Operator`s manual
3.
Set
the
stop
collar
(P/N
64905)
5.
75 inches
above
the
cutting
edge
of
special
piloted
reamer
(P/N
64902).
4.
Assemble
the
universal
(P/N
64908)
to
a 1/2
inch
electric
drill
motor,
the
reamer
to the
uni-
versal
and
proceed
to
ream
0. 547
inch
through
thru-
stud
holes
from
the
even
cylinder
number
side.
Continue
reaming
until
the
reamer
reaches
the
collar.
Make
sure
the
drill
and
reamer
has
stopped
before
removal
from
the
stud
hole.
CAUTION
A
liberal
amount
of
kerosene
must
be
con-
stantly
flowing
into
the
hole
as
the
reamer
is
passing
through.
This
will
prevent
over-
heating
and
scoring.
5.
Remove
the
stop
collar
fromthe
0.
547
inch
dia-
meter
reamer
and
assemble
the
collar
5.
50
inches
from
the
cutting
edge
of
the
0.
563
inch
diameter
finish
reamer
(P/N
64903).
OVERHAUL
MANUAL
LYCOMING
DIRECT
DRIVE
AIRCRAFT
ENGINES
Section
7
Crankcase,
Crankshaft,
and
Reciprocating
Parts
6. Assemble
reamer
to
universal
and
proceed
to
finish
ream
the
holes,
once
again
paying
attention
to
the
preceding
"caution"
note.
-REMOVE
PROPELLER
FLANGE
BUSHING
BEFORE
\GRINDING.
MASK
HOLES
BEFORE
PLATING.
REPLACE
\WITH
NEW
BUSHING
AFTER
PLATING.
7.
Disassemble
crankcase
halves
and
hand
tap
the
anchor
threads
0.
007
inch
oversize
using
tap
(P/N
64907).
8.
Use
a
3/4
inch
counterbore
(P/N
64904)
and
standard
tap
handle
to
resize
the
oil
seal
counter-
bore
hole.
Exercise
caution
so
as
not
to go
deeper
than
the
present
depth.
See
figure
7-10.
9.
Burr
to
clean
up
all
rough
edges
caused
by
the
reaming
operations.
Wash
and
clean
the
crankcase
thoroughly.
10.
Assemble
new
body
fit thru-studs
(P/N
72698-
P07)
in
the
threaded
half
of
the
crankcase.
The
same
size
"O"
ring
seal
is
used
with
the
9/16
inch
thru-studs
as
was
previously
used.
7-56.
Oil
Relief
Valve
Sleeve
(Non-adjustable
oil
re-
lief
valve).
If the
sleeve
is
badly
scored
or otherwise
damaged,
remove
and
replace
the
sleeve
in
the
follow-
ing
manner.
1.
Apply
a
liberal
coating
of
heavy
grease
to
the
threads
of
a
standard
1/2-20
bottoming
hand
tap.
This
will
aid
in
subsequent
cleaning
of the
relief
valve
bore,
since
loose
metal
particles
resulting
from
the
action
of the
tap
will
tend
to
adhere
to the-
tap
when
it
is withdrawn
from
the
bore.
Insert
the
tap
into
the
relief
valve
bore,
making
sure
that
the
tap
is
centered
in the
ball
seat
of
the
sleeve.
Screw
the
tap
into
the
sleeve
a
maximum
of
four
full
turns.
CAUTION
Do
not
rotate
tap
in excess
of four
full
turns
because
the
tap
may
damage
the
crankcase
if
it
is inserted
too
far
beyond
the
sleeve.
Figure
7-13.
Reconditioning
Crankshaft
Oil
Seal
Surface
0-320-B
Series
0-340
Series
0-360-A,
-C
Series
0-540
Series
Engines
prior
to 3815-39
Engines
prior
to
405-30
Engines
prior
to
3042-36
Engines
prior
to
2790-40
1.
With
the
crankcase
assembled
as
directed
in
paragraphs
7-34
and
7-35,
loosen
and
remove
the
thru-studs
from
the
locations
shown
in figure
7-11.
2.
Place
the
crankcase
with
the
odd
numbered
cyl-
inder
side
down
on eight
inch
parallel
blocks.
COUNTERWEIGHT
ROLLER
BUSHING
COUNTERWEIGHT
EAR
ON
CRANKSHAFT
4
3
2
COUNTERWEIGHT
BUSHING
PULLER
Figure
7-14.
Removal
of Crankshaft
Counterweight
Bushing
Revised
January,
1971
7-11