Put the dial indicator on zero; rock the ring gear back and forth to determine how much play it has while the pinion gear remains stationary. Placing it on a large piece of non-shag gray (or any light color) carpet makes it easier to locate dropped parts. 20 Your completed front suspension should look like this unit, which is installed on a 1980 Corvette. The completed differential now needs to be attached to the frame crossmember. It should not bind after installation. Largest Inventory. This bolt has a 13/16- inch head. Housing Cover Outer Lonestar Caliper power steering pumps are not equipped with drive pulleys, which means you will need to use your existing pulley or order the right one for your application. Whether youre maintaining your Shark Corvette or completing a full restoration, our selection of C3 Corvette Power Steering parts is unsurpassed. Backlash occurs when you take your foot off the throttle; you hear a clunking noise coming from the rear of the car. Rest the spring on a floor jack and raise it to the differential to attach it with the steel plate and four 13/16- inch bolts. Notice here that the shock absorbers have been mounted and the halfshafts are bolted to the trailing arms and differential. Then its removed from the jig and turned around to repeat this process in the opposite direction. The carpet stops parts from bouncing under a table or into a small crevice. This bracket is attached to the lower control arm on each side of the front suspension. Steering is a vital function for the cars safe operation and a worn or failing steering box needs to be replaced. Use a long pry bar or long screwdriver to push the lower part of the spring into the lower spring well. Housing Bolts (front) Then, service the pump to "full" on the dipstick at operating temperature and you're good to go. When installing the control arm, dont forget to replace the factory alignment shims (two in the rear and one in the front). This is the perfect time to install the gas tank between the back frame rails. Notice how the end of the coil spring rests in the lower control arm. ft. Reconnect the power steering lines to the control valve. The ideal contact pattern (centered on the teeth) is the drawing in the middle. Install and adjust the parking brake assembly prior to mounting the rear brake rotor. The Posi-Traction unit has small clutches that are stacked on each side of the springs; they are held in place with these springs. Rocker These are fairly inexpensive and it is a good idea to install fresh bump stops when putting the front suspension together. The pump is connected to the power valve and the power steering cylinder. Removing Pitman arm from steering box 1,948 views Apr 5, 2018 Like Dislike Share Save Fun with cars - mostly Corvettes 640 subscribers Frame off refresh of a 1974 Corvette. Verify that each bolt has been properly installed and torqued to specifications by marking them with White-Out. Check and make sure you can turn the shaft by hand. 30, Mount Bolts Three bolts fasten the steering box to the left side of the frame. Now use a ball joint separator to loosen the ball joint from the spindle. The 19801982 automatics use 12-mm x 1.75 x 10.9 x 35-mm bolts and 19801981 4-speeds use 12-mm x 1.75 x 10.9 x 80-mm bolts. Secure the lower shock with two 1/2-inch bolts and torque to 35 ft-lbs. The upper control arm bushings are now fitted with new rubber units. Torque sensitive drives are particularly suited to those applications where immediate response to torque demand is required for down shifting and engine speed is ideally maintained at its peak rpm. Zip Corvette sales and customer service representatives are here to serve you during the following hours: Our showroom is open to the public Monday-Friday from 8:30am-5:30pm (EST). The movable face angle of all Comet asymmetric system drivers and drivens is 18 degrees, their "stationary" (opposing) face is 2-1/2 degrees and the Comet asymmetric belt angles likewise correspond. This prevents them from loosening and backing out. The rear transverse leaf spring and spring bolts have not been installed. Just be sure to dial them down after you are finished playing or your fillings might fall out. Manifold Refurbished units are fairly inexpensive and return a Corvettes steering to its original responsive feel. You may have to use a small wrench on the upper shaft to prevent it from turning as you tighten the 9/16- inch nut. Because quality is so critical, Lonestar Caliper rebuilds all of its power steering pumps, rams, control valves and steering gears in-house. Now that the frame has been returned to your work area, reconfirm your factory frame measurements. The larger the bars, the more taut the ride. Torque the two front bolts to 70 ft-lbs with a 5/8-inch socket. You can use the social sharing