Dynomite
01-23-2015, 11:38 PM
LT5 Piston Liner Removal Tool
I came up with a tool to easily Remove Liners (Removal of number 4 liner shown). The Removal of Number 3 and 4 liners have additional difficulty because of the Crankshaft Position Sensor Wheel. The beauty of this Liner Removal Tool is that once the Liner is pulled approximately 3 inches the Top Nut is further tightened to capture the Liner between the Top and Bottom Plate. The whole unit including the Liner then becomes solid as if one piece and by then the Liner is pulled far enough to have a looseness that you can wiggle the whole assembly out of the block with nothing falling loose.
Initial breakout of the Liner surprisingly does not take much force at all with the Liner Removal Tool.
http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/90a8fbcd-397b-4715-ab50-460671d19e64.jpg
Wood Blocks on the Top of the Block to protect ............Liner Removed showing Liner Removal Tool fully retracted.
the Block Surface. The ALL thread has a two flats..........Once fully retracted the Liner is compressed by the Liner
on the top inch of thread to hold from turning. .............Removal tool and the liner can then be removed by hand.
http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/1738393c-127c-4ccc-ad4a-4388987ba5eb.jpghttp://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/b07f5a6a-aefc-498b-8ab1-0d17db8e3d2a.jpg
The Components are made from 1/2 inch aluminum plate and one 12 inch long x 1/2 inch All Thread Rod.
There is absolutely NO damage to any aluminum surfaces of the Block during this Liner Removal.
http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/e4c8de0b-21d2-4c31-af64-d677efe57a2e.jpghttp://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/cc3da345-e5e3-4177-a896-cf89cf68e44a.jpg
The 1/2 inch x 12 inch All thread rod has two FLATS
on the Top End (end with blocks) so the rod can be
prevented from turning as the Top Nut is tightened.
http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/0f9f5181-483c-4177-a5c2-6a0fdf4cc9ec.jpg
See The Rebuild and Assembly of a 1991 Spare LT5 (http://www.corvetteforum.com/forums/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-10.html#post1588695474) for a complete LT5 Restoration
I came up with a tool to easily Remove Liners (Removal of number 4 liner shown). The Removal of Number 3 and 4 liners have additional difficulty because of the Crankshaft Position Sensor Wheel. The beauty of this Liner Removal Tool is that once the Liner is pulled approximately 3 inches the Top Nut is further tightened to capture the Liner between the Top and Bottom Plate. The whole unit including the Liner then becomes solid as if one piece and by then the Liner is pulled far enough to have a looseness that you can wiggle the whole assembly out of the block with nothing falling loose.
Initial breakout of the Liner surprisingly does not take much force at all with the Liner Removal Tool.
http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/90a8fbcd-397b-4715-ab50-460671d19e64.jpg
Wood Blocks on the Top of the Block to protect ............Liner Removed showing Liner Removal Tool fully retracted.
the Block Surface. The ALL thread has a two flats..........Once fully retracted the Liner is compressed by the Liner
on the top inch of thread to hold from turning. .............Removal tool and the liner can then be removed by hand.
http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/1738393c-127c-4ccc-ad4a-4388987ba5eb.jpghttp://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/b07f5a6a-aefc-498b-8ab1-0d17db8e3d2a.jpg
The Components are made from 1/2 inch aluminum plate and one 12 inch long x 1/2 inch All Thread Rod.
There is absolutely NO damage to any aluminum surfaces of the Block during this Liner Removal.
http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/e4c8de0b-21d2-4c31-af64-d677efe57a2e.jpghttp://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/cc3da345-e5e3-4177-a896-cf89cf68e44a.jpg
The 1/2 inch x 12 inch All thread rod has two FLATS
on the Top End (end with blocks) so the rod can be
prevented from turning as the Top Nut is tightened.
http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite10/0f9f5181-483c-4177-a5c2-6a0fdf4cc9ec.jpg
See The Rebuild and Assembly of a 1991 Spare LT5 (http://www.corvetteforum.com/forums/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-10.html#post1588695474) for a complete LT5 Restoration