service repair manual

1. OH-339
a00
OVERHAUL MANUAL

2. INDUSTRIAL TRUCK DIVISION
MARKETING TRAINING DEPT.
TABLE OF CONTENTS
SUBJECT GROUP SECTION
ENGINE OVERHAUL (GAS) ..................
ENGINE OVERHAUL (DIESEL). ................
ENGINE OVERHAUL (PERKINS DIESEL). ............
EXHAUST EMISSION SYSTEM .................
CARBURETOR OVERHAUL (BENDIX-ZENITH) ...........
LPG SYSTEM MAINTENANCE .................
.................
.................
TRANSMISSION OVERHAUL (HYDRAT~RK) ............
TRANSMISSION OVERHAUL (MANUAL) .............
ENGINE TEST PROCEDURES .................
STARTER OVERHAUL ....................
DISTRIBUTOR MAINTENANCE .................
ALTERNATOR MAINTENANCE .................
ALTERNATOR OVERALL ...................
AXLE END MAINTENANCE ..................
BRAKE MAINTENANCE ....................
NEUTRAL STARTING SWITCH .................
STEER CYLINDER MAINTENANCE ...............
HYDRAULIC PUMP OVERHAUL (GEAR) .............
HYDRAULIC PUMP OVERHAUL (VANE) .............
HYDRAULIC VALVE OVERHAUL ................
TILT LOCK VALVE .....................
TILT CYLINDER ......................
ACCUMULATOR OVERHAUL ..................
UPRIGHT LIFT CYLINDER OVERHAUL. .............
UPRIGHT ROLLER CHECK AND ADJUSTMENT PROCEDURES. .....
00 03
00 04
00 12
02TS200A-K
02M200A-02S553A
02 05
02 06
02 08
06TS205A-06M406E
08M104A-08TS106A
llTSOOOA-1lTSOOOBK
llM103A-llS199C
llM602A-llM602D
12TSlOOA-12S102A
12 03
20M801A-20S801B
23M500HB-23M867G
23M900A-26TSlOlA
26TSlOlA-26SlOlA
29 01
29M007A-30S202B
30M203A-30TS203A
30TS301A-30M301D
32 06
32 01
34 01
34 02
Code: OH-339, REV MAY 83 Page 1

3. INDUSTRIAL TRUCK DIVISION
MARKETING TRAINING DEPT.
FOREWORD
This overhaul manual has been written
to aid the mechanic in the disassembly
and assembly of the main components of
the specific truck that this manual
includes. Every improvement has been
made to help the mechanic to discharge
his duties in a safe and practical
procedure.
This manual has been written in groups
and sections with a table of contents
for easy reference.
Each section includes many photographs
and drawings to directly show how to
do these operations.
The mechanic is told to always use
Genuine Clark Parts when replacements
are needed. "Look alike" parts from
other supplies never work as well
as the original parts.
Specifications and notes on safety
have been included as needed for each
step to be done. The mechanic is
told to use safety and accuracy in his
work because we cannot control his
work and procedures.
If the mechanic does not understand the
right procedure in the maintenance of
this truck, he is told to see his
immediate supervisor instead of risking
injury of personnel.
Approved methods of service and correct
procedures of repair are important for
the safe operation of all trucks as
well as the safety of personnel and the
mechanic doing the work. This manual
gives directions for service and
repairs with procedures that are
tested.
There are many different procedures,
tools, and parts for servicing
vehicles, as well as in the ability
of the mechanic doing the work. This
manual cannot be written for all such
variations. Any mechanic who works
differently from this manual must first
make sure that he works safely and
accurately.
Code: OH-339, MAR 81 P.S.L. Page 1