buttons to the left, or copy and paste the website link: https://www.chevydiy.com/c3-corvette-restoration-guide-suspension-differential-reassembly/. Attach a nut to the bottom of the bolt using a 7/8-inch socket on the nut and a 13/16- inch wrench on the bolt head and torque it to 100 ft-lbs. Both are now ready to be installed into the frame. The C3 rear suspension was an engineering breakthrough when introduced in 1963 on the C2. Add the right rear bearing support to the unit. Invert the arm in the press. Repeat this process until you get the correct measurement. This spring is under a lot of tension and might require the use of sandbags to be placed on the frame to help attach these end links. drag link (center link) - part #3740402 (See the part in the middleof Photo #12.) Driveshaft When taking a differential apart, be sure to mark the left- and right-side pieces. Bolts Outlet Be sure to select the correct front spring for your particular model and/or application. With the center of the spring secure, install the spring end links. These bump stops play a very important role in protecting the suspension in case you hit an unexpected bump too fast and the suspension bottoms out. 75, Lower Shock Mount Bolt The lower shaft is installed in the same manner although you will have to make another longer control arm support. A couple of spacer plates are employed between the subframe and framerails. 18, Door Hinge Bolts 65, Sway Bar Link Brackets: speaking of torque specs in the AIM, mine seems to show 40-60 lb-in for the upper ball joint castle nut. in/lbs, Lower The block is attached to the Pitman arm gear that turns the steering system when it moves back and forth. If using a differential rebuilding kit, it includes a dye to help determine the gear mesh pattern. Tighten the 11/16-inch locking nuts to 50 ft-lbs. The parts are then sent to the powdercoating shop to have their surfaces covered and protected. Insert the trailing arm bolt through the trailing arm. This system greatly improved handling and ride and that is why it was installed on all C3 Corvettes. 10: To remove the upper control arm, start by placing a jack securely under the lower control arm as support. Attach the frame crosspiece to the differential with two 7/16-18 x 118-inch bolts and 7/16-inch lock washers. 480 In-Lbs. Once the knuckle has been pushed into the ball joint stud, secure it with a 3/4-inch nut and torque to 45 ft-lbs. As you know, both the Eaton 65-79 and the Dana 80-82 Corvette differentials use springs to preload the clutch pack that transfers torque to the unloaded tire. Do not overtighten this nut because the bearing could seize. Power-assisted versions feature a hydraulic pump that is driven off the engine, and it pushes fluid into a ram that greatly reduces the steering effort. The lower control arm has a deep well that supports the bottom of the front suspension coil spring. Contact us here24 hours a day 7 days a week. The upper and lower control arms should look like this once they have been installed. Make sure it sits evenly on the lip of the housing then use a hammer to gently tap the seal into place. This car received a new steering knuckle, wheel bearings, and brake rotor. These parts reduce the unsprung weight of your front suspension and are just as strong as the stamped-steel factory parts. These shims will have to go back in their same location to keep the front end aligned. in/lbs, Carrier Front Support to "X" Member Trestle Systems 2470 Island Dr, Suite 308 Spring Park, MN 55384 Similar to a turnbuckle, there are right hand (RH) and left hand (LH) threaded connections at each end of the tie rod adjuster tube. 42: Install the rotors and calipers and tighten the wheel bearings as per the instructions in the shop manual. Tap it several times with a mallet or hammer to make sure it is seated properly on the pinion shaft. You use shims to make it match the desired pattern. Small-blocks from 1968 to 1979 use two U-bolts on each side to attach the shaft to the differential, which are secured with 9/16-inch nuts. Change the power steering fluid whenever you change the transmission and rear axle lubrication, which should be roughly every 30,000 miles. Use a torque wrench to secure the box with 9/16-inch bolts and torque to 30 ft-lbs. This process is the best for identifying any cracks. Pinion gears5. 120 Install the ring gear onto the Posi unit with new Grade 8 bolts and lock washers. Insert it through the control arm steel shaft from the top. Torque Converters (CVT's) Comet has been manufacturing torque converters for recreational vehicles for over 60 years.Our torque converters are designed and built to withstand the extreme rigors of rough applications. First start stacking a side gear with a clutch disc that has two tabs or ears on it. If you marked these parts during disassembly, re-torque the bolts to the same location. the past. The C3 AIM sheet for tie rod clamping indicates that when you tighten the adjuster tube Several well-known Corvette specialty shops offer like-new components at a competitive price that includes a warranty. 