Specifications

PART 1-1-GENERAL ENGINE SERVICE
1-17
A1024-A
FIG. 29-Flywheel Face Runout
than 0.045 inch of stock from the
original thickness, replace the fly-
wheel.
Inspect the ring gear for worn,
chipped, or cracked teeth. If the
teeth are damaged, replace the ring
gear.
With the flywheel installed on the
crankshaft, check the flywheel face
runout.
FLYWHEEL FACE RUNOUT
Install a dial indicator so that the
indicator point bears against the
flywheel face (Fig. 29). Turn the
flywheel making sure that it is full
forward or rearward so that crank-
shaft end play will not be indicated
as flywheel runout.
RING GEAR REPLACEMENT
Heat the defective ring gear with
a blow torch on the engine side of
the gear, then knock it off the fly-
wheel. Do not hit the flywheel when
removing the ring gear.
Heat the new ring gear evenly
until the gear expands enough to
slip onto the flywheel. Make sure
the gear is seated properly against
the shoulder. Do not heat any por-
tion of the gear to a temperature
higher than 500°F. If this limit is
exceeded, the temper will be re-
moved from the ring gear teeth.
CYLINDER BLOCK
CLEANING
Thoroughly clean the block in
solvent. Remove old gasket material
from all machined surfaces. Remove
all pipe plugs which seal oil pas-
sages, then clean out all the pas-
sages. Blow out all passages, bolt
holes, etc. with compressed air.
Make sure the threads in the cyl-
inder head bolt holes are clean. Dirt
in the threads may cause binding
and result in a false torque reading.
Use a tap to true-up threads and to
remove any deposits.
INSPECTION
After the block has been
thoroughly cleaned, make a check
for cracks. Minute cracks not visible
to the naked eye may be detected
by coating the suspected area with
a mixture of 25% kerosene and 75%
light motor oil. Wipe the part dry
and immediately apply a coating of
zinc oxide dissolved in wood alcohol.
If cracks are present, the coating
will become discolored at the de-
fective area. Replace the block if
it is cracked.
Check all machined gasket sur-
faces for burrs, nicks, scratches,
and scores. Remove minor imperfec-
tions with an oil stone. Check the
flatness of the cylinder block gasket
surface following the procedure and
specifications recommended for the
cylinder head.
Replace all expansion-type plugs
that show evidence of leakage.
Inspect the cylinder walls for
scoring, roughness, or other signs
of wear. Check the cylinder bore for
out-of-round and taper. Measure
the bore with an accurate gauge
following the instructions of the
manufacturer. Measure the diam-
eter of each cylinder bore at the top,
middle, and bottom with the gauge
placed at right angles and parallel
to the centerline of the engine (Fig.
30).
Refinish cylinders that are deeply
scored and/or when out-of-round
•CENTER LINE OF ENGINE
A
% A ^
1. OUT-OF-ROUND = DIFFERENCE BETWEEN
A AND B
2. TAPER = DIFFERENCE BETWEEN THE A
MEASUREMENT AT TOP OF
CYLINDER BORE AND THE A
MEASUREMENT AT BOTTOM OF
CYLINDER BORE A1O25-A
FIG. 30—Cylinder Bore Out-of-
Round and Taper
and/or taper exceed the wear limits.
If the cylinder walls have minor
surface imperfections, but the out-
of-round and taper are within limits,
it may be possible to remove the
imperfections by honing the cyl-
inder walls and installing new serv-
ice piston rings providing the piston
clearance is within limits. Use the
finest grade of honing stone for this
operation.
REPAIRS
Refinishing Cylinder Walls. Hon-
ing is recommended for refinishing
cylinder walls only when the walls
have minor imperfections, such as
light scuffs, scratches, etc. The grade
of hone to be used is determined by
the amount of metal to be removed.
Follow the instructions of the hone
manufacturer. If coarse stones are
used to start the honing operation,
leave enough material so that all
hone marks can be removed with the
finishing hone which is used to ob-
tain the proper piston clearance.
Cylinder walls that are severely
marred and/or worn beyond the
specified limits should be refinished.
Before any cylinder is refinished, all
main bearing caps must be in place
and tightened to the proper torque
so that the crankshaft bearing bores
will not become distorted from the
refinishing operation.
Refinish only the cylinder or cyl-
inders that require it. All pistons are
the same weight, both standard and
oversize; therefore, various sized
pistons can be intermixed without
upsetting engine balance.
Refinish the cylinder with the
most wear first to determine the
maximum oversize. If the cylinder
will not clean up when refinished
for the maximum oversize piston rec-
ommended, replace the block.
Refinish the cylinder to within ap-
proximately 0.0015 inch of the re-
quired oversize diameter. This will
allow enough stock for the final step
of honing so that the correct surface
finish and pattern are obtained. Use
clean sharp hones of No. 220-280
grit for this operation.
For the proper use of the re-
finishing equipment, follow the in-
structions of the manufacturer. Only
experienced personnel should be al-
lowed to perform this work.
After the final operation in either
of the two refinishing methods de-
scribed and prior to checking the