4. INDUSTRIAL TRUCK DIVISION
MARKETING TRAINING DEPT.
SAFETY MESSAGES
La! WARNING
LIFT TRUCK MAINTENANCE
DO NOT WORK ON THIS TRUCK
UNLESS YOU ARE TRAINED AND
AUTHORIZED AND KNOW THE
CORRECT MAINTENANCE PROCE-
DURES.
a! WARNING
BATTERY SERVICE
BATTERY SERVICE MUST BE DONE
BY TRAINED PERSONNEL. BATTERY
ACID CAN CAUSE SEVERE BURNS
AND INJURY.
a! WARNlNG
-~
HYDRAULlC FLUID PRESSURE
DO NOT USE YOUR HANDS TO CHECK
FOR HYDRAULIC LEAKAGE. FLUID
UNDER PRESSURE CAN PENETRATE
YOUR SKIN AND CAUSE SERIOUS
INJURY.
a! WARNING
STEAM
DO NOT REMOVE THE RADIATOR
CAP WHEN THE RADIATOR IS
HOT. STEAM FROM THE RADIATOR
WILL CAUSE SEVERE BURNS.
cWEAR EYE GLASSES, SAFETY
SHOES AND CORRECT FITTING
CLOTHING #IEN WORKING ON
LIFT TRUCKS. INJURY CAN
RESULT IF YOU DO NOT WEAR
PROTECTION.
a! WARNING
CARBON MONOXIDE
INTERNAL COMBUSTION ENGINES
GENERATE TOXIC GASES WHICH
CAN CAUSE SERIOUS INJURY OR
DEATH WHEN INHALED. BE SURE
THERE IS ENOUGH VENTILATION.
I
a! WARNING
AIR PRESSURE
WEAR EYE PROTECTION & PROTEC-
TIVE CLOTHING WHEN CLEANING
OR DRYING WITHAIR PRESSURE.
REDUCE PRESSURE TO ['207kPa]
30 PSI. DEBRIS REMOVED WITH
AIR PRESSURE CAN CAUSE INJURY.
/IDO NOT WALK OR STAND UNDER
RAISED FORKS. THE FORKS CAN
FALL AND CAUSE INJURYOR
DEATH.
Code: OH-339, MAY 83 1308-z

5. cl!!wIs GR&uP
GROUP
00
SECTION
3
CLARK (WAUKESHA) ENGINE OVERHAUL
D 155G, D155GA, D176G (G A S>
Code: OH-369, MAR 80
Section 3, Page 1

6. INDUSTRIAL TRUCK DIVISION
CUSTOMER SERVICES GROUP
TROUBLE SHOOTING
ENGINE WILL NOT CRANK The cause of the trouble is usually in the starting system.
If the trouble is not in the starting system, check for
hydrostatic lock or a seized engine, as follows:
Remove the spark plugs, and attempt to crank the engine
with the starter. If coolant is ejected from the openings
it indicates that water is leaking into the cylinders.
Remove the cylinder head and inspect the gasket and head
for cracks. Examine the cylinder block for cracks.
ENGINE CRANKS Check the fuel supply. If there is sufficient fuel in the
NORMALLY, BUT WILL tank, the cause of the trouble probably lies in either the
NOT START ignition or the fuel system.
To determine which system is at fault, perform the
following test:
Disconnect a spark plug wire, check the spark intensity
at the end of the wire by installing a terminal adaptor
in end of the wire. Then, hold adaptor approximately 3116
inch from the cylinder block and crank the engine.
IF THERE IS NO SPARK OR A WEAK SPARK AT THE SPARK PLUGS
The cause of the trouble is in the ignition system.
Disconnect starter relay leads ... install an auxiliary
starter switch between the battery and the starter relay.
To determine if the cause of the trouble is in the primary
or the secondary circuit, remove coil high tension lead
from the top of the distributor, and hold it approximately
3/16 inch from the cylinder head. With the ignition on,
$
crank the engine and check for a spark. %
0
If the spark at the high tension lead is good, the cause 0
of the trouble is probably in the distributor cap, rotor
or spark plug wires.
If there is no spark or a weak spark at the coil high
tension lead, the cause of the trouble is probably in the
primary circuit, coil to high tension lead, or the coil.
IF THERE IS A GOOD SPARK AT THE SPARK PLUGS
Check the spark plugs. If the spark plugs are not at
fault, check the following items:
Section 3, Page 2 Code: OH-369, MAR 80

7. CMRK GR&up
TROUBLE SHOOTING
CHOKE
Check the choke linkage for binding or damage. Make
certain the choke plate closes when the choke knob is
pulled out and that the plate opens when the knob is
pushed in.
FUEL SUPPLY AT CARBURETOR
Disconnect carburetor fuel inlet line at the carburetor.
Use a suitable container to catch the fuel. Crank the
engine to see if fuel is reaching the carburetor.
If fuel is not reaching the carburetor, check: The fuel
pump, the fuel filter, the carburetor fuel inlet line for
obstructions; the fuel pump inlet line for a collapsed
condition; the fuel tank line for obstructions; the fuel
tank vent.
If fuel is reaching the carburetor, check: The fuel inlet
system including fuel inlet screen, fuel inlet needle and
seat assembly and the float assembly.
ENGINE
Mechanical failure in the camshaft drive.
ENGINE STARTS BUT
FAILS TO KEEP
RUNNING
FUEL SYSTEM
Idle fuel needle not properly adjusted, engine idle speed
set too low; float setting incorrect; float inlet system
not operating properly; dirt or water in the carburetor
fuel lines or in the fuel filter; defective fuel pump.
Check for dirt in the carburetor, not allowing fuel to
enter or to be discharged from the idle system.
IGNITION SYSTEM
Defective spark plugs, breaker points not properly
adjusted.
ENGINE RUNS, BUT
MISSES
Determine if the miss is steady or erratic and at what RPM
the miss occurs by operating the engine at various RPM(s)
under load.
Code: GH-369, MAR 80 Section 3, Page 3

