23. Adjuster plug (61) with side bearing cup (33) and
O-ring seal (62) (K3 models). Use J 36615 (figure
10
).
24. Nut (46). Use J 8614-01 to hold the pinion flange
(figure 11).
25. Washer (45).
26. P in io n fla n g e (44) w ith d e fle c to r (43). Use
J 8614-01 (figure 12).
• Mount the left carrier case in J 36598. Be sure to
use the adapter plate (J 36598-6) for K1, 2 models.
27. Ring and pinion (37) with shim (38), bearing cone
(39), and spacer (40). Use J 36598 (figure 13).
28. Spacer (40) from the pinion.
29. Pinion bearing (39). Use J 8612-B (K1, 2 models)
or J 36606 (K3 models) and a press (figure 14).
30. Shim (38).
31. Seal (42), and bearing cup and cone (41). Use
J 36598-6 (figure 15).
32. Bearing cup (39). Use J 36598-6 (figure 16).
33. Side bearings (33). Use J 22888-D and J 8107-2
(K1, 2 models) or J 36597 (K3 models) (figure 17).
34. Ring gear bolts (34).
• Ring gear bolts have left-handed threads.
NOTICE: Do not pry the ring gear from the
case. This will damage the ring gear and the
differential case.
35. Ring gear (37) from the differential case.
• Drive the ring gear off with a brass drift.
36. Pin (36) (K1, 2 models). Drive out with a drift and
hammer (figure 18).
37. Bolt (34) (K3 models).
38. Shaft (52).
39. Differential pinion gears (56) and side gears (54).
A. Roll the pinion gears out of the case with the
pinion thrust washers (55).
B. Remove the side gears and the side gear thrust
washers (53). Mark the gears and the differen
tial case as left and right.
C. Remove spacer (57) (K3 models only).
40. Vent plug (60). Use a 6-point deep socket.
41. Bushings (48). Use J 36616 (figure 19).
CLEANING
• Do not steam-clean drive parts having ground and
polished surfaces such as gears, bearings, and
shafts. All parts should be disassembled before
cleaning. These parts should be cleaned in a suit
able solvent.
• Parts should be thoroughly dried immediately after
cleaning. Use soft, clean, lintless rags. Parts may
be dried with compressed air. Do not allow the
bearings to spin while drying them with com
pressed air.
INSPECTIO N
It is very important to carefully and thoroughly inspect
all drive unit parts before assembly.
Thorough inspection of the parts for wear or stress
and replacement of worn parts will help prevent costly
drive component repair after reassembly.
AXLE HOUSING
I ?
Inspect
• Axle housing bore for nicks or burrs that would
prevent the outer diameter of the pinion seal from
sealing. Remove any burrs that are found.
• Bearing cup surfaces for nicks or burrs. Remove
any burrs that are found.
• Housing for cracks. Replace the housing if any
cracks are found.
• Housing for foreign material such as metal chips,
dirt, or rust. Refer to “ Cleaning.”
DIFFERENTIAL
L9
Inspect
• Pinion gear shaft for unusual wear.
• Pinion gear and side gear teeth for wear, cracks,
scoring, and spalling.
• Thrust washers for wear.
• The fit of the differential side gears in the differen
tial case.
• The fit of the side gears on the axle shafts.
• Differential case for cracks and scoring.
• All parts for wear and replace if necessary.
PINION AND RING GEAR
• Ring and pinion gears are matched sets and must
both be replaced any time a replacement of either
is necessary.
1?
Inspect
• Pinion and ring gear teeth for cracking, chipping,
scoring, or excessive wear.
• Pinion gear splines for wear.
• Pinion flange splines for wear.
• The fit of the pinion flange on the pinion gear.
• Sealing surface of the pinion flange for nicks, burrs,
or rough tool marks which would cause damage to
the inside diameter of the pinion seal and result in
an oil leak.
• All parts for wear and replace if necessary.
BEARINGS
I?
k .
Inspect
Bearings for smooth rotation after oiling them.
Bearing rollers for wear.
Bearing cups for wear, cracks, brinelling and scor
ing.
Important
• When replacing worn or cracked bearings and
cups, make sure to replace bearings in sets.
• Low m ileage b e a rin g s m ay have ve ry sm all
scratches and pits on the rollers and the bearing
cups from the initial preload. Do not replace a
bearing for this reason.
