated in fig. 18. Rotor thickness shoule not be less than 0.998 inch. OUTER Fig. '7-Measuring Clearance Between Outer Rotor and Pump Body onm,,_ 1136 Fig. 19-0il Pump Rofor and Shalf Kif