8. INDUSTRIAL TRUCK DIVISION
CUSTOMER SERVICES GROUP
TROUBLE SHOOTING
MISSES STEADILY AT ALL SPEEDS
Isolate the miss by operating the engine with one cylinder
not firing. This is done by operating the engine with
the ignition wire removed from one spark plug at a time
until all cylinders have been checked. Ground the spark
plug wire removed.
If the engine RPM changes when a particular cylinder is
shorted out, that cylinder was delivering power before
being shorted out. If no change in the engine operation
is evident, the miss was caused by that cylinder not
delivering power before being shorted out. In this case
check the:
IGNITION SYSTEM
If the miss is isolated in a particular cylinder, perform
a spark test on the ignition lead of the cylinder. If a
good spark does not occur, the trouble is in the secondary
circuit of the system. Check the spark plug wire, and the
distributor cap. If a good spark occurs, check the spark
plug. If the spark plug is not at fault, a mechanical
component of the engine is probably at fault.
ENGINE
Intake manifold leak (vacuum). Perform a manifold vacuum
or a compression test to determine which mechanical
component of the engine is at fault.
MISSES ERRATICALLY AT ALL SPEEDS
EXHAUST SYSTEM
Exhaust system restricted.
IGNITION SYSTEM
Breaker points not properly adjusted.
Defective breaker points, condenser, secondary wiring,
coil or spark plug.
High tension leakage across the coil, rotor or distributor
cap.
Defective ignition switch.
Section 3, Page 4 Code: OH-369, MAR 80

9. C19RK GRoOo
TROUBLE SHOOTING
FUEL SYSTEM
Float setting incorrect.
Fuel inlet system not operating properly.
Dirt or water in the fuel lines or carburetor.
Restricted fuel filter.
COOLING SYSTEM
Check the cooling system for internal leakage and/or for
a condition that prevents the engine from reaching normal
operating temperature.
ENGINE
Damaged cylinder head gasket.
Perform a compression or manifold vacuum test to determine
which mechanical component of the engine is at fault.
MISSES AT IDLE ONLY
FUEL SYSTEM
Idle fuel mixture needle not properly adjusted.
Restriction in idle fuel system.
IGNITION SYSTEM
Excessive play in distributor shaft.
Worn distributor cam.
Defective coil, rotor, condenser, breaker points, ignition
wiring or spark plugs.
ENGINE
Valve clearance (engines with mechanical lifters) or valve
adjustment (engines with hydraulic valve lifters) set too
tight. Worn camshaft lobe.
Perform a compression test to determine which mechanical
component of the engine is at fault.
Code: OH-369, MAR 80 Section 3, Page 5

10. INDUSTRIAL TRUCK DIVISION
CUSTOMER SERVICES GROUP
TROUBLE SHOOTING
MISSES AT HIGH SPEED ONLY
FUEL SYSTEM
Low or erratic fuel pump pressure.
Fuel inlet system not operating properly.
Restricted fuel filter.
Restricted main fuel system.
ENGINE
Perform a compression test to determine which mechanical
component of the engine is at fault.
COOLING SYSTEM
Engine overheating.
IGNITION SYSTEM
Defective spark plugs.
ROUGH ENGINE IDLE FUEL SYSTEM
Engine idle RPM set too low.
Idle fuel mixture needle not properly adjusted.
Float setting incorrect.
Air leaks between the carburetor and the manifold, or the
manifold and cylinder head, and/or fittings. 5
0
Fuel leakage at the carburetor fuel bowl.
0
Idle fuel system air bleeds or fuel passages restricted.
Leaking fuel pump, lines or fittings.
Section 3, Page 6 Code: OH-369, MAR 80