13906-C Denton Drive. Farmers Branch, TX 75234. 2, Wheel Nuts Much has happened since our kick-off of the Project. Secure and tighten all lug nuts. When the ball joint is aligned, continue to raise the jack while pushing the ball joint stud through. Use two 11/1616 x 7/8-inch bolts to attach the front caliper bracket and dust shield to the knuckle. Remember that the threaded end of the link kit must point up. Insert a cotter key in the provided hole. 130, Rear Bolt These springs were installed on Corvettes built at the new Bowling Green assembly plant. That way when the linkage is installed, the front end alignment will be close enough for you to be able to drive to your local Corvette alignment shop without doing any damage to the front end or tires. Torque to specs. Vette. It is much easier to install the strut rod with the trailing arm in this position. The Eaton system uses four coil springs, while the Dana utilizes a conical Belleview spring to preload the clutch pack. Oil Then cut approximately a 1 slot into the pipe. Use a 1/2-inch-drive torque wrench with a 7/8-inch nut and torque it to 75 ft-lbs. This is a manual steering application, which is why power steering components are not seen in this photo. 53-74 Electronic Tachometer Conversion Kit. Use a hammer to strike the pickle fork to knock the trailing arm away from the bearing support. Make sure the springs coil ends are positioned in their respective slots in the frame bucket and control arm. Make sure the guide pin on the spring aligns with the guide hole in the differential. Manifolds C3 C4 C56 C56-A C59 C6 C66M-R CD4E Chrysler CIB5 Cruise-O-Matic . However, if you are going to aggressively drive your Corvette or use it for autocross competition, install a front spring with a higher spring rate. This tool will seat the pulley onto the pump shaft. Torque them to 35 ft-lbs. 60 As with the top control arm, the lower ball joint is bolted to the steering knuckle with one nut. 18, Bracket Bolts Phone (972) 243-3838. Slowly rotate the gears to check for any obvious signs of one gear rubbing on another. 34 Third-generation Corvettes use a series of rods attached to the steering box and the suspension steering knuckles to turn the wheels. 27, Flywheel to Engine Yellow or white dye (or marking compound) is usually found in a differential kit. 80 You can also potentially get hydraulic lines backward during installation from the control valve to the ram and steering becomes erratic quickly. Clip off the excess ends with a pair of cutting pliers. Fill oil reservoir to proper level and let the oil remain undisturbed for at least two minutes. The bump stop is a triangle of rubber mounted to a metal bracket. It is critical to catch any imperfections on the workbench and not on the car. Four bolts in the middle secure it. Cover Bolts Check belt tightness and check for a bent or loose pulley. New ball joints with rubber or polyurethane bushings are included in the rebuild process. Driveshaft and Rear Axles, Lower Control Arm Shaft Bolts Lay out the critical components of your front suspension assembly as shown. Low Price Guarantee. Then install the nut and tighten until you get the proper drag on the nut (18 to 22 inch-pounds) on new gears. One bolt holds these arms in place. 70, Upper However, if this is not in your budget, at a minimum you need to replace the ball joints and the rubber bushings. The worm gear retainer and the Pitman shaft cap can be installed and torqued to specification according to your assembly manual. Is your Pitman arm on upside down by chance? The ram (shown) is attached to the relay rod. 60 When you service the pump with fluid, keep in mind as fluid gets hot it expands and can overflow out of the pump. 30, Bracket to Torque Arm This new design can be found in all 19801982 Corvettes. Heads New parts have been welded into place by a professional Corvette repair shop. Apply some dye according to the kit instructions. The tie rod screws into the sleeve and connects to the steering knuckle. After the oil has been drained, remove the back cover on the differential. The measurement should be .006 to .008 inch. Slide the control arm steel bracket through the two bolts and thread on the 11/16-inch nuts. Three basic types of Saginaw power steering pumps were used in C2 and C3 Corvettes. Camber The store will not work correctly in the case when cookies are disabled. 26: Install the new ball joints into the arms and torque them to specs. 