Liner Removal Tool - ZR-1 Net Registry Forums

Dynomite · 01-23-2015

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.

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.

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.

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.

See The Rebuild and Assembly of a 1991 Spare LT5 for a complete LT5 Restoration

bdw18_123 · 01-24-2015

Nice job, Cliff!

mike100 · 01-24-2015

necessity is the mother of invention...especially if it costs less than $10.

01-23-2015	#1
Dynomite Join Date: Aug 2009 Location: South Dakota/California Posts: 3,794	Liner Removal Tool 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. 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. 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. 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. See The Rebuild and Assembly of a 1991 Spare LT5 for a complete LT5 Restoration __________________ Left Clickable links -Solutions- LT5 Modifications/Rebuild Tricks Low Mileage ZR-1 Restoration 1990 Corvette (L98) Modifications LT5 Eliminated Systems LT5 Added Systems LT5/ZR-1 Fluids 1995 LT5 SPECIFIC TOP END REBUILD TRICKS Last edited by Dynomite; 01-27-2015 at 06:28 PM.

01-24-2015	#2
bdw18_123 Join Date: Apr 2009 Location: Prather, CA Posts: 809	Re: Liner Removal Tool Nice job, Cliff! __________________ [IMG]http://i13.photobucket.com/albums/a292/bdw18_123/_zr1netforumsigphoto.jpg[/IMG][B] 1990 Corvette ZR-1 [/B][I] White/Flame Red, #2299, mostly stock, 144K miles.[/I] -Cams timed to the '93-'95 405HP LT5 stock timing. -IAT sensor relocated to below front bumper. -Haibeck hoops installed in airduct. -OBX cat-back exhaust. [COLOR=DarkRed][B](SOLD - December 2012 [/B][/COLOR][COLOR=DarkRed][B]:hello:)[/B][/COLOR] 1993 Corvette Coupe Black/Black, 6-speed (SOLD - October 2009 :hello:)

01-24-2015	#3
mike100 Join Date: Feb 2011 Location: San Marcos CA Posts: 1,802	Re: Liner Removal Tool necessity is the mother of invention...especially if it costs less than $10.