11. CMRK GR&up
TROUBLE SHOOTING
IGNITION
Improperly adjusted or defective breaker points.
Fouled or improperly adjusted spark plugs.
Incorrect ignition timing.
Spark plug misfiring.
ENGINE
Loose engine mounting bolts or worn engine support
insulator.
Cylinder head bolts not properly torqued.
Damaged cylinder head gasket.
Valve adjustment or valve clearance too tight.
Worn camshaft lobes.
Perform a manifold vacuum or compression test to determine
which mechanical component is at fault.
POOR ACCELERATION IGNITION SYSTEM
Incorrect ignition timing.
Fouled or improperly adjusted spark plugs.
Improperly adjusted or defective breaker points.
Distributor not advancing properly.
Defective ignition wires.
FUEL SYSTEM
Float setting incorrect.
Throttle linkage not properly adjusted.
Distributor vacuum passages in the carburetor blocked.
Restricted fuel filter.
Code: GH-369, MAR 80
Defective fuel pump.
Section 3, Page 7

12. INDUSTRIAL TRUCK DIVISION
CUSTOMER SERVICES GROUP
TROUBLE SHOOTING
ENGINE
Perform a manifold vacuum or compression test to determine
which mechanical component of the engine is at fault.
ENGINE DOES NOT
DEVELOP FULL POWER
OR HAS POOR HIGH
RPM PERFORMANCE
FUEL SYSTEM
Restricted air cleaner.
Restricted fuel filter.
Clogged main jet, and/or low float setting.
Fuel pump pressure incorrect.
IGNITION SYSTEM
Ignition timing not properly adjusted.
Defective coil, condenser or rotor.
Distributor not advancing properly.
Excessive play in the distributor shaft.
Distributor cam worn.
Fouled or improperly adjusted spark plugs or incorrect
heat range.
Improperly adjusted or defective breaker points.
EXHAUST SYSTEM
Restriction in system.
COOLING SYSTEM
Thermostat inoperative or of incorrect heat range.
.Thermostat installed incorrectly.
Check the cooling system for internal leakage and/or for
a condition that prevents the engine from -reachingnormal
operating temperature.
Section 3, Page 8 Code: OH-369, MAR 80

13. Cl!!lRK GR&uP
TROUBLE SHOOTING
GOVERNOR
Incorrect adjustment.
Defective governor.
ENGINE
Perform an engine compression or manifold vacuum test to
determine which mechanical component is at fault.
One or more camshaft lobes worn beyond wear limit.
Worn valve guides.
EXCESSIVE FUEL
CONSUMPTION
EXHAUST SYSTEM
(BLACK ExHAusT
SMOKE)
System restricted.
IGNITION SYSTEM
Check ignition timing.
Distributor breaker points.
Spark plug condition
FUEL SYSTEM (Check):
Fuel pump pressure.
Engine idle RPM.
and point gap.
Idle fuel mixture needle improper adjustment.
Air cleaner for restrictions.
Float setting or fuel level.
Jet for wear and/or damage.
Accelerator linkage for binds.
Code: OH-369, MAR 80 Section 3, Page 9

14. INDUSTRIAL TRUCK DIVISION
CUSTOMER SERVICES GROUP
TROUBLE SHOOTING
IGNITION SYSTEM (Check):
Ignition timing.
Spark plug condition and adjustment.
Distributor spark advance operation.
ENGINE
Perform a manifold vacuum or engine compression test to
determine which mechanical component of the engine is at
fault.
Check valve adjustment or valve clearance.
COOLING SYSTEM
Check thermostat operation and heat range.
ENGINE OVERHEATS TEMPERATURE SENDING UNIT AND GAUGE
Section 3, Page 10
Unit or gauge defective (not indicating the correct
temperature), or constant voltage regulator defective.
ENGINE
Cylinder head bolts not properly torqued.
Incorrect valve adjustment or valve clearance.
Low oil level or incorrect viscosity oil used.
COOLING SYSTEM
Insufficient coolant,
Cooling system leaks.
Drive belt tension incorrect.
Radiator fins obstructed.
Thermostat defective.
Thermostat improperly installed.
Code: OH-369, MAR 80

