Crankshaft

Crankshaft

Reconditioning of these crankshafts can be done by grinding the "journals" (bearing surface on the crankshaft for the connecting rod bearings and main bearings) .010 in. (0.25 mm), .020 in. (0.51 mm) or .050 in. (1.27 mm) "undersize" (smaller than the original size).

The diameter of the "journals" for the connecting rod bearings is 2.7496 ± .0006 in. (69.840 ± 0.015 mm). The diameter of the "journals" for the main bearings is 3.4995 ± .0006 in. (88.887 ± 0.015 mm). The minimum permissible diameter of the "journals" for the connecting rod is 2.7486 in. (69.814 mm). The minimum permissible diameter for the "journals" for the main bearings is 3.4985 in. (88.862 mm). Measure each "journal" in several places around the diameter to find the maximum wear point. If the diameter of any "journal" is smaller than the minimum permissible diameter, grind all of the "journals." Before a crankshaft is ground, check to be sure the crankshaft is not bent. To check for a crankshaft that is bent, place crankshaft main bearing journals 2 and 4 on 5P8637 V-Blocks. Use a dial indicator and check the runout (total indicator reading) for main bearing journals 1, 3 and 5. The maximum total indicator reading is .005 in. (0.13 mm) for each journal. If the total indicator reading is more than .005 in. (0.13 mm) the crankshaft must be straightened before it is ground. Make reference to Guideline for Reusable Parts PROCEDURE TO MEASURE BENT CRANKSHAFTS, Form No. SEBF8030.

Another procedure must be used to determine if a bent crankshaft can be straightened.

Place the crankshaft main bearing journals 1 and 5 on 5P8637 V-Blocks. Use a dial indicator and check the runout (total indicator reading) of the center main bearing journal. If the total indicator reading is more than .050 in. (1.27 mm) the crankshaft cannot be straightened.

If the total indicator reading is less than .050 in. (1.27 mm), the crankshaft can be straightened. Before the crankshaft is straightened it must be heated to 350 to 450°F (177 to 232°C). Make reference to Guideline For Reusable PartsPROCEDURE TO STRAIGHTEN BENT CRANKSHAFTS, Form No. SEBF8040.

With the crankshaft installed in the cylinder block, check the end play for the crankshaft. End play for the crankshaft is .003 to .010 in. (0.08 to 0.25 mm). Maximum permissible end play for the crankshaft is .014 in. (0.36 mm).

NOTE: If end play for the crankshaft is more than the maximum permissible end play, check the crankshaft thrust bearing.

Crankshaft Grinding Specifications

The dimensions and finish for grinding crankshafts are as follows:

Diameter (A) for connecting rod bearing journals is:

.010 in. (0.25 mm) Undersize ... 2.7396 ± .0006 in.(69.586 ± 0.015 mm)

.020 in. (0.51 mm) Undersize ... 2.7296 ± .0006 in.(69.332 ± 0.015 mm)

.050 in. (1.27 mm) Undersize ... 2.6996 ± .0006 in.(68.570 ± 0.015 mm)

Surface finish must be 10 micro inches (0.25 micrometers) or less.

Radius (B) must be .100 ± .010 in. (2.54 ± 0.25 mm).

Surface finish must be 63 micro inches (1.6 micrometers) or less.

The radius must blend smoothly with the newly machined journals.

DIMENSIONS FOR GRINDING
A. Diameter of connecting rod bearing journals. B. Radius on connecting rod bearing journals. C. Width to grind journals for the connecting rods. D. Diameter of main bearing journals. E. Radius on main bearing journals. F. Width to grind journals for the main bearings.

Width (C) is 2.314 ± .003 in. (58.77 ± 0.08 mm)

Diameter (D) for main bearing journals is:

.010 in. (0.25 mm) Undersize ... 3.4895 ± .0006 in.(88.633 ± 0.015 mm)

.020 in. (0.51 mm) Undersize ... 3.4795 ± .0006 in.(88.379 ± 0.015 mm)

.050 in. (1.27 mm) Undersize ... 3.4495 ± .0006 in.(87.617 ± 0.015 mm)

Surface finish must be 10 micro inches (0.25 micrometers) or less.

Radius (E) must be .095 ± .010 in. (2.41 ± 0.25 mm).

Surface finish must be 63 micro inches (1.6 micrometers) or less.

The radius must blend smoothly with the newly machined journals.

Width (F) is 1.258 ± .002 in. (31.95 ± 0.05 mm) for number 4 main bearing journal. Surface finish on the thrust faces of the number 4 main must be 18 micro inches (0.45 micrometers) or less.