Summary of Contents for Light Duty Truck 1994 Series
Page 1: ......
Page 11: ...VIEW A p n n n j VIEW C F7554 Figure 10 Hydra Matic 4L60 E Transmission I D Location ...
Page 24: ...NOTES ...
Page 26: ... ...
Page 69: ...NOTES ...
Page 71: ...3 2 STEERING ...
Page 73: ......
Page 84: ......
Page 102: ...40 ...
Page 130: ...NOTES ...
Page 146: ...NOTES ...
Page 162: ...NOTES ...
Page 166: ...Figure 5 Removing the Pinion Flange Figure 6 Pressing the Drive Pinion from the Cage ...
Page 178: ...Figure 3 Spreading the Differential Case Figure 4 Removing the Differential ...
Page 190: ...NOTES ...
Page 202: ...NOTES ...
Page 206: ...F5785 ...
Page 212: ...B Button Moved Out of Bearing Bore F5791 ...
Page 228: ...NOTES ...
Page 232: ......
Page 234: ......
Page 236: ...Adjuster 63 Bolt 64 Lock Figure 10 Turning the Adjuster Plug K3 Models ...
Page 237: ...Figure 13 Removing the Pinion Seal 39 Bearing Cup Figure 16 Removing the Inner Bearing Cap ...
Page 261: ...F7475 ...
Page 267: ...B Button Moved Out of Bearing Bore F5791 ...
Page 294: ...NOTES ...
Page 300: ...NOTES ...
Page 318: ...NOTES ...
Page 322: ...SR207LN2 EDS ...
Page 324: ......
Page 326: ...OVERHEAD OILING AND RETURN MAIN OIL GALLERY N30005 6A2 J EDS ...
Page 368: ...103 153 127 V1200 ...
Page 370: ......
Page 372: ......
Page 374: ...F9375 Figure 7 Engine Lubrication Diagram Engines Without Balance Shaft ...
Page 376: ...Figure 9 Engine Lubrication Diagram Engines With Balance Shaft ...
Page 399: ...V2974 ...
Page 410: ......
Page 412: ...195 196 201 174 252 163 165 164 244 3706r3924 ...
Page 452: ......
Page 454: ...163 164 V1202 ...
Page 456: ...20 21x 302 210 4 0 41 2 5 2 5 1 2 51 4 2 e3 54 3 9 252 252 S 255 255 25 6 256 209 V1196 ...
Page 458: ...100 1 8 4 185 183 177 v 75 201 3706r1204 ...
Page 460: ......
Page 510: ......
Page 512: ...V2131 ...
Page 514: ...110 106 106 103 90 93 89 88 87 86 v 7 7 7 7 j A _ 111 f t 2 a a s 53 49 L 47 46 3706r4751 ...
Page 566: ...NOTES ...
Page 574: ...NOTES ...
Page 618: ...SPECIAL TOOLS ...
Page 620: ...NOTES ...
Page 672: ......
Page 682: ......
Page 686: ......
Page 694: ...RH0213 4L60 E ...
Page 695: ...657 659 m i J 8092 H J 34196 4 3 34196 5 657 658 665 J 23907 J 7004 1 J 8092 RH0214 4L60 E ...
Page 696: ...J 8092 J 34196 4 33 31 J 8092 RH0215 4L60 E ...
Page 697: ...SPECIAL TOOLS ...
Page 698: ...SPECIAL TOOLS ...
Page 758: ...RH0194 4L80 E ...
Page 764: ......
Page 770: ...SPECIAL TOOLS ...
Page 771: ...SPECIAL TOOLS CONT ...
Page 772: ......
Page 775: ......
Page 776: ......
Page 785: ......
Page 804: ...NOTES ...
Page 806: ......
Page 808: ......
Page 822: ...3707r5079 ...
Page 840: ......
Page 848: ...NOTES ...
Page 852: ......
Page 860: ...F5435 ...
Page 866: ......
Page 878: ...F9167 ...
Page 882: ...16 FrontOutputShaft 18 DrivtQNr 19 DrivenGm t 20 DriveChain 22 FrontOutputBearing V2836 ...
Page 890: ...F9168 ...
Page 908: ......
Page 919: ......