15. CMRIS GRooo
TROUBLE SHOOTING
COOLING SYSTEM (Cont'd)
Cooling system passages blocked.
Water pump inoperative.
IGNITION SYSTEM
Incorrect ignition timing.
Incorrect distributor advance.
EXHAUST SYSTEM
Restrictions in system.
ENGINE FAILS TO
REACH NORMAL
OPERATING
TEMPERATURE
TEMPERATURE SENDING UNIT AND GAUGE
Unit or gauge defective (not indicating the correct
temperature), or constant voltage regulator defective.
COOLING SYSTEM
Thermostat inoperative or of incorrect heat range.
LOSS OF COOLANT COOLING SYSTEM
Leaking radiator or water pump.
Loose or damaged hose connections.
Radiator cap damaged.
Overheating.
ENGINE
Cylinder head gasket defective.
Cracked cylinder head or block, or warped cylinder head or
block.gasket surface.
Code: OH-369, MAR 80 Section 3, Page 11

16. INDUSTRIAL TRUCK DIVISION
CUSTOMER SERVICES GROUP
TROUBLE SHOOTING
MANIFOLD VACUUM TEST: (Ilg. 9759)
1. Operate the engine until it is at
normal operating temperature.
2. Connect vacuum gauge to the intake
manifold and test with engine
operating at idle speed, with no
load condition.
GAUGE READINGS ENGINE CONDITION
18-19 Inches at Idle speed (Approx.)
HIGH & STEADY Good
LOW & STEADY Loss of power in all
cylinders caused
possibly by late
ignition or valve
timing, or loss of
compression due to
leakage around the
piston rings.
VERY LOW Manifold, carburetor
or cylinder head
gasket leak.
NEEDLE FLLJCTLJ- A partial or complete
ATES STEADILY loss of power in one
AS SPEED or more cylinders
INCREASES. caused by: a leaking
valve, cylinder head
or intake manifold
gasket leak, a defect
in the ignition system
--- or weak valve spring.
GRADUAL DKOP IN Excessive back pressure
READING AT in the exhaust system.
ENGINE IDLE.
INTERMITTENT An occasional loss of
FLUCTUATION. power possibly caused
by a defect in the
ignition system or a
sticking valve.
SLOW FLUCTU- Improper idle mixture
ATION OR DRIFT adjusement, or
OF THE NEEDLE. carburetor, spacer or
_&take manifold gasket
leak.
Fig. 9759
Fig. 9868
CYLINDER COMPRESSION TEST: (Fig. 9868)
1. Warm the engine up to operating
temperature.
2. Shut down engine.
3. Throttle must be held in the open
position.
Section 3, Page 12 Zode: OH-369, MAR 80

17. Cl!lRK GROUP
00
TROUBLE SHOOTING
4. Install compression gauge.
5. With ignition coil high tension lead
disconnected, crank engine and note
the number of compression strokes
required to obtain highest reading.
6. Repeat the test on each cylinder,
cranking engine the same number of
times for each cylinder as was
required to obtain highest reading
on the No. 1 cylinder.
7. See the specification page for
compression specifications.
MECHANICAL VALVE LIFTER ADJUSTMENT:
(Fig. 9871)
Fig. 9871
1. Set lifters with engine cold.
2. Bar over to compression stroke on
each cylinder in firing order.
3. Adjust to specifications, using a
flat type feeler gauge.
CAMSHAFT LOBE CHECK: (Fig. 9839)
If only one camshaft lobe is to be
checked, loosen the valve rocker arm
adjusting screw. Slide rocker arm
assembly serving the camshaft lobe to be
checked, to one side. If all cam lobes
are to be checked, remove rocker arm
assembly.
1. Make sure push rod is in the valve
lifter socket. Install a dial
indicator so the actuating point of
indicator is in push rod socket and
in the same plane as the push rod
movement.
3.
2. Rotate crankshaft until lifter is in
its lowest position.
Fig. 9839
Zero the dial indicator. Continue
to rotate crankshaft slowly until
push rod is in the fully raised
position.
Code: OH-369, REV MAY 83 Section 3, Page 13

18. INDUSTRIAL TRUCK DIVISION
CUSTOMER SERVICES GROUP
TROUBLE SHOOTING
4. Compare the total lift recorded on
the indicator with specifications.
5. If the lift on any lobe is below
specified wear limits, the camshaft
and all valve lifters must be
replaced.
NOTE
Another method of checking
cam lift is to measure the
valve lift.
NOTE
When a new camshaft is to be
installed to replace a failed
or worn camshaft, an entire
set of new valve lifters must
also be installed. The new
camshaft will not be covered
by warranty unless new lifters
are also installed. Wear
patterns on the old lifters
and/or damaged old lifters can
result in early failure of the
new camshaft when new lifters
are not installed.
To measure valve lift, tighten rocker
arm adjusting screw until ZERO lash is
obtained between valve and arm. Place
the actuating rod of indicator on
valve spring retainer.
Follow steps 2 thru 5 to finish the
measuring operation.
Section 3, Page 14 Code: OH-369, MAR 80

19. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

20. CMRK
GRood
TROUBLE SHOOTING
TIMING OIL PUMP SHAFT
TO DISTRIBUTOR SHAFT
FIRING PGSITION//
(A) #1 PISTON ON
COMPRESSION STROKE
(D) ROTOR TIMED
TO #1 CYLINDER
/ -
(B) POINTER AND TIMING
MARKS IN ALIGNMENT
(C) SLOT OFFSET
TOWARD ENGINE BLOCK
/
OIL PUMP SHAFT
Code: OH-369, MAR 80
Section 3, Page 15

21. INDUSTRIAL TRUCK DIVISION
MARKETING TRAINING DEPT.
CYLINDER HEAD OVERHAUL:
Prior to disassembly of the engine:
(Fig. 83M052)
1. Drain oil and coolant.
2. Carefully inspect magnetic drain
plug. The particles adhered to it
will give an indication of excessive
internal wear.
3. Remove and clean the crankcase
breather element.
IMPORTANT
83M052
CLEAN ALL PARTS AND ASSEMBLIES IN
AN APPROVED TYPE CLEANING SOLVENT.
Remove rocker arm cover (Fig. 9665).
1. Carefully inspect rocker arm
assembly for breakage, excessive
wear and leakage or breakage of
oil line.
Water outlet assembly removal
(83M1/53)*
B:
Old Style
New Style
Water outlet and thermostat housing
removal:
1. Loosen hose clamps and disconnect
by-pass hose from water outlet
by-pass pipe and water pump by-pass
connection.
2. Remove the assembly retainer,
marking for reassembly in same
position as removed (retainers vary
in length).
Fig. 9665
83M053
Section 3, Page 16 Code: OH-369. REV MAY 83

22. CL!WIIC GROUP
00
Water Dump retainer removal (Fig. 10569).
1. Captive retainer shown by arrow can
be loosened sufficiently to remove
water pump but cannot be completely
removed until pulley is removed
from water pump. If pulley is
removed from water pump, always
install the retainer before
reinstalling pulley.
2. Loosen and remove all retainers
securing pump to cylinder block.
3. Check casting for cracks and
breakage.
4. Remove thermostat housing retainers,
housing gasket and thermostat.
Check thermostat for proper operation
(should open at [79'-82"C] 175-180°F
and be fully open at [91”C] 195°F).
Note : Engines in Lot 5085 and above
have the thermostat mounted on the
cylinder head.
Water Pump removal (Fig. 9815).
I. Carefully tap on pump (not the
pulley), using a soft faced hammer
until pump can be removed.
Fig. 10569
5. Engines in Lots before Lot 5085 only-
water outlet assembly need not be
disassembled unless vaporizer hole
cover gasket requires replacement.
Fig. 9815
Code: OH-369, REV MAY 83 Section 3, Page 17

23. INDUSTRIAL TRUCK DIVISION
CUSTOMER SERVICES GROUP
Rocker arm shaft assembly removal
(Fig. 9668).
1. Remove the retainers noting the
thickness as compared to the cover
retainers. Do not mix these or .the
rocker arm cover will not fit
properly if these special retainers
are not used.
Rocker arm shaft assembly disassembly
(Fig. 9669).
1.
2.
3.
4.
Remove retainer clip as shown by
arrow.
Slide parts off shaft, number the
rocker arms as they are removed for
reassembly in same order as removed.
Check for wear and broken parts,
clean . . . making sure all the oil
passages are clear of dirt, varnish
and gum deposits.
Rocker arms cannot be rebushed and
must be replaced if the bushing
surface is excessively worn or is
otherwise unfit for further service.
Push rod removal and inspection
(Fig. 9670).
1.
2.
3.
Number push rods for assembly in the
same order as removed.
Check for bent or broken push rods.
Replace bent or broken rods ... do
not attempt to straighten or repair.
Do not interchange push rods
between engines with solid lifters
and those with hydraulic lifters.
The length will vary.
Fig. 9668
Fig. 9669
z
g
Fig. 9670
Section 3, Page 18 Code: OH-369, MAR 80