Width (F) is 1.268 + .020 - .010 in. (32.21 + 0.51 - 0.25 mm) for number 2, 3 and 5 main bearing journals.

There is no width (F) for number 1 main bearing journal.

When grinding a crankshaft, no material can be removed from the crankshaft webs or counterweights.

Crankshaft Gear Removal

Remove the gear using a 8B7548 Push Puller, 8B7551 Bearing Pulling Attachment, 8B7561 Step Plate, and 8H684 Ratchet Box Wrench.

PULLING CRANKSHAFT GEAR

The 1P820 Hydraulic Puller Group can also be used to pull gear from crankshaft. Tools required are 1P820 Hydraulic Puller Group, 8B7551 Bearing Pulling Attachment, 8B7549 Puller Legs (two), 8B7561 Step Plate, 3H465 Plate (four), 1B4207 Nut (two) and 5P3100 Pump Group.

USING HYDRAULIC PULLER

Crankshaft Gear Installation

1. Install the key in keyway of crankshaft. Remove all burrs from key and keyway inside of crankshaft gear.

2. Heat gear to 500°F (260°C) maximum.

3. Install gear on crankshaft with timing mark on gear facing front of crankshaft.

Crankshaft Front Oil Seal Removal

Remove the crankshaft front pulley. Use the 1P3075 Puller Group to remove the crankshaft front oil seal.

REMOVING FRONT OIL SEAL (Typical Example)

Remove Crankshaft Rear Seal And Wear Sleeve

Remove the crankshaft rear oil seal with the 1P3075 Puller Group.

REMOVING REAR OIL SEAL

Install a 5P7338 Distorter Ring from the 5P7318 Wear Sleeve Distorter Group, in the rear seal bore. Install 5P7312 Distorter between distorter ring and wear sleeve. Turn the distorter until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose. Remove the tools and wear sleeve.

REMOVING REAR WEAR SLEEVE (Typical Example)

Install Crankshaft Rear Seal And Wear Sleeve

NOTE: New seal groups must be installed dry (no lubrication). Seal groups that have been separated must not be used. Only new seal groups are acceptable for installation.

SEAL AND WEAR SLEEVE INSTALLATION
1. Locator. 2. Seal group. 3. Crankshaft. 4. Installer. 5. Nut.

1. Install the crankshaft rear seal and wear sleeve assembly with tooling as follows:

a. Install locator (1) in position on the crankshaft.

b. Use 6V1541 Quick Cure Primer to clean outer diameter of the crankshaft flange and the inside diameter of the wear sleeve.

c. Put 9S3265 Retaining Compound on the outside diameter of the crankshaft and the inside diameter of the wear sleeve.

d. Put seal group (2) on locator (1). Put installer (4) on locator (1). Put lubrication on the face of washer and nut (5). Install and tighten nut (5) until installer (4) comes in contact with locator.

e. Remove tooling, and check the wear sleeve and seal for correct installation.

Crankshaft Front Oil Seal Installation

1. Put the seal over the short end of the 5P4194 Installer Assembly (A). Put a sealer on the outer diameter of the seal metal shell. The lip of the seal must be toward the inside of the engine.

2. Put the seal and installer assembly (A) in position on the end of the crankshaft. Install bolt (1) and washer (2) that hold the crankshaft pulley in place. Tighten bolt (1) until the installer assembly (A) makes contact with the crankshaft gear.

NOTE: If a new wear surface for the front seal is needed, put 5P4230 Spacer between the seal and flange of the installer assembly.

INSTALLING FRONT OIL SEAL
1. Bolt. 2. Washer. A. 5P4194 Installer Assembly.

3. Put engine oil on the lip of the seal before installing the pulley.

Crankshaft Pulley Removal

1. Remove pulley retaining bolt and washer.

2. Remove the pulley using a 5F7465 Puller Assembly, 8B7560 Step Plate, two 5M2894 Washers, and two S1571 Bolts.

PULLEY REMOVAL (Typical Example)

Crankshaft Pulley Installation

1. Lubricate lip of crankshaft front oil seal and the sealing surface of crankshaft pulley with engine oil (SAE 30).

2. To install pulley, start pulley on crankshaft. Put screw (4) from the 8B7548 Push Puller into the crankshaft until it bottoms out. Put crossbar (1) from the 8B7548 Push Puller onto screw (4). Install washer (2) and nut (3) onto screw (4). Hold screw (4) and turn nut (3) to press pully onto crankshaft. When installed, the pulley hub will contact the crankshaft gear.

3. Remove the tool setup. Install the pulley retaining bolt and washer. Tighten the pulley retaining bolt to the torque shown in the specifications.

INSTALLING PULLEY
1. Crossbar. 2. Washer. 3. Nut 4. Screw