30, Pressure Plate Bolts Optional equipment, such as air conditioning, also impacts the spring rates that are recommended by the factory. The 19681982 Corvette steering linkage was first used in the 1963 Stingray. A forum community dedicated to Chevrolet Chevelle owners and enthusiasts. This is a good preventive maintenance procedure to makes sure the parts are not dry. Whenever there is a need, want and use for a torque sensitive drive system device that is infinitely variable from engagement . This is how toe-out and toe-in are adjusted on the front suspension. For a better experience, please enable JavaScript in your browser before proceeding. Once the bolt is attached with the nut and washer, slowly lower the jack. 80 in/lbs, Jounce Bumper to Frame Be careful to not over tighten them, as it damages the roller bearings. Once they are snug, go one-quarter turn more with a wrench. This bolt has a 13/16- inch head. When this is done, the sway bar can be removed. Some even include multistep adjustments to dial in the ride you want. Recheck the adjustment after putting 100 miles on the car. 03: We are going to remove the entire steering linkage as one unit. Push the gasket to the back of the spindle. Tie rod assemblies operate on the principle of the common turnbuckle. 80, Mount Bolts Two 7/16-13 x 214-inch bolts secure the upper control arm to the frame. Install a French lock that serves as a washer. Front Suspension: How To Rebuild Your 1963-1982 Corvette Front Suspension, Source:ZipCorvette Parts8067 Fast Lane | Mechanicsville, VA 23111 | (800) 962-9632, Your email address will not be published. The large block moves up and down the shaft as the steering wheel is turned. Maybe I'll snap some pics tomorrow and post them. Ford used this Bendix-design "power-assist" steering design on a wide variety of vehicles ranging from the humble Falcon to the behemoth Lincoln. Repeat this step on the opposite side. It is important to make sure that this seal is correctly seated into the top of the differential housing. When draining the oil from the differential, check for a burning odor, which indicates overheating of the gears and case. Four 1/2-inch or 9/16-inch bolts, depending on the year the car was built, fasten the brackets to the frame. 41: Re-pack the front wheel bearings and install them into each rotor along with the grease seals. Loosen the upper ball joint nut. Use the same procedure on these bolts as discussed in step 2 above. Does the new picture look ok as far as the shaft sticking thru the nut far enough? Connecting Leave it alone. 25, Lower Screw it on and line up the slot in the valve with the groove in the threads. To reassemble the trailing arms, simply reverse the disassembly procedure discussed in Chapter 6. With all the new parts installed, you want to have your Corvettes front suspension set to factory specifications. The transverse leaf spring bolts to the differential and is connected to the rear suspension trailing arms. Oil Everything was of excellent quality and fit just as it should. We take orders in our showroom or you may call your order in over the phone and we will prepare your items in advance so you do not have to wait. Exhaust . To take the desired measurements, refer to the top right photo on page 87. This photo shows a typical pinion bearing with a crush sleeve between the inner and outer bearing. Use a liberal application of silicone on the washer (shown) to make sure there are no differential oil leaks. My assembly manual calls for the nut to be torqued to 120-160 pound feet. This will be one of the last bolts to tighten. Notice where the relay rod is attached to the passenger-side idler arm sleeve. At this stage, the frame has been inspected, repaired, and finished. 20: If you want to freshen up the control arms for a new look, thoroughly clean them and spray 2 or 3 light, even coats of Eastwoods Underhood Black. 90 When Zora Duntov unveiled the independent rear suspension of the 1963 Corvette, he elevated the American sports car to a world class level. We call it power-assist because it provides hydraulic assistance to the Corvette's existing steering system. The differentials are basically all the same inside, but you find some minor changes during an overhaul. 3. If the control valve is out of adjustment too much pressure will be applied in one direction or the other and steering will pull left or right. This frame has been carefully placed on four safety stands and four large pieces of cardboard to protect the frame from any scratches. Four discs without tabs are on each side. These arms need to be moved up and down during the spring and steering knuckle installation. Tolerances of .005 or less are the runout target. Once the spring is securely in both wells, slowly raise the jack to prevent the spring from popping out of the upper and lower spring wells. 70, Lower Control Arm Shaft Bolts: