GMC S Series 1994, Repair Manual

Page 1: ......

Page 2: ...gned for the purpose Accordingly anyone who intends to use a replacement part service procedure or tool that is not recom m ended by the veh icle manufacturer must first determine that neither his saf...

Page 3: ...and electronic diagnosis for these models are published in the Driveability Emissions and Electrical Diagnosis Manual NATP 9444 This manual should be kept in a handy place for ready reference If prope...

Page 4: ...tions contained in this manual are based on the latest product information available at the time of publication approval The right is reserved to make changes at any time without notice General Motors...

Page 5: ...1 4 INCH RING 4B3 10 1 2 INCH RING GEAR GEAR 4B4 DANA MODEL 80 11 INCH RING 4C3 ALL WHiEEL DRIVE FRONT AXLE 4B5 GEAR 7 1 4 1NC H RING GEAR c QDAI PQ 5A MASTER CYLINDER 5D2 HYDRAUilC BOOSTER O DnAIVCO...

Page 6: ...information Your name Your dealership s name technicians only Your phone number Model year and vehicle line Publication book number if present Vehicle Identification Number of vehicle being worked on...

Page 7: ...CALLSUN 225 5786 6 45 a m 7 00 p m CST SERVICE PARTS IDENTIFICATION LABEL The service parts identification label is provided on all models figure 1 It is located on the inside of the instrument panel...

Page 8: ...le identification plate Stick on labels attached to the engine or laser etch ing or stampings on the engine block indicate the engine unit number or date code VEHICLE IDENTIFICATION NUMBER VIN Nation...

Page 9: ...EL IDENTIFICATION Models and body styles are shown in figures 15 through 19 METRIC FASTENERS Current model GM vehicles are primarily dimensioned in the metric system Many fasteners are metric and are...

Page 10: ...with other North American Industries has adopted a portion of the standard metric fastener sizes defined by ISO International Standards Organization This was done to reduce the number of fastener siz...

Page 11: ...VIEW A p n n n j VIEW C F7554 Figure 10 Hydra Matic 4L60 E Transmission I D Location...

Page 12: ...ANSMISSION I D LOCATION 2 TRANSMISSION IDENTIFICATION TAG SERIAL NUMBER P 4 B 17 X z MODEL I NEWVENTUREGEAR 3500 5LM60 BUILDMONTH A JANUARY B FEBRUARY C MARCH D APRIL E MAY Ho JUNE K JULY M AUGUST P S...

Page 13: ...United States and may be of a lower strength may not have the numbered head marking system and may be of a different thread pitch The metric fasteners used on GM products are designed to new internat...

Page 14: ...c and English conversions refer to figure 23 DECIMAL AND METRIC EQUIVALENTS For determining decimal and metric equivalents refer to figure 24 J1930 WORD CONVERSION Starting with the 1993 model year Ge...

Page 15: ...G VAN MODELS Rally Sportvan Cutaway Van Extended Van Vandura Chevy Van Magnavan Hi Cube Van F7569...

Page 16: ...PASSENGER VAN CARGO VAN EXTENDED VAN Figure 17 M L Models P3 MOTOR HOME CHASSIS P3 FORWARD CONTROL CHASSIS V1378...

Page 17: ...S T PICKUP REGULAR CAB 2 DOOR S T UTILITY VEHICLE S T PICKUP EXTENDED CAB 4 DOOR S T UTILITY VEHICLE 2900r4506...

Page 18: ...INCH IN MILLIMETERS THREADS IN MILLIMETERS THREAD PITCH V1262 Figure 20 Thread Notation 1 Grade 2 GM 260 M 2 Grade 5 GM 280 M 3 Grade 7 GM 290 M 4 Grade 8 GM 300 M 5 Manufacturer s Identification 6 N...

Page 19: ...7 500 562 625 750 4 5 N m 0 4 0 6 1 4 1 8 2 4 3 2 4 2 6 2 In Lbs 4 0 5 0 12 15 20 27 35 51 1 2 3 6 8 9 N m 0 4 0 6 1 0 1 4 1 8 2 6 3 4 5 2 In Lbs 4 0 5 0 9 0 12 15 22 28 43 A Metric Sizes 1 Top Lock T...

Page 20: ...newtons Pound 4 448 newtons TEMPERATURE Degree Fahrenheit t F 32 7 1 8 degree Celsius C 4 CO 1 Multiply by to get equivalent number of ACCELERATION Foot sec2 0 304 8 meter sec2 m s2 Inch sec2 0 025 4...

Page 21: ...17 85937 7 32 0 21875 5 55625 23 32 0 71875 18 25625 15 64 0 234375 5 95312 47 64 0 734375 18 65312 1 4 0 250 6 3500 3 4 0 750 19 05000 17 64 0 265625 6 74687 49 64 0 765625 19 44687 9 32 0 28125 7 1...

Page 22: ...ECM Controlled Canister Purge CCP Evaporative Emission Canister Purge EVAP Canister Purge Coolant Temperature Switch CTS Engine Coolant Temperature Switch ECT Switch Coolant Temperature Sensor CTS En...

Page 23: ...itrogen Oxides NOx Nitrogen Oxides NOx Oxygen OJ Oxygen 02 Oxygen Sensor 02 1 Heated Oxygen Sensor H02S 2 Oxygen Sensor 02S Park Neutral Switch P N Switch Park Neutral Postion Switch PNP Switch Port F...

Page 24: ...NOTES...

Page 25: ...R CONDITIONING CONTENTS SUBJECT PAGE HR100T HR110 MD Air Conditioning Compressor 1D1 1 HD6 HR6 HE Air Conditioning Compressor 1D2 1 V 5 Air Conditioning Compressor 1D3 1 SD 7H15 Air Conditioning Compr...

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Page 27: ...foreign material from getting on or into the compressor parts and system during disassembly or reassembly Clean tools and clean work area are very important for proper service The compressor connectio...

Page 28: ...ASSEMBLY 3 RETAINER RING ROTOR BEARING ASSEMBLY 4 PULLEY ROTOR 5 ROTOR BEARING 6 COIL HOUSING ASSEMBLY 7 RETAINER SHAFT SEAL 8 SHAFT SEAL 9 O RING SHAFT SEAL 10 PUMP ASSEMBLY 11 O RING PRESSURE RELIEF...

Page 29: ...gerant system must be reclaimed evacuated and recharged to complete service Illustrations used in describing these operations show the compressor removed from the vehicle only to more clearly illustra...

Page 30: ...all the Clutch Plate and Hub Installer J 9401 illustrated in Figure 7 B as Hold the hex portion of the Installer Body J 9401 B with a wrench and tighten the center screw to press the hub onto the shaf...

Page 31: ...ign the new bearing squarely with the hub bore and using Pulley and Bearing Installer J 9481 A with Universal Handle J 29886 drive the bearing fully into the hub Fig 12 The Installer will apply force...

Page 32: ...line adjust or replace pulley rim 8 Tighten pulley rim mounting screws to 11 N m 100 in lbs torque and lock screw heads in place by bending screw head washer similar to original crimp 9 Reinstall Clut...

Page 33: ...if used as shown Place Bearing Staking Guide J 33019 1 and Bearing Staking Pin J 33019 2 in the hub bore as shown in Figure 19 Shift the rotor and bearing assembly on the J 21352 A Support Block to g...

Page 34: ...r Guide J 25031 to the front head and install Puller J 8433 with Poly V Belt Puller Leg Set J 24092 and remove the clutch coil from the front head Fig 24 Clutch coil may also be removed by using rotor...

Page 35: ...JOR REPAIR PROCEDURES Service repair procedures to the Compressor Shaft Seal and Pressure Relief Valve and Compressor Switches are considered MAJOR SINCE THE REFRIGERATION MUST BE RECOVERED EVACUATED...

Page 36: ...e knurled tangs of Seal Remover Installer J 23128 A into the recessed portion of the Seal by turning the handle clockwise Remove the Seal from the compressor with a rotary pulling motion Discard the S...

Page 37: ...igerant and repair as necessary Remove discard and later replace the shaft nut 7 Remove any excess oil resulting from installing the new seal parts from the shaft and inside the compressor neck 8 Inst...

Page 38: ...l to all cylinder and piston areas 10 Install a M9 x 1 25 threaded nut on the compressor crankshaft if the drive plate and clutch assembly are not installed 11 Using a box end wrench or socket and han...

Page 39: ...BEARING REMOVER 17 J 25031 ROTOR AND BEARING PULLER WITH 7 J33013 B HUB DRIVE PLATE ASSEMBLY GUIDE REMOVER 18 J 25287 CLUTCH COIL PULLER 8 J9401 B HUB DRIVE PLATE ASSEMBLY 19 J 26271 A ROTOR AND BEAR...

Page 40: ...ifferences in installations mounting brackets pulleys torque cushions and switches none of which will affect the following overhaul procedures There are two clutch driver designs for these compressors...

Page 41: ...P ASSEMBLY 8 SWITCH O RING 9 SYSTEM CONTROL SWITCH 10 HIGH PRESSURE RELIEF VALVE 11 RETAINER RING SWITCH 12 SUCTION DISCHARGE PORT SEALING WASHERS 13 SPECIAL 134a SUCTION PORT 1 4 SPECIAL 134a DISCHAR...

Page 42: ...remove only the parts that preliminary diagnosis shows are in need of service Refer to Figures 2 and 5 for information relative to part names and location Removal and installation of external compres...

Page 43: ...ce in the keyway before installing the clutch plate and hub assembly to its final position The air gap between frictional surfaces of the clutch plate and clutch rotor should be 0 50 0 76mm 020 030 NO...

Page 44: ...y supported J 33020 PULLEY ROTOR AND BEARING PULLER G60120 1D2 EK R1 Fig 8 Removing Pulley Rotor and Bearing Assembly E l J 33020 LESS FORCING SCREW INVERTED AND USED TO SUPPORT HUB OF ROTOR FOR BEARI...

Page 45: ...ult if outer bearing race is deformed while staking The stake metal should not contact the outer race of the bearing Stake three places 120 degrees apart as shown in Figure 12 Q j J 33019 1 BEARING ST...

Page 46: ...nstall J 8433 1 puller crossbar with J 33025 puller legs as show n in Figure 14 Tighten J 8 4 3 3 3 forcing screw against the puller pilot to remove the clutch coil 4 Install or Connect 1 Place the cl...

Page 47: ...ortant as is the use o f proper clean service tools NOTICE A ny attem pt to use m akeshift or inadequate service tools or equipm ent m ay result in dam ag e and or im proper co m p resso r operation A...

Page 48: ...roughly clean O ring seal groove in front head NOTICE Seals should not be re used Always use a new specification service seal on rebuild Fig 18 Be sure that the seal to be installed is not scratched o...

Page 49: ...e any excess oil resulting from installing the new seal parts from the shaft and inside the co m p resso r neck 7 Install the clutch plate and hub assem bly as described in m in o r repair procedures...

Page 50: ...t to the co m p resso r assembly Rotate the com plete co m p resso r assem bly not the crankshaft or drive plate hub slow ly several turns to distribute oil to all cylinder and piston areas 10 Install...

Page 51: ...SUPPORT BLOCK 12 J 33011 O RING INSTALLER 13 J 33013 HUB DRIVE PLATE REMOVER INSTALLER 14 J 39500 GM R134a A C REFRIGERANT RECOVERY RECYCLING AND RECHARGING SYSTEM ACR4 1 5 J 33017 PULLEY BEARING ASS...

Page 52: ...portant for proper service The compressor connections and the outside of the compressor should be cleaned before any on vehicle repairs or before removal of the compressor The parts must be kept clean...

Page 53: ...rvice Removal and installation of external compressor parts and disassembly and assembly of internal parts must be performed on a clean workbench The work area tools and parts must be kept clean at al...

Page 54: ...LEY BEARING 5 PULLEY ROTOR 6 CLUTCH COIL ASM 7 SHAFT SEAL PARTS 8 SERVICE COMPRESSOR WITHOUT CLUTCH 9 COMPRESSOR CONTROL VALVE ASM 10 HIGH PRESSURE RELIEF VALVE 11 SYSTEM CONTROL SWITCHES 12 SUCTION P...

Page 55: ..._______________________ 520006 1D3 R1 Fig 4 Removing Shaft Nut 1 CLUTCH PLATE AND HUB ASSEMBLY 2 J 33013 B HUB AND CLUTCH DRIVE PLATE ASSEMBLY REMOVER 3 J 34992 1 THUMB SCREW 4 J 34992 HOLDING FIXTURE...

Page 56: ...rotor should be 0 50 076mm 0 20 030 If the center screw is threaded fully onto the end of the compressor shaft or if the body of the installer is held and the center screw is rotated the key will ass...

Page 57: ...aged Install or Connect Place the pulley rotor on the J 21352 A support block to fully support the rotor hub during bearing installation Fig 12 NOTICE Do Not support the rotor by resting the pulley ri...

Page 58: ...Tighten the center screw in the J 8433 1 puller crossbar to force the pulley rotor and bearing assembly onto the compressor front head Fig 15 Should the J 33017 pulley rotor and bearing installer slip...

Page 59: ...CEDURES When replacing the shaft seal assembly Fig 20 pressure relief valve or rear head mounted pressure switches Fig 21 even if the compressor remains on the vehicle during the operation it will be...

Page 60: ...cification service seal kit Fig 20 Be sure that the seal to be installed is not scratched or damaged in any way Make sure that the seal is free of lint and dirt that could damage the seal surface or p...

Page 61: ...tem 3 Leak test system 1 2 3 4 5 2 Remove or Disconnect Recover refrigerant Disconnect the electrical connector from the switch in the rear head of the compressor Fig 21 Remove the switch retaining ri...

Page 62: ...edure 1 With sealing washers in place install test plate J 9625 A on rear head of compressor 2 Attach center hose of manifold gage set on charging station to a refrigerant drum standing in an upright...

Page 63: ...CONNECTOR SEAL SEAT INSTALLER REMOVER SUPPORT BLOCK O RING INSTALLER 14 J 33013 B HUB DRIVE PLATE REMOVER AND INSTALLER 15 J 33017 PULLEY BEARING ASSEMBLY INSTALLER 16 J 38100 C REFRIGERANT RECOVERY...

Page 64: ...date code is stamped on the front left mounting ear viewed as facing the clutch figure 1 It will be either a two digit number or a num ber letter combination The first number gives the year of manufa...

Page 65: ...e clutch front plate Hold the clutch plate stationary figure 3 1 Hex nut using a 14 mm socket 2 Clutch front plate using J 37825 figure 4 Align the puller center bolt to the compressor shaft Thumb tig...

Page 66: ...9886 Driver Handle J 37872 Spanner Wrench J 38467 Bearing Remover and Installer Figure 8 Removing the Coil Snap Ring o J 29886 J 38467 F9443 Figure 9 Installing the Rotor Pulley 1 Clutch coil and snap...

Page 67: ...l the plate bottoms to the clutch shims NOTICE Refer to Notice on page 1D4 1 6 Shaft hex nut Hold the plate with J 37872 figure 3 Tighten Nut to 14 N m 124 lbs in Check the air gap with a feeler gauge...

Page 68: ...OLS 1 J 8433 2 J 29886 3 J 37825 4 J 37872 1 PULLER SET 2 DRIVER HANDLE 3 PULLER PLATE ASSEMBLY 4 SPANNER WRENCH 5 PULLER FINGERS 6 BEARING REMOVER INSTALLER 7 PULLER PILOT 5 J 37828 J 38467 J 37827 2...

Page 69: ...NOTES...

Page 70: ...SECTION 3 STEERING CONTENTS SUBJECT PAGE Power Steering Gear Unit Repair 3B1A 1 Power Steering Pump Unit Repair 3B1B 1 Manual Steering Gear Unit Repair 3B2A 1...

Page 71: ...3 2 STEERING...

Page 72: ...orrect torque value must be used when installing fasteners that require it If the above conditions are not followed parts or system damage could result CONTENTS Subsection A 708 Power Steering Gear 70...

Page 73: ......

Page 74: ...justments The steering gear requires two adjustments The worm thrust bearing preload The pitman shaft over center preload adjustment The worm thrust bearing preload is controlled by the amount of comp...

Page 75: ...te the stub shaft 40 from stop to stop using a 12 point socket and count the number of turns 6 Starting at either stop turn the stub shaft 40 back 112 the total number of turns This is the center of t...

Page 76: ...AN SHAFT AND SIDE COVER REPLACEMENT Figures 1and 2 Remove or Disconnect Steering gearfrom vehicle Referto PowerSteering Gear Replacement in Section 3B Pitman arm from steering gear Refer to Steering L...

Page 77: ...0 to 60 N m 44 lb ft Adjust Pitman shaft Refer to Pitman Shaft Over Center Preload Adjustment in this section 1 Install or Connect Steering gear Refer to Power Steering Gear Replacement in Section 3B...

Page 78: ...ng ring 50 Position adjuster plug 55 face down on a suitable support see Figure 13 Needle bearing 53 dust seal 51 and lip seal 52 using J 6221 to drive them from adjuster plug 55 Assemble Position adj...

Page 79: ...eplacement in Section 3B 4 A VALVE ASSEMBLY 13 SHAFT WORM 15 RACE 16 BEARING 17 RACE 20 HOUSING 40 SHAFT STUB Important Do not move or rotate worm shaft 13 while valve assembly is removed Any rotation...

Page 80: ...Refer to Steering Gear Adjustments in this section Install or Connect Steering gear Refer to Power Steering Gear Replacement in Section 3B Figure 17 Remove and Install Spool RACK PISTON AND WORM SHAFT...

Page 81: ...ck piston balls 25 are reinstalled in the rack piston Improper rack piston ball installation may result in personal injury Notice The black rack piston balls are smaller than the silver balls The blac...

Page 82: ...Installer J 4245 Internal Snap Ring Pliers Remove or Disconnect Pitman arm from steering gear Refer to Steering Linkage in Section 3B3 Clean Exposed end of pitman shaft 12 and housing 20 Use awire br...

Page 83: ...e Notice Use care not to damage threads of housing when removing check valve Check valve 18 by prying from housing with a small screwdriver Assemble Check valve 18 using a 3 8 inch diameter piece of t...

Page 84: ......

Page 85: ...STUB SHAFT 33 WORM ASM PIN 34 RACE THRUST BEARING WORM 35 BEARING ASM ROLLER THRUST WORM 36 RACE THRUST BEARING WORM 37 SEAL O RING RELIEF VALVE 38 PLATE BYPASS 39 SEAL O RING RELIEF VALVE 40 VALVE AS...

Page 86: ...n 50 bottoms in housing 6 Align the end tooth of the pitman shaft 5 with the center groove of the rack piston 50 and 7 see Figure 7 Turn stub shaft 31 counterclockwise until the plug 12 separates from...

Page 87: ...5 14 Worm shaft 33 from valve assembly 15 Races 34 and bearing 35 from worm shaft 33 Important Do not attempt to reuse damaged or worn parts by welding or having them straightened Replace all bent bro...

Page 88: ...g 19 loosely in the gear housing Retainer ring 15 see Figure 10 Dust seal 16 Seal 17 Pry with a screwdriver from the bore of the adjuster plug 19 Do not scratch or score the seal bore see Figure 11 17...

Page 89: ...ring 18 if required Place the new bearing over tools J 8524 1 and J 7079 2 with the manufacturer s ID against the tool Place a block of wood under the adjuster plug 19 then press the bearing into the...

Page 90: ...grooves of the spacer away from small race 23 see Figure 18 10 New bearing retainer 25 Tap on the flat surface of the retainer see Figure 19 m Important The retainer projections must not extend beyon...

Page 91: ...ssively worn or broken replace the complete valve and shaft assembly Torsion bar and stub shaft 31 for leaking If there is leaking replace the valve assembly see Figure 23 Ground surface of the stub s...

Page 92: ...y pin before installing the valve body into the gear assembly 6 Valve spool and shaft 31 assembly into the valve body 28 The shaft cap should be below the valve body notch see Figure 25 Lubricate a ne...

Page 93: ...ng and exces sive wear Rack piston 50 teeth and external ground surfaces for scoring or excessive wear If condition exists replace the rack piston 50 and worm 33 1 Assemble New Seal 9 and ring 10 to r...

Page 94: ...seals be careful notto score the housing bore or leakage may result 4 L Inspect Brass inverted flare connectors 51 for looseness Remove or Disconnect Flare connectors 51 if necessary and discard A mod...

Page 95: ...l J 6222 A over the end of the stub shaft 3 Adjuster plug 19 assembly into the housing until it seats against the valve body 28 Adjust 1 Bearing preload Use tool J 7624 01 Turn the adjuster plug 19 cl...

Page 96: ...impossible to eliminate lash between the primary gear teeth Install a new seal 3 on the side cover and lubricate with power steering fluid Push the side cover 3 into the housing 6 until the adjuster...

Page 97: ...he combined ball and bearing preload by turning the torque wrench through the center of travel and recording the highest reading 4 Tighten the adjusting screw on pitman shaft 5 until the torque wrench...

Page 98: ...ck to vertical Subtract this reading from reading taken in step 5 If the reading in step 5 is 0 23 N m 2 lb in then the gear is adjusted properly Go to step 7 If less than 0 23 N m 2 lb in proceed wit...

Page 99: ...7 N m 29 lb ft 40 Relief Valve 47 N m 35 lb ft 48 Lockwasher Screws 8 N m 6 lb ft ADJUSTM ENT TIGHTENING SPECIFICATIONS 708 Power Steering Gear 40 Pitman Shaft Over Center Preload 0 7 1 I N m 6 10 lb...

Page 100: ...TALLER 2 INTERNAL SNAP RING PLIERS 11 SEAL AND BEARING REMOVER 3 SPANNER WRENCH 12 VALVE CONNECTOR SEAT INSTALLER 4 RACK PISTON TEFLON RING COMPRESSOR 13 SHAFT SEAL PROTECTOR 5 RACK PISTON ARBOR 14 DR...

Page 101: ...re it If the above conditions are not followed parts or system damage could result CONTENTS Subsection A P Series Power Steering Pump Subsection B CB Series Power Steering Pump P Series Power Steering...

Page 102: ...40...

Page 103: ...pump from vehicle Refer to Power Steering Pump Replacement in section 3B Disassemble Protect drive shaft 12 with shim stock Seal 11 by cutting with a chisel Assemble Lubricate seal 11 with power steer...

Page 104: ...that might require replacement of the entire housing 4 Pressure plate 21 by using a rubber mallet to tap lightly on the drive shaft 12 5 Pump ring 20 6 Pump vanes 18 7 Shaft rotor and thrust plate ass...

Page 105: ...EL 7 SHAFT DRIVE 8 SEAL O RING 10 HOUSING ASM HYD PUMP 11 SEAL DRIVE SHAFT 12 SPRING FLOW CONTROL 13 VALVE ASM CONTROL 15 SEAL O RING KEY NO PART NAME 16 FITTING O RING UNION 25 PLATE THRUST 26 RING P...

Page 106: ...4 Fitting 16 into hydraulic pump housing assembly 10 Q Tighten Fitting 16 to 75 N m 55 lb ft 5 Pump assembly to vehicle if removed DRIVE SHAFT SEAL without disassembly of pump Figures 2 and 3 Tool Re...

Page 107: ...Pump ring 26 and vanes 27 from drive shaft subassembly Shaft retaining ring 30 from drive shaft 7 Pump rotor 28 and thrust plate 25 from drive shaft 7 jgi Clean All parts in power steering fluid Dry...

Page 108: ...ve in pump housing 10 with ring opening near access hole in pump housing see Figure 7 C RETAINING RING OPENING D BOLT HOLE 37 RING RETAINING Figure 7 Retaining Ring Installation Housing SPECIFICATIONS...

Page 109: ...e lower end of the steering shaft The ball nut is mounted on the worm and the steel balls act as a rolling thread between the worm and nut to provide a low friction drive between them Teeth on the bal...

Page 110: ...all Nut Worm Shaft Upper Worm Bearing Upper worm Bearing Cup Pitman Shaft Seal Housing Worm Shaft Seal Side Cover Gasket Pitman Shaft Needle Bearing Pitman Shaft Preload Adjuster Preload Adjuster Shim...

Page 111: ...Before installing turn preload adjuster screw counterclockwise until it bottoms then back screw off one half turn 2 Install parts as shown Checking end clearance If clearance is greater than 05 mm 00...

Page 112: ...up Install Cup 4 DISASSEMBLE AND ASSEMBLE WORM BEARING ADJUSTER DISASSEMBLE 1 Pry lower bearing retainer out with screwdriver 2 Remove cup using J 29369 1 puller and slide hammer WORM BEARING ADJUSTER...

Page 113: ...m bearing adjuster until it bottoms then loosen one quarter turn 2 Carefully turn the wormshaft all the way to end of travel then turn back one half turn 3 Tighten adjuster plug until torque wrench re...

Page 114: ...CIFICATIONS SAGINAW MODEL 535 Manual Steering Gear N m Ft Lbs Side Cover Bolts 18 13 Pitman Shaft Adjusting Screw Locknut 30 22 Clamp to Ball Nut Screw 5 5 4 T2506 SPECIAL TOOLS J 6219 J 6278 J 8092 1...

Page 115: ...requiring thread locking compound will be called out The correct torque value must be used when installing fasteners that require it If the above conditions are not followed parts or system damage co...

Page 116: ...axle continues to transmit the driving force This prevents tire scuffing during turns and premature wear on internal axle parts The axle is sealed by a pinion seal a seal at each axle shaft end and a...

Page 117: ...fferential Case 7 Axle Shaft Oil Seal 25 Ring Gear Bolt 8 Axle Shaft Bearing 26 Differential Gears 9 Axle Housing 27 Pinion Thrust Washers 10 Axle Air Vent 28 Side Gear Thrust Washers 11 Pinion Nut 29...

Page 118: ...not to damage the cover gasket surface The differ ential case must be supported when it is being removed to prevent the case from fall ing and being damaged 11 Differential case Pry the case from the...

Page 119: ...am mer and punch in the slots provided for this pur pose Work the cups out of the housing evenly mov ing the punch back and forth between one side of the cup and the other Figure 10 Pinion Collapsible...

Page 120: ...ring gear and pinion gear are replaced to maintain proper system balance BEARINGS Inspect Bearings for smooth rotation after oiling them Bearing rollers for wear Bearing cups for wear cracks brinelli...

Page 121: ...0 067 inch to a dial reading of 0 84 mm 0 033 inch as shown in figure 15 record the dial reading of 0 84 mm 0 033 inch NOT 1 70 mm 0 067 inch The dial indicator should be in the 0 50 to 1 27 mm 0 020...

Page 122: ...the differential case Drive the bearing onto the case using J 25299 and J 8092 11 Differential case to the axle housing Refer to Side Bearing PreLoad Adjustment SIDE BEARING PRELOAD ADJUSTMENT Figure...

Page 123: ...es sively larger feeler gage sizes between the axle housing and service shim A Push the feeler gage downward so it contacts the shim at the top and bottom and then con tacts the axle housing B The poi...

Page 124: ...on end play is just taken up Rotate the pinion while tightening the nut to seat the bearings Once there is no end play in the pinion the preload torque should be checked 20 Pinion F4686 B Remove J 861...

Page 125: ...thicker than the one removed from the left side Insert this shim between the spacer and left bearing race figure 25 11 Install the left bearing cap and bolts Do not tighten 12 Select a shim 0 10 mm 0...

Page 126: ...closer to or farther from the drive pinion The adjusting shims are also used to set side bearing preload If the thickness of the right shim is increased along with decreasing the left shim thickness...

Page 127: ...N AND MAKE ANY NECESSARY CORRECTIONS CORRECTION NONE SERVICE HINTS PATTERNS THAT MAY VARY MAY BE CAUSED BY LOOSE BEARINGS ON THE PINION OR THE DIFFERENTIAL CASE CHECK THESE BEARING PRELOAD SETTINGS TO...

Page 128: ...ng Spacer Differential Side Bearing Shim Kits N m Lbs Ft 27 20 75 55 35 26 120 90 Size 0 170 inch 0 040 0 046 0 052 0 058 0 064 0 072 0 080 0 088 0 096 0 044 0 050 0 056 0 063 0 070 0 078 0 086 0 094...

Page 129: ...r Plug 4 Pinion Flange Holder 5 Pinion Flange Remover 6 Side Bearing Remover 7 Rear Pinion Bearing Cone Installer 8 Axle Bearing Puller 9 Pinion Oil Seal Installer 10 Differential Side Bearing Install...

Page 130: ...NOTES...

Page 131: ...ch ring gear axle uses a con ventional ring and pinion gear set to transmit the driving force of the engine to the rear wheels This gear set transfers the driving force at a 90 degree angle from the p...

Page 132: ...1 The tangs of the tool should engage the bear ing outer race 8 Pinion gear 21 and side gears 22 Roll the pinion gears out of the case with the pinion thrust washers 20 Remove the side gears and side...

Page 133: ...D COVER 15 BOLT DIFF P GR SHF LK 17 SHAFT DIFF PINION 18 BOLT HEX 19 WASHER DIFF SIDE GEAR 20 WASHER DIFF PINION 21 GEAR DIFF PINION 22 GEAR DIFF SIDE 23 BOLT HYPOOID DRIVE GEAR 24 CASE DIFFERENTIAL 2...

Page 134: ...be cleaned in a suitable 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 whil...

Page 135: ...f either is necessary Figure 8 Removing the Drive Pinion Figure 9 Removing the Pinion Rear Bearing Important A new pinion flange must be replaced when ring gear and pinion gear are replaced to main ta...

Page 136: ...ld the stud stationary at the flats of the stud Tighten Stud nut to 2 2 N m 20 lbs in 5 Rotate the gauge plate and bearings several com plete revolutions to seat the bearings 6 Tighten the stud nut un...

Page 137: ...no plus or minus marked on it use the nominal pinion setting to select a shim 17 Remove bearing caps 10 and depth gauging tools 18 Install the correct pinion shim 6 to the pinion according to this pro...

Page 138: ...or below 2 3 to 2 8 N m 20 to 25 lbs in on new bearings or 1 1 to 1 7 N m 10 to 15 lbs in for used bearings figure 17 C If the preload torque is below the preloads giv en above continue torquing the n...

Page 139: ...l on the side opposite of bearing installation to protect the differential case B Drive the bearing onto the case using J 22761 and J 8092 8 Differential case 24 to the axle housing Refer to Side Bear...

Page 140: ...2779 the service spacer service shim feeler gauge and differential case from the axle housing 9 Measure J 22779 in three places using a microme ter Average the readings figure 23 10 Add the dimensions...

Page 141: ...l check or instead of checking pin ion depth and backlash adjustments This check is only to be used to verify the correct adjustment of the gear set after setup 1 Wipe all oil out of the case and care...

Page 142: ...MES COUNTERCLOCKWISE OBSERVE THE TOOTH CONTACT PATTERN AND MAKE ANY NECESSARY CORRECTIONS CORRECTION NONE SERVICE HINTS PATTERNS THAT MAY VARY MAY BE CAUSED BY LOOSE BEARINGS ON THE PINION OR THE DIFF...

Page 143: ...Lubricate the bearing with axle lubricant 2 Oil seal using J 23771 until the oil seal is flush with the axle tube figure 29 Lubricate the seal lips with gear lubricant 3 Axle shafts 33 into the axle...

Page 144: ...ial Side Bearing Spacer Differential Side Bearing Shim Kits Pinion Bearing Shim Kits Lubricant LUBRICATION N m Lbs Ft 27 20 80 60 35 26 120 90 Size 0 170 inch 0 040 0 044 nch 0 046 0 050 nch 0 052 0 0...

Page 145: ...Backlash Gauge 3 Driver Handle 13 Rear Pinion Bearing Cone Installer 4 Dial Indicator Set Not Shown 5 Rear Pinion Bearing Cone Installer J 21777 1 Arbor 6 Pinion Flange Remover J 21777 29 Gauge Plate...

Page 146: ...NOTES...

Page 147: ...d Shim Specifications 4B3 14 Lubrication 4B3 14 Special Tools 4B3 15 GENERAL DESCRIPTION The corporate 9 1 2 inch ring gear rear axle uses a conventional ring and pinion gear set to transmit the drivi...

Page 148: ...sh the axle shaft 3 in towards the center of the differential case 27 5 Axle shaft 3 from the axle housing 12 6 Oil seal 4 using a seal removal tool behind the seal lip Be careful not to damage the ho...

Page 149: ...T RING AND PINION 16 LOCK DIFF BRG ADJ NUT 17 NUT DIFF BRG ADJ 18 SCREW HEX SERRATED WASHER 19 CAP DIFF BEARING 20 BOLT HEX 21 SHIM DIFF BEARING ADJ 22 BEARING DIFF 23 CLIP BRK CROSSOVER PIPE 24 BOLT...

Page 150: ...with two bolts 24 to keep the pinion from falling C Drive the pinion out of the housing with a ham mer and soft drift figure 8 Remove the cover 25 and the pinion 15 21 Collapsible spacer 11 from the p...

Page 151: ...ear and side gear teeth for wear cracks scoring and spalling Thrust washers for wear The fit of the side gears in the differential case The fit of the side gears on the axle shafts Differential case f...

Page 152: ...red J 8001 Dial Indicator Gage Set J 21777 1 Arbor Figure 11 Installing the Rear Pinion Bearing Cup J 21777 8 Rear Pilot Washer J 21777 42 Front Pilot Washer J 21777 43 Stud Assembly Bolt J 21777 85 G...

Page 153: ...ween movement to the left and to the right 14 At the point of greatest deflection set the dial indi cator to zero Repeat the rocking action of the gage shaft to verify the zero setting 15 Rotate the g...

Page 154: ...earing onto the pinion 5 Pinion oil seal 9 using J 22388 and J 22804 01 figure 16 6 The pinion flange 8 to the pinion by tapping it with a soft faced hammer until a few threads show through the pinion...

Page 155: ...de as when removed 4 Pinion gears 31 to the differential without the pin ion thrust washers 30 A Install the pinion gears onto the side gears so the holes in the pinion gears are 180 degrees apart B R...

Page 156: ...emble the caps loosely B Turn the adjusting nut until the nut contacts the shim Then tighten the nut three additional slots figure 22 Bolts 20 to 80 N m 60 lbs ft 6 Adjusting nut lock 16 and lock bolt...

Page 157: ...ole Figure 24 Installing the Axle Bearing NOTICE For steps 6 7 and 9 refer to No tice on page 4B3 1 9 Important Anytime a differential pinion shaft locking screw is removed it is important to coat the...

Page 158: ...backlash and pinion depth The effects of bearing preloads are not readily apparent on hand load ed tooth contact pattern tests However these adjust ments should be within specifications before procee...

Page 159: ...VE THE TOOTH CONTACT PATTERN AND MAKE ANY NECESSARY CORRECTIONS CORRECTION NONE SERVICE HINTS PATTERNS THAT MAY VARY MAY BE CAUSED BY LOOSE BEARINGS ON THE PINION OR THE DIFFERENTIAL CASE CHECK THESE...

Page 160: ...im Kits 5 59 mm 0 220 nch 5 64 mm 0 222 nch 5 69 mm 0 224 nch 5 74 mm 0 226 nch 5 79 mm 0 228 nch 5 84 mm 0 230 nch 5 89 mm 0 232 nch 5 94 mm 0 234 nch 5 99 mm 0 236 nch 6 05 mm 0 238 nch 6 10 mm 0 24...

Page 161: ...aring Cone Installer 6 Front Pinion Bearing Cup Installer 7 Driver Handle 8 Dial Indicator 9 Differential Side Bearing Installer 10 Side Bearing Remover 11 Rear Pinion Bearing Cone Installer 12 Pinion...

Page 162: ...NOTES...

Page 163: ...1 2 inch ring gear rear axle uses a conventional ring and pinion gear set to transmit the driving force of the engine to the rear wheels This gear set transfers this driving force at a 90 degree angl...

Page 164: ...ring gear from the case This will damage the ring gear and the differential case 12 Ring gear 14 from the differential Drive the ring gear off with a brass drift if nec essary 13 Side gears 29 and thr...

Page 165: ...n Gear Thrust Washer 8 9 1 Pinion Nut 10 2 Washer 11 3 Pinion Flange 12 4 Slinger 13 5 Pinion Oil Seal 14 Pinion Front Bearing Bolt Washer Brake Line Clip Pinion Cage Shim Collapsable Spacer Pinion Re...

Page 166: ...Figure 5 Removing the Pinion Flange Figure 6 Pressing the Drive Pinion from the Cage...

Page 167: ...lange must be replaced when both ring gear and pinion gear are replaced to maintain proper system balance L Inspect Pinion and ring gear teeth for cracking chipping scoring or excessive wear Pinion sp...

Page 168: ...Pinion oil seal 5 using J 24433 and J 8092 8 Pinion flange oil deflector 4 and pinion flange 3 to the pinion splines 9 Washer 2 and pinion nut 1 A Place the pinion cage assembly into the vise B Flange...

Page 169: ...t be clean 4 Pinion cage 10 to the axle housing figure 13 NOTICE Refer to Notice on page 4B4 1 5 Cage bolts 7 Tighten Bolts to 88 N m 65 lbs ft DIFFERENTIAL CASE ASSEMBLY 4 Install or Connect Figure 1...

Page 170: ...ting nut lock 21 and lock bolt 22 to the left nut A Do not tighten B Tighten the right adjusting nut firmly to force the case into solid contact with the left adjusting nut Rotate the pinion several t...

Page 171: ...the oppo site direction 5 Observe the pattern on the ring gear teeth and compare this with figure 19 ADJUSTMENTS AFFECTING TOOTH CONTACT Two adjustments can be made that affect tooth con tact pattern...

Page 172: ...N AND MAKE ANY NECESSARY CORRECTIONS CORRECTION NONE SERVICE HINTS PATTERNS THAT MAY VARY MAY BE CAUSED BY LOOSE BEARINGS ON THE PINION OR THE DIFFERENTIAL CASE CHECK THESE BEARING PRELOAD SETTINGS TO...

Page 173: ...g Gear Bolts SPACER AND SHIM SPECIFICATIONS Spacer and Shim Sizes Pinion Bearing Shims N m Lbs Ft 30 22 27 20 183 135 35 26 88 65 163 120 Size 0 006 0 007 0 008 0 009 0 010 0 011 0 012 0 013 0 014 0 0...

Page 174: ...ange Remover 2 Side Bearing Remover 3 Rear Pinion Bearing Cup Installer 4 Driver Handle 5 Rear Pinion Bearing Cone Installer 6 Side Bearing Adjustment Spanner 7 Rear Pinion Bearing Cone Remover 8 Pini...

Page 175: ...ar Tooth Pattern Check 4B5 12 Adjustments Affecting Tooth Contact 4B5 12 Final Assembly 4B5 12 Specifications 4B5 14 Fastener Tightening Specifications 4B5 14 Ring Gear Bolts 4B5 14 Available Shim Siz...

Page 176: ...Pinion Flange Holder J 24385 01 Differential Housing Spreader J 29721 Differential Side Bearing Remover J 29721 70 Side Bearing Adapters C 4171 Universal Handle C 4307 Bearing Cup Remover Rear D 128 D...

Page 177: ...PRELOAD SHIMS 23 RING GEAR BOLT 7 BEARING 24 PINION GEAR 8 SLINGER 25 SIDE GEAR 9 PINION OIL SEAL 26 PINION THRUST WASHER 10 PINION FLANGE YOKE 27 SIDE GEAR THRUST WASHER 11 WASHER 28 PINION SHAFT 12...

Page 178: ...Figure 3 Spreading the Differential Case Figure 4 Removing the Differential...

Page 179: ...s left or right Check outboard spacers for damage e g bent or deep grooves caused by worn bearings If damaged they should be replaced with new ones at time of reassembly Note the ring gear fastener st...

Page 180: ...ts All parts should be disassembled before cleaning These parts should be cleaned in a suitable solvent Parts should be thoroughly dried immediately after cleaning Use soft clean lintless rags Parts m...

Page 181: ...ential without the thrust washers 26 A Install the pinion gears to the side gears so the holes in the pinion gears are 180 degrees apart B Rotate the pinion gears into place and verify that the pinion...

Page 182: ...side they were removed They must be reassembled as removed or the reading taken in step 7 will not be correct PINION DEPTH ADJUSTMENT Tools Required D 115 Dial Indicator D 115 3 Arbor D 116 1 Pinion...

Page 183: ...h 24 Tools Required J 5590 Rear Pinion Bearing Cone Installer J 7818 Front Pinion Bearing Cup Installer J 8092 Handle J 8614 01 Pinion Flange Remover D 128 Dial Indicator Set or Equivalent D 115 3 Arb...

Page 184: ...ue should be checked Figure 26 Installing Differential Bearings B Remove J 8614 01 Using an inch pound torque wrench check the pinion preload by rotating the pinion with the wrench figure 24 Preload s...

Page 185: ...er shims on the differential side bearing hub ring gear side and drive the differen tial bearing onto the hub using J 8092 and J 23690 figure 26 11 Place the proper shims on the differential side bear...

Page 186: ...e with a wrench until the ring gear rotates one full revolution then reverse the rotation until the ring gear rotates one revolution in the opposite direc tion 5 Observe the pattern on the ring gear t...

Page 187: ...ERN AND MAKE ANY NECESSARY CORRECTIONS CORRECTION NONE SERVICE HINTS PATTERNS THAT MAY VARY MAY BE CAUSED BY LOOSE BEARINGS ON THE PINION OR THE DIFFERENTIAL CASE CHECK THESE BEARING PRELOAD SETTINGS...

Page 188: ...5334mm 0 021 inch 0 5588mm 0 022 inch 0 5842mm 0 023 inch 0 762mm 0 030 inch Inner Pinion Bearing Shim 0 0762mm 0 003 inch 0 127mm 0 005 inch 0 254 mm 0 010 inch Inner Pinion Bearing Shim 0 005 inch...

Page 189: ...HEIGHT BLOCK MILLER 4 SCOOTER GAGE MILLER 5 MASTER DIFFERENTIAL BEARINGS MILLER 6 MASTER PINION BLOCK MILLER 7 CUP INSTALLER MILLER 8 HANDLE MILLER 9 DIFFERENTIAL SIDE BEARING REMOVAL PLUG 10 FRONT PI...

Page 190: ...NOTES...

Page 191: ...ssembly of the Differential 4B7 5 101 2 Inch Ring Gear 4B7 5 Disassembly of the Differential 4B7 5 Cleaning and Inspection 4B7 7 Cam Unit Assembly 4B7 7 Adjustment of the Differential 4B7 7 Assembly o...

Page 192: ...04r5914 Figure 1 Differential Components F4799 Figure 2 Removing the Governor Bushings 13 Left side gear 21 cam plate 16 and clutch plates 12 as an assembly cam unit 14 Side gear thrust washer 13 CAM...

Page 193: ...eve 14 using J 22910 01 Press the sleeve from the side gear figure 4 3 Clutch plates 12 4 Wave washer 15 5 Cam plate 16 6 Side cam gear 21 CLEANING AND INSPECTION Clean All parts with an approved solv...

Page 194: ...ress down the side gear and install the pinion shaft 18 and lock screw 3 If the side gear cannot be pressed down far enough to install the pinion shaft replace the side gear thrust washer with a thinn...

Page 195: ...thrust block must face the small window opening 7 Pinion shaft 18 8 A new lockscrew 3 Install finger tight Tighten to specifications after installed in the vehicle 9 Governor assembly 11 and latching...

Page 196: ...ew 38 Pinion Thrust Washer 44 Plates 33 Cam Plate 39 Pinion Gear 45 Side Gear Thrust Washer 34 Guide Clip 40 Side Cam Gear 46 Side Gear 35 Thrust Sleeve 41 Reaction Block 47 Guide Clip 36 Side Gear Th...

Page 197: ...d the overall length of the gear to the back of the thrust sleeve 35 including the side gear thrust washer 36 B Compare this reading with the reading obtained earlier C If the new reading is more than...

Page 198: ...o the differential 4 Clamp the side gear in place using a set of wash ers a nut and a bolt long enough to hold the side gear in place figure 13 5 Place the pinion gears and pinion thrust washers on th...

Page 199: ...Gear Backlash Adjustment in this section Some older locking differentials had select fit reaction blocks without the thrust washer between them These models require replac ing the reaction blocks wit...

Page 200: ...15 inch 0 027 nch 0 020 inch 0 032 nch 0 025 inch 0 036 nch 0 030 inch 0 040 nch 0 035 inch 0 042 nch 0 040 inch 0 044 nch 0 045 inch 0 048 0 052 nch nch REACTION BLOCK THRUST WASHERS 0 787 inch 0 022...

Page 201: ...SPECIAL TOOLS 1 fo f J J 22912 01 2 J 26252 1 Rear Pinion Bearing Cone Remover 2 Locking Differential Governor Remover F4804...

Page 202: ...NOTES...

Page 203: ...must be used when installing fasteners that require it If the above conditions are not followed parts or system damage could result CONTENTS SUBJECT PAGE General Description 4C1 2 Disassembly of The A...

Page 204: ...g a collapsible spacer between the pinion bearings in the axle housing The ring gear is bolted to the differential case with left hand thread bolts The differential case is supported in the axle housi...

Page 205: ...the case figure 6 17 Differential case 35 18 Bolts 18 and lock tabs 19 from the side bearing adjuster sleeves 32 figure 7 19 Bearing cups 33 and sleeves 32 from the case Turn the sleeves 32 using J 3...

Page 206: ...F5785...

Page 207: ...ing and Pinion Gears 52 Shaft 8 Retaining Ring 23 Output Shaft 38 Shim 53 Thrust Washer 9 Carrier Connector 24 Washer 39 Bearing 54 Side Gear 10 Shift Cable 25 Plug 40 Spacer 55 Thrust Washer 11 Shift...

Page 208: ...Carrier Case Halves 18 Bolt 29 Carrier Case 19 Lock Tab 32 Sleeve F1780 Figure 7 Removing the Lock Tabs 30 Bearing 32 Sleeve 30 J 21551 32 I _ F1782 Figure 9 Remove the Sleeve Bearing F5788 Figure 10...

Page 209: ...Figure 11 Remove the Pinion Flange F4696 F4759 Figure 14 Removing the Differential Side Bearing...

Page 210: ...rs are matched sets and both are replaced any time a replacement of either is necessary Inspect Pinion and ring gear teeth for cracking chipping scoring or excessive wear Pinion splines for wear Pinio...

Page 211: ...thrust washers 4 Shaft 52 and bolt 36 5 Ring gear 37 onto the differential case 35 NOTICE Refer to Notice on page 4C1 1 Install or Connect Figures 1 2 17 and 18 Tool Required J 33837 Pinion Bearing Re...

Page 212: ...B Button Moved Out of Bearing Bore F5791...

Page 213: ...t be of the proper size as select ed previously 2 Bearing 39 onto the pinion gear 37 using J 33785 figure 20 3 New spacer 40 onto the pinion gear 37 4 Bearing 41 into the case 5 Seal 42 into the case...

Page 214: ...s 28 to 50 N m 37 lbs ft ADJUSTING BACKLASH Tools Required Figures 1 and 2 J 33792 Side Bearing Adjuster Wrench J 8001 1 Dial Indicator Clamp 1 Tighten the right sleeve 32 to 140 N m 100 lbs ft using...

Page 215: ...or both With a pattern check the best contact between the ring gear and the drive pinion for low noise level and long life can be ensured GEAR TOOTH NOMENCLATURE The side of the ring gear tooth which...

Page 216: ...CT PATTERN AND MAKE ANY NECESSARY CORRECTIONS CORRECTION NONE SERVICE HINTS PATTERNS THAT MAY VARY MAY BE CAUSED BY LOOSE BEARINGS ON THE PINION OR THE DIFFERENTIAL CASE CHECK THESE BEARING PRELOAD SE...

Page 217: ...olts 28 2 Right carrier case half Clean Sealing surfaces on the carrier case halves Remove all oil and grease Use a chlorinated sol vent such as carburetor cleanej 4 Install or Connect Figures 1 2 29...

Page 218: ...with retainer ring 8 Tap into place A Remove all oil and grease from the tube and carrier gasket surfaces Use carburetor cleaner or equivalent Figure 33 Checking the Shift Mechanism B Apply sealer GM...

Page 219: ...seal 13 from C V joint race 18 at large diameter and slide seal away from joint along axle shaft 4 Wipe excess grease from face of C V inner race 18 5 Spread ears on race retaining ring 14 with J 8059...

Page 220: ...5 RETAINER NEEDLE 6 BALL TRI POT JOINT 7 ROLLER NEEDLE 8 RING SPACER 9 RING SWAGE 10 SEAL TRI POT JOINT 11 CLAMP SEAL RETAINING 12 SHAFT AXLE 13 SEAL C V JOINT 14 RING RACE RETAINING 15 BALL 16 RACE C...

Page 221: ...TEN NUT UNTIL RING BOTTOMS AGAINST SHOULDER OF OUTER RACE 20 C V Joint Outer Race 21 Deflector Ring A 3 Pipe Coupling B Sheet Steer 3mm Min Thickness With 28mm Drilled Hole C M24 x 2 0 Nut F7484 Figur...

Page 222: ...IS SEATED IN GROOVE ON AXLE SHAFT 13 Axle Shaft 20 C V Joint Outer Race F7486 Figure 39 Installing C V Joint to Axle MAKE SURE SWAGE RING AND SWAGE RING CLAMP ARE IN PROPER ALIGNMENT 15 A B C D E Swag...

Page 223: ...retaining ring side of inner race 16 faces axle shaft 12 3 Install outer joint seal Refer to Outer Joint Seal in this section Assemble Figures 34 43 and 44 Apply chassis grease to the ball grooves of...

Page 224: ...10 from tripot housing by separating at large diameter and sliding seal away from joint along axle shaft 5 Tripot housing from spider 3 and shaft 6 Spread spacer ring 8 with J 8059 and slide spac er...

Page 225: ...oove of axle shaft with J 8059 7 Slide tripot spider A towards end of shaft and reseat spacer ring 8 in groove on shaft figure 46 8 Place approximately half of grease provided in seal kit 10 and use r...

Page 226: ...nd Output Shaft Cover Bolts 25 18 Tube Attaching Bolts 48 35 AVAILABLE SHIM SIZES Pinion Shim Kits 0 53 0 64 mm 0 66 0 79 mm 0 81 0 94 mm PINION PRELOAD AND BACKLASH 1 7 2 8 N m 15 25 lbs in 0 08 0 25...

Page 227: ...ng Adjuster Wrench 8 Differential Side Bearing Installer 12 13 14 15 16 17 18 J 8614 01 J 33844 J 33893 J 29369 2 J 29307 J 33791 J 8001 5 J 25025 1 J 36652 9 Bearing Cup Installer 10 Pinion Bearing C...

Page 228: ...NOTES...

Page 229: ...nion and Ring Gear 4C2 3 Bearings 4C2 3 Shims Thrust Washers and Adjuster Sleeves 4C2 5 Shift Mechanism 4C2 5 Actuator Check 4C2 5 Assembly of the Axle 4C2 10 Pinion Bearing Cup Installation 4C2 10 Pi...

Page 230: ...xle problem It will also help when setting up the shim packs for locating and preloading the differential case 3 Inspect the case for metal chips Determine where the metal chips came from such as a br...

Page 231: ...o not allow the bearings to spin while drying them with com pressed air INSPECTION It is very important to carefully and thoroughly inspect all drive unit parts before assembly Thorough inspection of...

Page 232: ......

Page 233: ...rom the power source The plunger should retract within several seconds If the actuator does not operate as specified it should be replaced 1 Right Output Shaft 2 Deflector 3 Seal 4 Output Shaft Bearin...

Page 234: ......

Page 235: ...26 Washer 27 Pin 28 Bolt 29 Carrier Case 30 Differential Case Bearing 31 Insert 32 Sleeve 33 Side Bearing 34 Ring Gear Bolt 35 Differential Case 36 Pin 37 Ring and Pinion Gears 38 Pinion Shim 39 Pini...

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 238: ...he forcing screw until the installer is snug against the bearing cup F Rotate the tool several times to make sure the bearing cup is not cocked in the bore Pull the bearing cup into place with the for...

Page 239: ...Bearing Installer K1 2 Models J 36614 Bearing Installer K3 Models J 8614 01 Pinion Flange Remover J 36333 Seal Installer J 36598 3 K15 25 J 36598 4 K35 39 Bearinq Cup F5868 Figure 21 Installing the In...

Page 240: ...601 4 K15 25 J 36601 3 K35 A Button Located In Bore B Bearing Swung Out of Bore C Nut D Washer E Pilot F Flats 39 Bearing Inner Pinion 41 Bearing Outer Pinion J 21777 35 K15 25 J 21777 8 K35 J 29763 F...

Page 241: ...pinion gear 56 between the side gears making sure the hole in both pinion gears line up 3 Thrust washers 55 Rotate the pinion gears toward the opening just enough to permit the sliding in of the thrus...

Page 242: ...5 Differential assembly to the carrier case half Place the differential assembly into the carrier case half which contains the pinion gear Turn the left sleeve 32 K1 2 models or adjuster plug 61 K3 m...

Page 243: ...tion of 0 13 0 18 mm 0 005 0 007 inch If the backlash is incorrect adjust the sleeves as necessary Always maintain the one notch preload on the side bearings Example If it is necessary to turn the RIG...

Page 244: ...identical amount To decrease backlash turn the right sleeve in and turn the left sleeve out an identical amount It is important that the contact pattern be centrally located up and down on the face o...

Page 245: ...HE TOOTH CONTACT PATTERN AND MAKE ANY NECESSARY CORRECTIONS CORRECTION NONE SERVICE HINTS PATTERNS THAT MAY VARY MAY BE CAUSED BY LOOSE BEARINGS ON THE PINION OR THE DIFFERENTIAL CASE CHECK THESE BEAR...

Page 246: ...e available in the following sizes K1 2 models 1 27 mm 1 78 mm 2 29 mm 2 70 mm 3 30 mm 3 81 mm K3 models 1 80 mm 2 30 mm 2 80 mm 3 30 mm 3 80 mm 4 30 mm 4 80 mm Alternate Method Use only if proper too...

Page 247: ...C Measure with Axle Shaft Forced Outboard 1 Shaft 5 Tube 9 Carrier Connector 23 Output Shaft 29 Carrier Case F5877...

Page 248: ...m Size Install or Connect Figures 1 through 4 NOTICE For steps 6 7 8 and 10 refer to Notice on page 4C2 1 I S him 20 as selected previously to the output shaft 23 Use grease to hold it in place 2 Slee...

Page 249: ...39245 1 Sensor Ring Installer J 39245 2 Sensor Ring Spacer K1 K2 1 Deflector ring 20 from C V outer race 18 and discard 2 Sensor ring 19 with a drift figure 43 4 Install or Connect 1 Light film of oil...

Page 250: ...5 RETAINER NEEDLE 6 BALL TRI POT JOINT 7 ROLLER NEEDLE 8 RING SPACER 9 RING SWAGE 10 SEAL TRI POT JOINT 11 CLAMP SEAL RETAINING 12 SHAFT AXLE 13 SEAL C V JOINT 14 RING RACE RETAINING 15 BALL 16 RACE C...

Page 251: ...TIGHTEN NUT UNTIL RING BOTTOMS AGAINST SHOULDER OF OUTER RACE 18 C V Joint Outer Race 19 Deflector Ring F6723 Figure 42 Installing Outer Deflector Ring PUSH C V JOINT ASSEMBLY ONTO AXLE SHAFT UNTIL R...

Page 252: ...pe the seal by hand and remove the tool D Refer to the chart in figure 46 and select the correct size swage clamp tool J 36652 E Mount the proper size swage clamp tool in the vise and proceed as follo...

Page 253: ...with a brass drift to tilt it enough to install the balls figure 48 B Pack the joint with chassis grease V Important PIVOT CAGE AND INNER RACE AT 90 TO CENTER LINE OF OUTER RACE WITH CAGE WINDOWS ALI...

Page 254: ...d the second groove as shown figure 52 Slide the tripot spider assembly against the spacer ring 8 and the shaft 12 Important Be sure that the counterbored face of the tripot spider 3 faces the end of...

Page 255: ...t in figure 47 and select the proper size swage clamp tool J 36652 11 Mount the swage clamp tool in the vise and pro ceed as follows A Position the inboard end of the axle assembly in the tool B Place...

Page 256: ...0 029 inch 0 030 0 034 inch 0 035 0 039 inch K35 Models 0 508 0 5842 mm 0 6096 0 7112 mm 0 7366 0 8382 mm 0 8386 0 9398 mm Output Shaft Shims K15 25 Models 1 27 1 78 2 29 2 70 3 30 3 81 mm K35 Models...

Page 257: ...lot K35 7 Pinion Bearing Remover K15 25 Models 8 Pinion Bearing Remover K35 Models 9 Pinion Flange Remover 10 Case Bushing Replacer 11 Differential Side Bearing Installer K15 25 Models 12 Differential...

Page 258: ...er K35 Models 21 Pinion Seal Installer 22 Axle Seal Installer K15 25 Models 23 Axle Seal Installer K35 Models 24 Holding Fixture and Pinion Service Tool 25 Dial Indicator Adapter 26 Side Bearing Adjus...

Page 259: ...le 4C3 2 Inspection 4C3 2 Disassembly 4C3 2 Cleaning 4C3 4 Inspection 4C3 4 Axle Housing 4C3 4 Differential 4C3 5 Ring and Pinion Gears 4C3 5 Bearings 4C3 5 Thrust Washers Shims and Adjuster Sleeves 4...

Page 260: ...e cause of the axle problem It will also help when setting up the shim packs for locat ing and preloading the differential case 3 Inspect the case and oil for metal chips Determine where the metal chi...

Page 261: ...F7475...

Page 262: ...al case 35 23 Differential pinion gears 56 and thrust washers 55 24 Side gears 54 and thrust washers 53 Mark the side gears and case so they can be reinstalled in their original location 25 Bolts 34 2...

Page 263: ...ION GEARS Ring and pinion gears are matched sets and both are replaced any time a replacement of either is necessary 30 Bearing 32 Sleeve F1782 L Figure 8 Removing the Sleeve Bearing Inspect Ring and...

Page 264: ...tches and pits on the rollers and the bearing cups from the initial preload Do not replace a bearing for this reason THRUST WASHERS SHIMS AND ADJUSTER SLEEVES L Inspect Shims and thrust washers for cr...

Page 265: ...faces with axle lubricant prior to assem bly DIFFERENTIAL CASE ASSEMBLY 44 Install or Connect Figures 1 2 and 15 Tool Required J 33790 Side Bearing Installer 1 Thrust washers 53 and side gears 54 into...

Page 266: ...ld the pinion bearings in position and install J 33838 and J 29763 figure 18 Set the dial indi cator at ZERO then position the indicator in J 33838 Push the dial indicator downward until the needle ro...

Page 267: ...B Button Moved Out of Bearing Bore F5791...

Page 268: ...rotate the pin ion several times to make sure that the bearings have seated Recheck the preload and adjust if necessary DIFFERENTIAL CASE INSTALLATION H Install or Connect Figures 1 2 and 22 through 2...

Page 269: ...should be the same at each point within 0 05 mm 0 002 inch If the backlash J 33788 F1791 Figure 22 Installing the Sleeve Bearing varies more than 0 05 mm 0 002 inch check for burrs a distorted case f...

Page 270: ...essive turning of the ring gear is not recommended 4 Observe the pattern on the ring gear teeth and compare with figure 28 ADJUSTMENTS AFFECTING TOOTH CONTACT Two adjustments can be made which will af...

Page 271: ...THE TOOTH CONTACT PATTERN AND MAKE ANY NECESSARY CORRECTIONS CORRECTION NONE SERVICE HINTS PATTERNS THAT MAY VARY MAY BE CAUSED BY LOOSE BEARINGS ON THE PINION OR THE DIFFERENTIAL CASE CHECK THESE BEA...

Page 272: ...5 N m 18 lbs ft 8 Shaft 59 with deflector 2 Tap into place Bolts to 48 N m 35 lbs ft 13 Shaft 1 Tap into place with a soft faced hammer 14 Bushings 48 Use J 33791 figure 14 DRIVE AXLE ASSEMBLY OUTER D...

Page 273: ...5 RETAINER NEEDLE 6 BALL TRI POT JOINT 7 ROLLER NEEDLE 8 RING SPACER 9 RING SWAGE 10 SEAL TRI POT JOINT 11 CLAMP SEAL RETAINING 12 SHAFT AXLE 13 SEAL C V JOINT 14 RING RACE RETAINING 15 BALL 16 RACE C...

Page 274: ...t shoulder of C V outer race 18 figure 32 OUTER JOINT SEAL Remove or Disconnect Figures 30 and 34 4 Tools Required J 8059 Snap Ring Pliers J 35910 Seal Clamp Tool J 37652 Swage Clamp Tool 1 Large swag...

Page 275: ...ip in housing groove Important Seal 13 must not be dimpled stretched or out of shape in any way If seal is not shaped cor rectly carefully insert a thin flat blunt tool no sharp edges between large se...

Page 276: ...IRST BALL REMOVE OTHER BALLS IN SIMILAR MANNER 17 Ball 18 C V Joint Inner Race 19 C V Joint Cage 20 C V Joint Outer Race A Hammer B Brass Drift F7489 PIVOT CAGE AND INNER RACE AT 90 TO CENTER LINE OF...

Page 277: ...to install the balls B Pack the joint with chassis grease Important Be sure that retaining ring side of inner race 16 faces axle shaft 12 figure 30 3 Install outer joint seal Refer to Outer Joint Seal...

Page 278: ...on shaft Important Be sure that counterbore face of tripot spider 3 faces end of shaft 6 Install shaft retaining ring 2 in groove of axle shaft with J 8059 7 Slide tripot spider A towards end of shaft...

Page 279: ...Hand Output Shaft Cover Bolts 25 18 Tube Attaching Bolts 48 35 AVAILABLE SHIM SIZES Pinion Shim Kits 0 53 0 64 mm 0 66 0 79 mm 0 81 0 94 mm PINION PRELOAD AND BACKLASH 1 7 2 8 N m 15 25 lbs in 0 08 0...

Page 280: ...763 J 33782 J 33785 J 33788 J 33790 J 33792 J 22912 01 J 23423 A 12 13 15 16 17 18 14 S J 8614 01 J 33844 J 33893 J 29369 2 J 29307 J 33791 J 8001 3 J 25025 1 J 36652 9 Bearing Cup Installer 10 Pinion...

Page 281: ...CE Do not hone the master cylinder bore When the brake master cylinder is overhauled it is recommended that the cylinder body be replaced rather than cleaned up by honing the bore The master cylinder...

Page 282: ...first digit indicates the plant where it was built The second digit digit shows the year it was built 1 means 1991 a 2 means 1992 etc The last digits show the day it was built Example 271 means it was...

Page 283: ...ome out of the bore with considerable force and cause personal injury 7 Secondary piston 9 With the rear port plugged apply a small amount of air pressure to the front port 8 Seals 8 and 10 9 Spring r...

Page 284: ...nents 5 Snap ring 11 The primary piston must be compressed when installing the snap ring 6 Grommets 4 7 Reservoir 3 figures 4 or 5 Press on the body while using a rocking motion 8 Diaphragm 2 in cover...

Page 285: ...ston 28 5 Primary piston assembly 30 6 Snap ring 31 The primary piston must be compressed to install the snap ring 7 Diaphragm 23 in cover 22 8 Cover 22 9 Tube seats if removed Seat the tube seats wit...

Page 286: ...fluid 1 Secondary spring 48 2 Secondary piston assembly 49 3 Piston return spring 50 4 Primary piston assembly 51 and snap ring 52 The primary piston must be depressed to install the snap ring 5 O ri...

Page 287: ...lows air at atmospheric pressure to enter one side of the diaphragm s This pressure difference pro vides the power assist Delco Moraine NDH vacuum boosters have a build date on a small paper label glu...

Page 288: ...t All parts for corrosion nicks cracks cuts scoring distortion or excessive wear Replace as needed Use crocus cloth to polish away minor corrosion of the housings or diaphragm support XJS jl Clean All...

Page 289: ...0 6 Reaction body retainer 25 7 Power piston bearing 6 in rear housing 8 Lubricate inside and outside of bearing with Delco Silicone Lube GM P N 18010909 or equivalent 9 Power piston group in rear hou...

Page 290: ...ary support plate 17 from housing divider 19 12 Primary diaphragm 16 from the primary support plate 17 13 Secondary diaphragm 20 and secondary support plate 21 from housing divider 19 12 Piston Rod Ga...

Page 291: ...rotector 1 Lubricate O ring 31 with a thin layer of Delco Silicone Lube GM P N 18010909 or equivalent and install on air valve pushrod assembly 32 2 Air valve pushrod assembly 32 in power piston 33 3...

Page 292: ...rimary diaphragm 16 lip with a thin layer of Delco Silicone Lube GM P N 18010909 or equivalent 16 Primary diaphragm 16 into the primary support plate 17 figure 11 Fold primary diaphragm 16 up and away...

Page 293: ...r equiva lent 26 Grommet 4 and vacuum check valve 3 27 Front housing seal 7 28 Silencer 2 and boot 1 GAGING PROCEDURE Tool Required J 37839 Push Rod Height Gage Gage the piston rod using J 37839 figur...

Page 294: ...NOTES...

Page 295: ...located on the left front cowl and near the inlet valve UNIT REPAIR BOOSTER ASSEMBLY CAUTION The accumulator contains com pressed gas Always use the proper tools and follow the recommended procedures...

Page 296: ...pring F0763 Figure 2 Removing the Accumulator 23 Return line fitting 12 and seal 10 lQg Clean All parts with power steering fluid Spool valve and spool valve bore for corrosion nicks and scoring Disco...

Page 297: ...Seal 10 and return line fitting 12 3 Accumulator valve 11 4 Spool valve 13 5 Seal 23 and piston assembly 22 figure 7 Lubricate J 24551 A or J 25083 with clean pow er steering fluid Use the proper tool...

Page 298: ...lease C clamp F Remove J 26889 17 Jam nut from repair kit on pedal rod 20 18 Eyelet on pedal rod 20 GAGING PROCEDURE Tool Required J 37839 Push Rod Height Gage 1 Gage the piston rod using J 37839 figu...

Page 299: ...SPECIAL TOOLS 1 POWER BRAKE PUSH ROD HEIGHT GAGE 2 PISTON SEAL PROTECTOR 3 PISTON SEAL PROTECTOR 4 ACCUMULATOR PISTON COMPRESSOR 5 VALVE CONNECTOR SEAL INSTALLER F9233...

Page 300: ...NOTES...

Page 301: ...used Fasteners that are not reused and those requiring thread locking compound will be called out The correct torque value must be used when installing fasteners that require it If the above condition...

Page 302: ...erstood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure This is considered standard shop practice even if not specifically stated USE OF RTV...

Page 303: ...equivalent If one or more cylinder bores are rough scored or worn beyond limits it will be necessary to smooth or true up such bores to fit new pistons No attempt should be made to cut down oversize...

Page 304: ...aper or wear they should be bored and honed to the smallest oversize that will permit complete resurfacing of all cylinders 4 Fine vertical scratches made by ring ends will not by themselves cause exc...

Page 305: ...ded particles and torn or folded metal 6 By measuring the piston to be installed at the siz ing point specified in the proper section and adding the average of the clearance specification the finish h...

Page 306: ...ng wear etc Ring grooves for burrs nicks etc Skirts and pin bosses for cracking Skirts for scuffing Connecting rod bearing inserts for scratches or deep pitting MEASURING PISTON PIN TO PISTON CLEARANC...

Page 307: ...s fitted ASSEMBLY Assembling the Piston and Connecting Rod Assemble Figure 11 Tool Required J 24086 B Piston Pin Remover and Installer Set 1 Piston and connecting rod A The piston and connecting rod m...

Page 308: ...fications in the proper section for correct gap 5 If the gap between the ends of the ring is not as specified remove the ring and try another for fit Inspect Figure 13 B4979 Figure 12 Measuring the Ri...

Page 309: ...ring Remover Installer A BEARING TOOL C NUT B PILOT D PULLER SCREW J 6098 01 B5276 1 Rear camshaft plug or cap 2 Inner camshaft bearings Use J 6098 01 figure 15 A Insert the pilot into the front camsh...

Page 310: ...ler screw with a wrench turn the nut with a second wrench to pull the camshaft bearing into place F Remove the puller screw pilot and bearing tool Important Make sure the camshaft bearing hole or hole...

Page 311: ...EAD L DISASSEMBLY Disassemble Valves and components Refer to the proper sec tion CLEANING AND INSPECTION I Clean Figures 19 and 20 Tools Required J 8089 Wire Brush J 8101 Valve Guide Cleaning Tool Car...

Page 312: ...nt of the valve stem from side to side crosswise to the head will cause a direct movement of the indicator stem The indicator stem must contact the side of the valve stem just above the valve guide bo...

Page 313: ...tial that valve guide bores be free from carbon or dirt to ensure proper centering of the pilot in the guide Refer to Specifications in the proper section for valve seat angle specifications NOTICE Va...

Page 314: ...RT m Measure Figure 27 Refer to the proper section for additional informa tion 1 Main bearing inserts and crankshaft as outlined in the proper section 2 Gaging plastic A Begin with the rear main beari...

Page 315: ...ay to measure con necting rod bearing clearance is with the use of gaging plastic This wax like material compresses evenly between the bearing and journal surfaces without dam aging them Proceed as fo...

Page 316: ...urpose thread repair kits are available commercially CAUTION Wear safety glasses to avoid eye damage 1 Determine size pitch and depth of damaged thread If necessary adjust stop collars on cutting tool...

Page 317: ...BRUSH 6 VALVE GUIDE CLEANING TOOL 7 DIAL INDICATOR 8 VALVE SPRING TESTER 9 VALVE GUIDE REAMER SET ALL ENGINES EXC 7 4L CONSISTS OF J 5830 1 0 08mm 0 003 INCH OVERSIZE J 5830 2 0 38mm 0 015 INCH OVERSI...

Page 318: ...NOTES...

Page 319: ...Shop Equipment 6A2 3 Accessory Removal 6A2 3 Cleaning 6A2 3 Draining the Engine 6A2 3 Oil Fill Tube Removal 6A2 9 Oil Filter Connector and By pass Valve Removal 6A2 9 Intake Manifold Removal 6A2 9 Exh...

Page 320: ...2 40 Start up Procedures 6A2 40 Specifications 6A2 41 Fastener Tightening Specifications 6A2 41 Special Sealers Adhesives Thread Lockers and Lubricants 6A2 41 Engine Specifications 6A2 43 Special Tool...

Page 321: ...rings by means of intersecting passages drilled in the crankshaft DISASSEMBLY OF ENGINE TOOLS AND SHOP EQUIPMENT A clean well lit work area should be available Other necessary aides include a suitable...

Page 322: ...SR207LN2 EDS...

Page 323: ...CRANKSHAFT BEARING 83 TENSIONER TIMING CHAIN 20 GASKET CAMSHAFT REAR CAP 84 BOLT CAMSHAFT SPROCKET COVER 52 CAP MAIN BEARING 85 WASHER CAMSHAFT SPOCKET 23 INLET COOLANT 53 SEALANT 86 SPROCKET CAMSHAFT...

Page 324: ......

Page 325: ...IL 61 BOLT CYLINDER HEAD 28 SEAT VALVE SPRING 62 TENSIONER SERPENTINE 29 STUD VALVE ROCKER ARM DRIVE BELT 30 GUIDE PUSH ROD 70 BOLT ACCELERATOR CABLE 31 GASKET COOLANT OUTLET BRACKET ADAPTER 71 NUT AC...

Page 326: ...OVERHEAD OILING AND RETURN MAIN OIL GALLERY N30005 6A2 J EDS...

Page 327: ...EGR solenoid valve 2 Accelerator and T V cable bracket 3 Upper intake manifold assembly 4 EGR valve injector 5 Fuel injector retainer bracket regulator and injectors 6 Intake manifold nuts 7 Lower int...

Page 328: ...Crankshaft pulley to hub bolt 3 Remove pulley CRANKSHAFT PULLEY HUB REMOVAL Figure 11 Tools Required J 24420 B Crankshaft Pulley Hub Puller 0Remove or Disconnect 1 Install Tool J 24420 B on hub turn p...

Page 329: ...2LN2 EDS Figure 9 Coolant Outlet Thermostat and Adapter 1 BOLT 25 N m 18 LBS FT L39100 68 J EDS Figure 10 Coolant Pump and Coolant Inlet Clean Sealing surface on block and crankcase front cover CRANKC...

Page 330: ...ean Dirt from around mating area of cover E3Remove or Disconnect 1 Crankcase vent valve from cover by unscrewing retainer 2 Rocker arm cover bolts 3 Rocker arm cover 1 BOLT 2 SPROCKET CAMSHAFT 3 BOLT...

Page 331: ...MOVAL Figure 54 B Remove or Disconnect 1 Oil pan bolts and nuts NOTICE Do not pry on oil pan when separating oil pan from block or damage to the oil pan will occur 1 BOLT 2 ROCKER COVER 3 GASKET 4 ROC...

Page 332: ...travel this ridge must be removed with a ridge reamer before removing piston and connecting rod assembly 4 Connecting rod cap 1 BRACKET 2 BOLT 3 OIL PUMP DRIVE ASSEMBLY 4 O RING 5 SHAFT 6 RETAINER HEA...

Page 333: ...well as various bristle brushes and gasket scrapers A source of compressed air will also be helpful in the cleaning operations Special tools are listed and illustrated throughout this section with a...

Page 334: ...nstalled correctly with the arrows pointing toward the front of the engine Measure m 1 Bearing bores with a bore gage measure concentricity and alignment refer to Figure 21 If outside specification re...

Page 335: ...assemble Tool required J 24086 B Piston Pin Remover Installer set CAUTION Use care when handling the piston Worn piston rings are sharp and may cause bodily injury 1 Piston rings Use a suitable tool t...

Page 336: ...to cylinder bore clearance as follows a Measure the cylinder bore diameter using J 8087 or equivalent refer to Figures 24 and 25 b Measure the piston diameter refer to Figure 24 c Subtract piston dia...

Page 337: ...oove although high spots in the ring groove may be cleaned up by careful use of a point file CONNECTING ROD AND PISTON ASSEMBLY Tool Required J 24086 B Piston Pin Remover Installer The piston must be...

Page 338: ...RANCE m Measure Bearing clearance To determine the correct replacement insert size the bearing clearance must be measured accurately Either of the following two methods may be used however method A gi...

Page 339: ...E Bearing inserts must not be shimmed scraped or filed Do not touch the bearing surface of the insert with the bare fingers Skin oil and acids will each the bearing surface 6 Remove all traces of the...

Page 340: ...V blocks instead 3 Install J 8520 and measure the cam lift refer to Figure 32 If any cam lift is out of specification replace the camshaft 4 Bearing journals With a micrometer measure run out and diam...

Page 341: ...and cylinder head EGR passage of excessive carbon deposits Inspect Manifold for cracks broken flanges and gasket surface damage EXHAUST MANIFOLD Clean Mating surfaces at cylinder head and exhaust man...

Page 342: ...remove all varnish soot and carbon DO NOT use a motorized wire brush Valve guides refer to Figure 36 Threaded holes Remains of sealer from plug holes Inspect 1 Cylinder head bolts for damaged threads...

Page 343: ...nd Figure 38 for reamer selection and usage NOTICE Avoid breaking reamer flutes or jamming the reamer into the valve guide due to packing of chips or carbon Clean the valve guides before reaming VALVE...

Page 344: ...uides in this section VALVE SEAT SERVICE Important Valve guides must be reconditioned prior to servicing valve seats Refer to Valve Guide Service in this section If the seats are reconditioned the val...

Page 345: ...ning It will take a few seconds for the lifter to fill after the engine is started 2 Intermittently noisy on idle only disappearing when engine speed is increased Intermittent clicking may be an indic...

Page 346: ...r end of pushrod Excessive wear of the spherical surface indicates one of the following conditions a Improper hardness of the pushrod ball The pushrod and rocker arm must be replaced b Improper lubric...

Page 347: ...Scoring Sticking Burrs may be removed with a fine oil stone Pressure regulator valve spring for Loss of tension Bending If in doubt replace the spring Suction pipe and screen assembly for Looseness If...

Page 348: ...ith petroleum jelly and reassemble Running the engine without measurable oil pressure will cause extensive damage 2 Start engine and observe oil pressure THREAD REPAIR Figure 46 Damaged threads may be...

Page 349: ...Main bearings 2 Lubricate main bearings and journals with engine oil 3 Crankshaft 4 Main bearing caps 5 Lubricate main bearing cap bolts NOTICE Refer to Notice on page 6A2 1 6 Main bearing cap bolts 7...

Page 350: ...Install or Connect 9 Important Old thread adhesive must be thoroughly removed from the flywheel bolts and bolt holes NOTICE Refer to Notice on page 6A2 1 1 Apply Loctite 271 GM P N 1052624 or equivale...

Page 351: ...ine NOTICE Guide the lower connecting rod end carefully to avoid damaging the crankshaft journal while tapping the piston into the cylinder 6 Remove thread protectors 7 Bearing inserts to clean and dr...

Page 352: ...ide clearance refer to Figure 52 and Engine Specifications in this section OIL PUMP DRIVE INSTALLATION Figure 17 Install or Connect 1 Oil pump drive by twisting NOTICE Refer to Notice on page 6A2 1 2...

Page 353: ...arallel to the anti rotation bracket the roller at the bottom of each lifter is parallel to the camshaft Refer to Figure 16 2 Anti rotation bracket s to lifter s and block observing Step 1 NOTICE Refe...

Page 354: ...nd 15 Install or Connect 1 Gasket NOTICE Refer to Notice on page 6A2 1 2 Rocker cover Tighten Cylinder Head CRANKSHAFT SPROCKET INSTALLATION Tools Required J 5590 Crankshaft Sprocket Installer M Insta...

Page 355: ...rea with engine oil 2 Apply RTV sealer GM P N 1052917 or equivalent to keyway in crankshaft 3 Place crankshaft pulley hub in position over key on crankshaft 4 Crankshaft pulley hub as follows Install...

Page 356: ...page 6A2 1 2 Coolant outlet adapter to cylinder head bolts Bolts to 11 N m 97 lbs in 3 Thermostat 4 Coolant outlet and new gasket 5 Coolant outlet to adapter nuts Tighten Nuts to 10 N m 89 lbs in EXHA...

Page 357: ...L BLOCK ASM CYLINDER SR204LN2 EDS Nuts in sequence to 33 N m 24 lbs ft refer to Figure 57 3 Fuel injectors regulator and injector retainer bracket Bolts to 3 5 N m 31 lbs in 4 EGR valve injector so th...

Page 358: ...stalling it in the vehicle If a suitable test stand is not available the following procedure can be used after the engine has been installed 1 Fill the crankcase with the proper quantity and grade of...

Page 359: ...el Bolts Automatic 75 N m 55 lbs ft Flywheel bolts Manual 75 N m 55 lbs ft Intake Lower Manifold Nuts 33 N m 24 lbs ft Intake Upper Manifold Bolts 30 N m 22 lbs ft Knock Sensor 19 N m 14 lbs ft MAP Se...

Page 360: ...ricant GM P N 1052367 Pan Oil to front cover RTV Sealer GM P N 1052914 Plug Camshaft Sealer GM P N 1052914 Plugs Cooling Jacket Sealer GM P N 1050026 Threads Rocker arm and ball Dri Slide Moly lubrica...

Page 361: ...0019 0 0082 PISTON PIN Diameter 20 320 20 325 0 8000 0 8002 Fit in Piston 0 010 0 022 0 0004 0 0009 Press Fit in Rod 0 025 0 045 0 00098 0 0017 CAMSHAFT Lift In 6 60 0 259 Ex 6 35 0 250 Journal Diame...

Page 362: ...Spring Free Length 48 1 89 Load Closed 350 380 N 41 58 mm 79 85 lbs 1 637 in Open 956 1036 N 31 67 225 233 lbs 1 247 in OIL PUMP Pressure 3000 rpm 65 C 150 F 384 kPa 56 psi Gear Lash 0 094 0 195 0 004...

Page 363: ...NER 7 J 8520 CAMSHAFT LOBE LIFT INDICATOR 8 J 9666 VALVE SPRING TESTER 9 J 22888 20 TIMING GEAR PULLER 10 J 23590 SPARK PLUG PORT ADAPTER 11 J 23600 B BELT TENSION G A G E 12 J 24086 B PISTON PIN REMO...

Page 364: ...ERING TOOL 3 J 35953 SUPPORT FOOT 4 J 36295 ENGINE TRANSAXLE FRAME HANDLER 5 J 36660 TORQUE ANGLE METER 6A J 38847 VALVE GUIDE REAMER FOR 0 075 mm O S VALVE 6B J 38848 VALVE GUIDE REAMER FOR 0 150 mm...

Page 365: ...S haft 6A3 3 Valve Train 6A3 3 Intake Manifold 6A3 3 Engine Lubrication 6A3 3 Disassembly of the Engine 6A3 14 Tools and Shop Equipment 6A3 14 Accessory Removal 6A3 14 Cleaning 6A3 14 Draining the En...

Page 366: ...iner Installation 6A3 29 Crankshaft Rear Oil Seal Installation 6A3 29 Balance Shaft Installation 6A3 30 Camshaft Timing Chain and Sprocket Installation 6A3 30 Front Cover Installation 6A3 30 Torsional...

Page 367: ...as the connecting rod travels from one side of the piston to the other side after a stroke The pins are a press fit in the connecting rod and a floating fit in the piston BALANCE SHAFT S T Vehicles an...

Page 368: ...103 153 127 V1200...

Page 369: ...Plug 117 Clutch Driven Plate 118 Spring Lock Washer 119 Clutch Cover Bolt 120 Clutch Pressure Plate Cover 121 Dowel Pin 122 Retainer 123 Oil Pump Bolt 124 Spring Stop Plug 125 Nut 126 Gasket 127 Oil...

Page 370: ......

Page 371: ...Bolt 171 Oil Pressure Sensor 41 Lifter Restrictor Retainer 172 Oil Pressure Fitting 42 Rocker Arm Nut 173 E G R Valve Gasket 43 Rocker Arm Ball 174 E G R Valve 44 Rocker Arm 175 Bolt 45 Push Rod 176 I...

Page 372: ......

Page 373: ...3 BOLT 195 NUT CAMSHAFT SPROCKET 94 FITTING 196 STUD CAMSHAFT SPROCKET 100 CAP MAIN BEARING 207 PLUG HEX 101 CRANKSHAFT 208 SEAL BALANCE SHAFT REAR BEARING PLUG 102 FILTER OIL 209 PLUG EXPANSION CUP 1...

Page 374: ...F9375 Figure 7 Engine Lubrication Diagram Engines Without Balance Shaft...

Page 375: ...Front View Rear View Showing Path Of Oil To Timing Chain Showing Main Gallery Oil Filter And Crankshaft Oil Feed V0575...

Page 376: ...Figure 9 Engine Lubrication Diagram Engines With Balance Shaft...

Page 377: ...HOWN IN OPEN POSITION B SUCTION C OIL PRESSURE SWITCH D VALVE LIFTER GALLERY E MAIN OIL GALLERY F BYPASS VALVE FRONT VIEW SHOWING PATH OF OIL TO TIMING CHAIN REAR VIEW SHOWING MAIN GALLERY OIL FILTER...

Page 378: ...e removing accessories CLEANING Remove the engine accessories before cleaning to provide better access to the engines exterior surfaces After removing the TBI unit distributor etc cover the openings w...

Page 379: ...heads 4 Head gaskets TORSIONAL DAMPER REMOVAL NOTICE The inertial weight section of the torsional damper is assembled to the hub with a rubber sleeve The removal proce dures must be followed with the...

Page 380: ...amshaft s threaded holes Use these bolts to handle the camshaft figure 16 B Use care to prevent damage to the camshaft bearings C Pull the camshaft out from the block BALANCE SHAFT REMOVAL For 4 3L en...

Page 381: ...cation marks Mark the parts if required Marking them from the front to the rear with the engine in an upright position and viewed from the front The right bank is numbered 1 3 5 The left bank is numbe...

Page 382: ...guide rod of J 5239 to push the connecting rod and piston out of the bore through the top of the engine 6 Connecting rod bearings FLYWHEEL REMOVAL Remove or Disconnect 1 Flywheel bolts 2 Flywheel CRA...

Page 383: ...CRANKSHAFT REAR OIL SEAL RETAINER REMOVAL Remove or Disconnect Figure 21 1 Screws 80 and nuts 81 2 Seal retainer 82 3 Gasket 84 CRANKSHAFT REMOVAL Important Check the main bearing caps for location ma...

Page 384: ...ents These include micrometers torque wrenches feeler gages dial indica tor set etc The inspection work when performed with the proper methods and tools is most important The rebuilt engine cannot be...

Page 385: ...SSEMBLY Notice The connecting rod and cap need to be stored together as mating parts so they may be reassembled in the same position from which they were removed Refer to SECTION 6A and perform the fo...

Page 386: ...e Excessively worn sprockets will rapidly wear a new chain An excessively worn chain will rapidly wear a new set of sprockets CRANKSHAFT SPROCKET REPLACEMENT Remove or Disconnect Figure 27 Tool Requir...

Page 387: ...ining around the weep hole is normal Replace the coolant pump only if coolant is dripping from the weep hole while the engine is running or while the system is pressurized OIL PAN AND ROCKER ARM COVER...

Page 388: ...ng disassembly 6 Pump cover 5 NOTICE Refer to Notice on page 6A3 1 7 Screws 9 Tighten With the shaft extension 1 installed on the pump turn the drive shaft by hand to check for smooth operation NOTICE...

Page 389: ...e components figure 30 A Cap 21 20 Valve Keeper 21 Cap 22 Shield 23 O Ring Seal 24 Seal 25 Damper 26 Spring 27 Intake Valve 28 Rotator 29 Exhaust Valve B7609 B Shield 22 C Seal 24 D Damper 25 E Spring...

Page 390: ...stud J 5715 for 0 003 inch oversize studs J 6036 for 0 013 inch oversize studs 2 Lightly lubricate lower end press fit area of rocker arm stud with hypoid axle lubricant 3 Rocker arm stud A Use J 688...

Page 391: ...thick between the spring and cylinder head NEVER shim the spring so as to give an installed height under the specified amount THERMOSTAT AND COOLANT OUTLET til Remove or Disconnect 1 Bolts 2 Coolant...

Page 392: ...ective fitting of both rod and main bearing inserts is necessary in production to obtain close tolerances For this reason you may find one half of a standard insert with one half of a 0 001 inch under...

Page 393: ...ulty insert could cause a lack of clearance at the bearing Tighten A ll main bearing cap bolts to 100 N m 75 lbs ft CRANKSHAFT REAR OIL SEAL RETAINER INSTALLATION Clean Gasket surfaces on the block an...

Page 394: ...figure 41 Handle the camshaft carefully to prevent damage to the cam shaft bearings 3 Thrust plate 87 and screws 88 Tighten Screws 88 to 12 N m 105 lbs in 4 Camshaft sprocket and timing chain Importa...

Page 395: ...n page 6A3 1 5 Torsional damper bolt and washer Tighten PISTON AND CONNECTING ROD INSTALLATION CONNECTING ROD BEARING SELECTION Connecting rod bearings are of the precision insert type and do not use...

Page 396: ...the crankpin with J 5239 figure 46 Hold the ring compressor against the block until all rings have entered the cylinder bore F Remove J 5239 from the connecting rod bolts Important Each connecting ro...

Page 397: ...t Oil pump to main bearing cap bolt to 90 N m 65 lbs ft Install or Connect Figure 48 Apply PST sealant GM P N 1052080 or equivalent to the front cover to block joint and to the crank shaft rear retain...

Page 398: ...n Cylinder head bolts in three steps using the sequence shown in figure 49 A The first sequence to 34 N m 25 ft lbs B The second sequence to 61 N m 45 ft lbs C Final torque sequence to 90 N m 65 lbs f...

Page 399: ...V2974...

Page 400: ...he mark comes up to the timing tab the engine is in the number four firing position and should be turned over one more time to reach the number one position 2 With the engine in the number one firing...

Page 401: ...ifold 2 Heat shield NOTICE Refer to Notice on page 6A3 1 3 Exhaust manifold bolts washers and tab washers 1 Tighten A Bolts on center exhaust tube to 36 N m 26 lbs ft B Bolts on front and rear exhaust...

Page 402: ...ade of engine oil Important If a new camshaft or hydraulic lifters were installed add Engine Oil Supplement GM P N 1052367 or equivalent to the engine oil 3 Fill the cooling system with the proper qua...

Page 403: ...027 Maximum PISTON RING c Production Top 0 0012 0 0032 U M Groove 2nd P R Clearance Service Limit 0 0042 Maximum E c Production Top 0 010 0 020 S 2nd 0 010 0 025 1 O N Service Limit 0 035 Maximum Groo...

Page 404: ...roduction 0 0005 Round Service Limit 0 001 Maximum Rod Bearing Production 0 0013 0 0035 Clearance Service Limit 0 0030 Rod Side Clearance 0 006 0 014 CAMSHAFT Lobe Intake 0 234 Lift 0 002 Exhaust 0 25...

Page 405: ...alve Stud 15 11 Engine Block Drain Plug Exhaust Manifold Bolts 30 22 Center Two Bolts 36 26 All Other Bolts 28 20 Flywheel Bolts 100 74 Flywheel Housing Bolts 44 32 Front Cover Bolts 14 124 Hydraulic...

Page 406: ...NAL DAMPER REMOVER AND INSTALLER 2 VALVE SPRING COMPRESSOR 3 CRANKSHAFT SEAL INSTALLER 4 MAIN BEARING REPLACER 5 PISTON RING COMPRESSOR 6 GUIDE SET 7 VACUUM PUMP 8 STUD REMOVER 9 REAMER 0 003 INCH OVE...

Page 407: ...rain 6A4 3 Intake Manifolds 6A4 3 Engine Lubrication 6A4 8 Disassembly of the Engine 6A4 10 Tools and Shop Equipment 6A4 10 Accessory Removal 6A4 10 Cleaning 6A4 10 Draining the Engine 6A4 10 Exhaust...

Page 408: ...d Main Bearing Installation 6A4 27 Crankshaft Rear Oil Seal Retainer Installation 6A4 28 Crankshaft Rear Oil Seal Installation 6A4 28 Camshaft Installation 6A4 28 Balance Shaft Installation 6A4 29 Tim...

Page 409: ...reduce piston slap as the connecting rod travels from one side of the piston to the other side after a stroke The pins are a press fit in the connecting rod and a floating fit in the piston BALANCE S...

Page 410: ......

Page 411: ...ASKET 193 BEARING BALANCE SHAFT REAR 92 ADAPTER 194 PLUG CUP 93 BOLT 195 NUT CAMSHAFT SPROCKET 94 FITTING 196 STUD CAMSHAFT SPROCKET 100 CAP MAIN BEARING 207 PLUG HEX 101 CRANKSHAFT 208 SEAL BALANCE S...

Page 412: ...195 196 201 174 252 163 165 164 244 3706r3924...

Page 413: ...RACKET ENGINE LIFT FRONT 44 ARM VALVE ROCKER 206 MANIFOLD LOWER INTAKE 45 ROD VALVE PUSH 231 GROMMET CRANKCASE VENT VALVE 46 GUIDE VALVE LIFTER 232 VALVE CRANKCASE VENT 47 LIFTER VALVE 241 CAP OIL FIL...

Page 414: ...r In case of excessive oil pressure a bypass valve is provided Fil tered oil flows into the main gallery and then to the camshaft balance shaft rear bearing and crankshaft bearings The valve lifter oi...

Page 415: ...HOWN IN OPEN POSITION B SUCTION C OIL PRESSURE SWITCH D VALVE LIFTER GALLERY E MAIN OIL GALLERY F BYPASS VALVE FRONT VIEW SHOWING PATH OF OIL TO TIMING CHAIN REAR VIEW SHOWING MAIN GALLERY OIL FILTER...

Page 416: ...ams of emissions and vacuum hose routings wiring harness routing accessory drive belt layout etc should be found or made before removing accessories CLEANING Remove the engine accessories before clean...

Page 417: ...intake manifold 12 lift brackets 17 and gaskets 13 Do not disassemble the CPI unit It is only serviced as an assembly For information on the upper and lower intake manifold components refer to the Dr...

Page 418: ...STUD 6 COIL 7 SUPPORT 8 BOLT 9 THERMOSTAT 10 GASKET 11 OUTLET 12 LOWER INTAKE MANIFOLD 13 GASKET 14 BOLT 15 NUT 16 GASKET 17 LIFT BRACKET 18 UPPER INTAKE MANIFOLD 81 PLASTIC COVER 85 EGR VALVE 86 SUP...

Page 419: ...er sleeve The removal proce dures must be followed with the proper tools or movement of the inertial weight sec tion of the hub will destroy the tuning of the torsional damper and the engine timing re...

Page 420: ...chain free play If the timing chain 41 can be moved back and forth in excess of 16 mm 5 8 inch make a note that the timing chain 41 should be replaced during assembly 1 Camshaft sprocket bolts 39 and...

Page 421: ...he camshaft out from the block being care ful to prevent damage to the camshaft bearings The balance shaft with front bearing are serviced as an assembly Use only the correct tools for bearing and sha...

Page 422: ...ank is numbered 1 3 5 The left bank is numbered 2 4 6 3 Check the connecting rod and cap for identification marks Mark the parts Marking them from the front to the rear with the engine in an upright p...

Page 423: ...OVAL Remove or Disconnect Figure 20 1 Screws 50 and nuts 51 2 Seal retainer 52 3 Gasket 54 CRANKSHAFT REMOVAL The crankshaft need not be removed for replacement of rear oil seal or main bearings These...

Page 424: ...onents These include micrometers torque wrenches feeler gages dial indica tor set etc The inspection work when performed with the proper methods and tools is most important The rebuilt engine cannot b...

Page 425: ...larities may be carefully machined from the block 6 Oil pan timing cover and intake manifold mounting surfaces for nicks Minor irregularities may be cleaned up with a flat file CYLINDER BORE L Inspect...

Page 426: ...e same side when installed in the cylinder bore If a connecting rod is ever trans posed from block or cylinder to another new con necting rod bearings should be fitted and the connecting rod should be...

Page 427: ...r Excessively worn sprockets will rapidly wear a new chain Timing chain for damage An excessively worn chain will rapidly wear a new set of sprockets CRANKSHAFT SPROCKET REPLACEMENT Remove or Disconne...

Page 428: ...eep hole Slight staining around the weep hole is normal Only replace the pump if coolant is dripping from the weep hole while the engine is running or while the system is pressurized OIL PAN AND ROCKE...

Page 429: ...mp cover 2 Pressure regulator spring 60 into the pump cover 3 Plug 62 4 Retaining pin 59 into the pump cover 5 Drive gear and shaft 63 into the pump body 6 Idler gear 55 into the pump body Match toget...

Page 430: ...us valve lifters Important Whenever the camshaft needs to be replaced a new set of hydraulic lifters must also be installed CYLINDER HEAD DISASSEMBLY Remove or Disconnect Figures 30 and 31 Tool Requir...

Page 431: ...r valve stem groove B Assemble the two valve keepers into the upper groove using the grease to hold them in place C Release the compressor tool J 8062 making sure the valve keepers stay in place D Rep...

Page 432: ...n general the lower inserts except the 1 bearing show the greatest wear and distress from fatigue Upon inspection if a lower insert is suitable for reuse it can be assumed that the upper insert is als...

Page 433: ...001 inch undersize insert which will decrease the clearance 0 0005 inch from using a full standard bearing Some engines may have rear main bearings that are 0 008 inch wider than standard across the...

Page 434: ...to 15 N m 135 lbs in CRANKSHAFT REAR OIL SEAL INSTALLATION Install or Connect Figure 36 Tool Required J 35621 Rear Main Seal Installer Crankshaft rear oil seal A Lubricate the inner and outer diamete...

Page 435: ...d on case 3 Install balance shaft bearing retainer 43 and bolts 48 Tighten Balance shaft retainer bolts 48 to 14 N m 120 lbs in 4 Balance shaft driven gear 42 and bolt 49 Tighten a Balance shaft drive...

Page 436: ...t Figure 41 1 Camshaft sprocket and timing chain Important Line up the timing marks on the camshaft sprocket and crankshaft sprocket figure 41 The number 4 cylinder is at top dead center of the compre...

Page 437: ...NOTICE Refer to Notice on page 6A4 1 5 Torsional damper bolt and washer Tighten Bolt to 95 N m 70 lbs ft PISTON AND CONNECTING ROD INSTALLATION CONNECTING ROD BEARING SELECTION Connecting rod bearing...

Page 438: ...ime from beneath the engine guide the connecting rod to Figure 46 Measuring Connecting Rod Side Clearance the crankpin with J 5239 figure 45 Hold the ring compressor against the block until all rings...

Page 439: ...e distributor shaft B The oil pump should slide easily into place C No gasket is used NOTICE Refer to Notice on page 6A4 1 2 Oil pump to main bearing cap bolt Tighten Oil pump to main bearing cap bolt...

Page 440: ...sequence to 61 N m 45 lbs ft C Final torque sequence to 88 N m 65 lbs ft VALVE TRAIN COMPONENT INSTALLATION 9 Important Replace all hydraulic lifters change the engine oil and filter and add GM Engine...

Page 441: ...RTV to the front and rear sealing surfaces on the block Apply a 5 mm 3 16 inch bead of RTV GM P N 1052366 or equivalent to the front and rear of the block Extend the bead 13 mm 1 2 inch up each cylin...

Page 442: ...upper and lower intake manifolds 3 Upper intake manifold bolts studs and support Tighten Upper intake manifold bolts and studs to 10 N m 88 lbs in in sequence figure 52 4 Coil and nuts Tighten Nuts to...

Page 443: ...1 New gasket 2 EGR valve N O T IC E R e fe r to N o tic e o n p a g e 6A 4 1 3 Bolts X Tighten Bolts to 20 N m 15 lbs ft FLYWHEEL INSTALLATION 4 Install or Connect 1 Flywheel N O T IC E R e fe r to N...

Page 444: ...Oil Supplement GM P N 1052367 or equivalent to the engine oil 3 Fill the cooling system with the proper coolant 4 Crank the engine several times Listen for any unusual noises or evidence that any part...

Page 445: ...Maximum PISTON RING C 0 M Production Top 0 0014 0 0032 Groove Clearance 2nd P R Service Limit 0 0042 Maximum E s Production Top 0 010 0 020 s 2nd 0 018 0 026 1 0 N Service Limit 0 035 Maximum 0 1 Gro...

Page 446: ...rvice Limit 0 001 Maximum Rod Bearing Production 0 0013 0 0035 Clearance Service Limit 0 0030 Rod Side Clearance 0 006 0 014 CAMSHAFT Lobe Intake 0 288 Lift 0 002 Exhaust 0 294 Journal Diameter 1 8682...

Page 447: ...lts Center Two Bolts 35 26 All Others 27 20 Flywheel Bolts 100 74 Front Cover Bolts 14 Hydraulic Lifter Restrictor Retainer Bolts 16 12 Intake Manifold Bolts Lower In Sequence 48 35 Intake Manifold Bo...

Page 448: ...IGNER AND OIL SEAL INSTALLER 4 MAIN BEARING SHELL REMOVER AND INSTALLER 5 PISTON RING COMPRESSOR 6 CONNECTING ROD BOLTGUIDE SET 7 VALVE STEM SEALTESTER 8 BALANCE SHAFT BEARING SERVICE KIT 9 DIAL INDIC...

Page 449: ...hop Equipment 6A5 13 Accessory Removal 6A5 13 Cleaning 6A5 13 Draining the Engine 6A5 13 Exhaust Manifold Removal 6A5 14 Coolant Pump Removal 6A5 15 Intake Manifold Removal 6A5 15 Rocker Arm Cover Rem...

Page 450: ...Installation 6A5 42 Connecting Rod Bearing Selection 6A5 42 Installation 6A5 42 Oil Pump Installation 6A5 43 Oil Pan Installation 6A5 44 5 0L and 5 7L Engines 6A5 44 7 4L Engines 6A5 44 Cylinder Head...

Page 451: ...res 1 2 and 3 ENGINE IDENTIFICATION Two basic types of engines with three different dis placements are covered in this section The first type is the small block engine which is available in 5 0L 305 C...

Page 452: ......

Page 453: ...oler From Oil Cooler From Oil Pump Camshaft Bearings Valve Lifters Oil Filter Oil Cooler Diverter Main Bearings Oil Cooler Bypass Valve J Oil Filter Bypass Valve F9477 Figure 3 Lubrication Diagram 7 4...

Page 454: ...163 164 V1202...

Page 455: ...ening Cover 143 Fuel Pump Opening Cover Gasket 144 Engine Block 145 Fitting 146 Oil Pressure and Fuel Pump Switch Sensor 147 Plug 148 Nut 149 Connecting Rod Bearing Cap 150 Connecting Rod Bearing 151...

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 457: ...4 Rocker Arm Cover Gasket 250 Rocker Arm Stud 36 Rocker Arm Cover Bolt 251 Valve Stem Key 39 Inlet Valve Spring Cap 252 Valve Stem Oil Seal O Ring 40 Rocker Arm Nut 254 Exhaust Valve Rotator 41 Rocker...

Page 458: ...100 1 8 4 185 183 177 v 75 201 3706r1204...

Page 459: ...Spring Retainer 178 Oil Pump Driveshaft 179 Connector 180 Oil Pump Body 182 Oil Pump Cover 183 Oil Pressure Regulator Valve 184 Oil Pressure Regulator Valve Spring 185 Spring Retaining Pin 187 Pick up...

Page 460: ......

Page 461: ...d safely accomplish the operations for which they are intended The use of these tools will also minimize possible damage to engine components Some precision measuring tools are required for inspection...

Page 462: ...Tighten Block drain plugs to 12 N m 112 lbs in EXHAUST MANIFOLD REMOVAL Remove or Disconnect Figures 12 and 13 1 Oil dipstick tube On 5 0L and 5 7L engines bend back the tab washers 3 4 f r t 1 Exhau...

Page 463: ...ools Required J 3049 A Valve Lifter Remover Plier Type J 9290 01 Valve Lifter Remover Slide Hammer Type 1 Nuts 40 5 0L and 5 7L engines or bolts 40 7 4L engines balls 41 rocker arms 42 and pushrods 43...

Page 464: ...8 29 and 30 1 Oil pan bolts 72 or 75 nuts 73 5 0L and 5 7L only and clips 2 Oil pan 71 or 76 3 Gasket 74 5 0L and 5 7L Engines OIL PUMP REMOVAL Remove or Disconnect Figures 28 and 30 4 1 Bolt 2 Oil pu...

Page 465: ...ct Figure 33 Camshaft A Install three 5 16 18 bolts 100 125 mm 4 5 inches long into the camshaft tapped holes Use these bolts to handle the camshaft B Pull the camshaft from the block C Use care to pr...

Page 466: ...ement of the connect ing rod markings to ensure they will be returned to their proper position during assem bly Mark the connecting rods with a scratch awl if necessary B Remove the connecting rod bol...

Page 467: ...om scoring the cylinder bore C Install the connecting rod cap onto the connect ing rod Do not tighten D Repeat this procedure on the remaining piston and connecting rod assemblies FLYWHEEL REMOVAL Rem...

Page 468: ...4 inch C 40m m 11 2 inch D 10 mm 3 s inch drill 25 mm 1 inch deep E 22 mm 7 e inch drill 25 mm 1 inch deep F Material 50 mm x 200 mm 2 x 8 inch lumber B5267 Check the main bearing caps for location m...

Page 469: ...haft journals and thrust flange surfaces 4 Rear seal 131 70 Oil Pump 71 Oil Pan 72 Bolt 73 Nut 74 Gasket 75 Reinforcement F9364 Figure 28 Oil Pan 5 0L and 5 7L Engines 5 Main bearing inserts 135 and 1...

Page 470: ...70 Oil Pump 76 Nut 77 Bolt 79 Oil Pan Baffle F9365 Figure 29 Oil Pan Baffle A Sealing Compound A 74 Gasket 75 Bolt 76 Oil Pan F9331 Figure 30 Oil Pan 7 4L Engines 91 Front Cover 93 Bolt F9357...

Page 471: ...100 A 16 mm 5 s inch Maximum 100 Bolt 101 Camshaft Sprocket 102 Timing Chain B8012 Figure 32 Timing Chain and Sprockets Figure 34 Removing the Cylinder Ridge Rod...

Page 472: ...WHEEL AUTOMATIC TRANSMISSION 111 BOLT FLYWHEEL 168 PIN FLYWHEEL DOWEL 111 V2878 Figure 36 Flywheel 5 0L and 5 7L Engines 80 SCREW SEAL RETAINER 81 NUT SEAL RETAINER 82 RETAINER SEAL 83 STUD SEAL RETAI...

Page 473: ...eler gages dial indicator set etc The inspection work performed with the proper meth ods and tools is most important The rebuilt engine cannot be expected to perform properly if parts worn beyond acce...

Page 474: ...the milled surface at the top of the cylinder block The surface 175 144 BLOCK ENGINE 175 PLUG ENGINE BLOCK COOLANT DRAIN HOLE 144 V2879 Figure 41 Engine Block Coolant Drain Hole Plug 5 0L and 5 7L Eng...

Page 475: ...iston to bore clearance and fit pistons as outlined PISTON SELECTION 1 Check the used piston to cylinder bore clearance as follows A Cylinder bore diameter Use a telescoping bore gage located 65 mm 2...

Page 476: ...d gasket surface damage Alignment of exhaust manifold flanges Use a straight edge and feeler gage figure 44 If the flanges do not align the manifold is warped and should be replaced or resurfaced AIR...

Page 477: ...Puller J 28509 A Crankshaft Sprocket Puller 1 Crankshaft sprocket On 5 0L and 5 7L engines use J 5825 figure 47 On 7 4L engines use J 28509 A figure 48 2 Key if necessary Assemble Figures 47 and 48 S...

Page 478: ...nd play exceeds 0 381 mm 0 015 inch replace the coolant pump Coolant pump body at the drain weep hole Slight staining around the weep hole is normal Replace the coolant pump only if coolant is drippin...

Page 479: ...parately If the parts are damaged or worn replace the entire oil pump assembly Pressure relief valve 183 for fit The regulator valve should slide freely in its bore without sticking or binding figures...

Page 480: ...other damage Rocker arm areas that contact the valve stems and the sockets that contact the pushrods These areas should be smooth and free of damage and wear Rocker arm nuts or bolts The 5 0L and 5 7L...

Page 481: ...following Measure Valve stem clearance Valve spring tension and free length Other information outlined includes Valve and seat grinding Valve guide reaming ROCKER ARM STUD REPLACEMENT 5 0L AND 5 7L EN...

Page 482: ...8062 figure 55 Compress the spring enough so the lower valve stem groove can be clearly seen 7 O ring seals 252 and valve keepers 251 A Push a new O ring seal onto the valve stem The seal must be ins...

Page 483: ...keepers using the grease to hold the keys in place Make sure the keep ers seat properly in the groove D Release the compressor tools Make sure the valve keepers stay in place E Repeat this procedure o...

Page 484: ...om the oil passages with com pressed air Main bearing inserts Wipe free of oil with a soft cloth Seal running surfaces with a non abrasive cleaner Inspect Crankshaft for cracks Use the magnaflux metho...

Page 485: ...sassemble Figure 66 Crankshaft rear oil seal Insert a screwdriver into the notches provided in the seal retainer and pry the seal out figure 66 I Clean All traces of old gasket from the retainer Inspe...

Page 486: ...identified by 008 stamped on the rear counterweight If the rear main bearings are replaced they must have the proper distance between thrust faces to obtain correct crankshaft end play Install or Con...

Page 487: ...not turn freely loosen the main bearing cap bolts on one cap at a time until the tight bearing is located Burrs on the bearing cap foreign matter between the insert and the block or the bearing cap or...

Page 488: ...J 35621 CAMSHAFT TIMING CHAIN AND SPROCKET INSTALLATION 4 Install or Connect Figures 72 and 73 Coat the camshaft lobes and journals with Engine Oil Supplement GM P N 1051396 or equivalent Camshaft fig...

Page 489: ...39046 Torsional Damper Puller and Installer 1 Crankshaft key N O T IC E T h e in e r tia l w e ig h t s e c tio n o f the to rs io n a l d a m p e r is a s s e m b le d to th e h u b w ith a r u b b...

Page 490: ...elective fitting of both rod and main bearing inserts is necessary to obtain close tolerances For this reason you may use for example one half of a standard insert with one half of a 0 2504 mm 0 001 i...

Page 491: ...linder 1 3 5 and 7 are the right bank and 2 4 6 and 8 are the left bank when viewed from the front of the engine The numbers on the connecting rod and bearing cap must be on the same side when install...

Page 492: ...Oil Pump 76 Nut 77 Bolt 79 Oil Pan Baffle F9365 Figure 84 Oil Pan Baffle 5 7L H D Engine Tighten Oil pan bolts 72 to 11 N m 100 lbs in Oil pan nuts 73 to 22 N m 200 lbs in 7 4L ENGINES Install or Con...

Page 493: ...40 N m 30 lbs ft B The second sequence to 80 N m 60 ft lbs C The final torque sequence to 110 N m 80 lbs ft VALVE TRAIN COMPONENT INSTALLATION Important Replace all hydraulic lifters if a new camshaft...

Page 494: ...d 5 7L engines only VALVE ADJUSTMENT 5 0L and 5 7L ENGINES 1 Remove the rocker arm covers 2 Crank the engine until the mark on the torsional damper lines up with the center or 0 mark on the timing tab...

Page 495: ...en viewed from the front of the engine 4 Back out the adjusting nut until lash is felt at the pushrod then turn in the adjusting nut until all lash is removed This can be determined by rotating the pu...

Page 496: ...g sequence shown in figure 95 7 4L ENGINES Install or Connect Figures 96 and 97 4 1 Gaskets 22 to the cylinder heads Apply a 5 mm 3 16 inch spot of RTV sealer GM P N 1052289 or equivalent on the front...

Page 497: ...Two center bolts 36 N m 26 lbs ft Outside bolts 28 N m 20 lbs ft Bend the tab washers against the bolt heads 7 4L engines 54 N m 40 lbs ft COOLANT PUMP INSTALLATION Install or Connect Figures 102 and...

Page 498: ...Manual Section Connect all vacuum hoses and electri cal equipment the same way as removed ENGINE SETUP AND TESTING After overhaul the engine should be tested before installation in the vehicle If a s...

Page 499: ...engine and listen for unusual noses 5 Run the engine speed at about 1000 until the engine is at operating temperature 6 Listen for improperly adjusted valves or sticking lift ers and other unusual noi...

Page 500: ...fold 4 Bolt Stud 6 Spark Plug Heat Shield F9328 Figure 101 Exhaust Manifold 7 4L Engines 10 Coolant Pump 12 Bolt 11 Gasket 13 Plug Figure 102 Coolant Pump 5 0L and 5 7L Engines Figure 103 Coolant Pump...

Page 501: ...Maximum Taper Relief Side 0 001 Maximum Service 0 001 Maximum PISTON Production 0 0007 0 0021 Service Limit 0 0027 Maximum PISTON RING C 0 M Production Top 0 0012 0 0032 Groove Clearance 2nd P R Servi...

Page 502: ...uction 0 0005 Maximum Service Limit 0 001 Maximum Rod Bearing Clearance Production 0 0013 0 0035 Service Limit 0 003 Maximum Rod Side Clearance 0 006 0 014 CAMSHAFT Lobe Lift 0 002 Intake 0 2336 0 256...

Page 503: ...01 Maximum PISTON Production 0 0018 0 0030 Service Limit 0 005 Maximum PISTON RING C r Production Top 0 0012 0 0029 M Groove Clearance 2nd 0 0012 0 0029 P R Service Limit Hi Limit Production 0 001 E s...

Page 504: ...Limit 0 001 Rod Bearing Clearance Production 0 0011 0 0029 Service Limit 0 003 Maximum Rod Side Clearance 0 0013 0 023 CAMSHAFT Lobe Lift 0 002 Intake 0 2343 Exhaust 0 2530 Journal Diameter 1 9482 1 9...

Page 505: ...Nuts H D 5 7L Only 36 26 Oil Pan Bolts 11 100 Oil Pan Drain Plug 22 16 Oil Pan Nuts 22 16 Oil Pan Studs to Oil Seal Retainer or Engine Block 2 15 Oil Pump Bolt 90 65 Oil Pump Cover Bolts 9 80 Rocker A...

Page 506: ...7 GUIDE SET 8 VACUUM PUMP 9 HYDRAULIC LIFTER REMOVER SLIDE HAMMER TYPE 10 HYDRAULIC LIFTER REMOVER PLIER TYPE 11 STUD REMOVER 5 0L AND 5 7L ENGINES 12 REAMER 0 003 INCH OVERSIZE 13 REAMER 0 013 INCH...

Page 507: ...s te m d a m a g e c o u ld re su lt CONTENTS SUBJECT PAGE General Description 6A7 3 Engine Lubrication 6A7 3 Disassembly 6A7 12 Tools and Shop Equipment 6A7 12 Accessory Removal 6A7 12 Cleaning 6A7 1...

Page 508: ...jection Nozzle Tests 6A7 36 Opening Pressure Test 6A7 36 Leakage Test 6A7 37 Chatter Test 6A7 37 Spray Test 6A7 37 Injection Lines 6A7 37 Injection Pump 6A7 37 Injection Pump Repair 6A7 37 Crankshaft...

Page 509: ...ee center main bearing The camshaft is supported by five plain type bearings and is chain driven Motion from the camshaft is trans mitted to the overhead valves by roller type hydraulic lifters pushro...

Page 510: ......

Page 511: ...Fill Tube 68 Nut 69 Oil Separator Grommet 70 Coolant Pump and Plate Stud 71 Fuel Injection Pump Stud 72 Bolt 73 Crankshaft Bearing Cap Bolt Outboard 74 Crankshaft Bearing Cap Bolt Inboard 75 Cranksha...

Page 512: ...V2131...

Page 513: ...xhaust Manifold Bolt 204 Exhaust Manifold Bolt 205 Coolant Temperature Switch Hole Plug 206 Prechamber 207 Intake Valve 208 Exhaust Valve 209 Cylinder Head 210 Hydraulic Valve Lifter Guide Clamp Upper...

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 515: ...60 Coolant Pump 61 Thermostat By Pass Nipple 62 Clamp 63 Oil Fill Tube 64 Nut 65 Oil Filler Cap 69 Oil Separator Grommet 70 Coolant Pump and Plate Stud 71 Fuel Injection Pump Stud 72 Bolt 73 Crankshaf...

Page 516: ...259 260 150 237 S lM 180 167180 J 1 82 183 170 169 1 1 78 1 7 9 213212 2 0 7 205 r i 3706r4752...

Page 517: ...aust Manifold Bolt 204 Exhaust Manifold Bolt 205 Coolant Temperature Switch Hole Plug 206 Prechamber 207 Intake Valve 208 Exhaust Valve 209 Cylinder Head 210 Hydraulic Valve Lifter Guide Clamp Upper 2...

Page 518: ...end These tools or their equiva lents are specially designed to quickly and safely accomplish the operations for which they were intend ed The use of these tools will also minimize possible damage to...

Page 519: ...rtant that the engine be as clean as possible to prevent dirt from entering critical areas during disas sembly FLYWHEEL REMOVAL Remove or Disconnect Figures 1 and 10 1 Bolts 18 2 Flywheel 19 DRAINING...

Page 520: ...o hold nozzle body while loosening injection line Cap the lines and nozzles immediately Do not bend injection lines 4 Injection lines at the pump Cap the lines and pump fittings immediately Tag the li...

Page 521: ...from pump 7 Fuel return lines as an assembly GLOW PLUG REMOVAL Remove or Disconnect Glow plugs Use a 3 8 inch deep socket EXHAUST MANIFOLD REMOVAL Remove or Disconnect Figures 15 16 and 17 1 Exhaust m...

Page 522: ...E D o n o t p r y o n th e ro c k e r a rm co ver D a m a g e to s e a lin g s u rfa c e s m a y re s u lt U se a b lo c k o f w o o d a g a in s t th e s id e o f ro c k e r c o v e r a n d s trik e...

Page 523: ...6 53 HOSE 62 CLAMP HOSE 103 GASKET 104 GASKET THERMOSTAT HOUSING 106 BOLT STUD 107 OUTLET COOLANT 108 THERMOSTAT 110 CROSSOVER COOLANT 3706r4644 Figure 19 Thermostat and Coolant Crossover L57 VIN Y Fi...

Page 524: ...238 Figure 23 Removing the Torsional Damper 3 Injection pump gear 241 4 Nuts 225 and throttle spring bracket 228 5 Injection pump 244 6 Gasket 242 FRONT COVER REMOVAL Remove or Disconnect Figure 22 1...

Page 525: ...TION 271 HUB INJECTION PUMP 225 244 B8067 Figure 25 Injection Pump L57 VIN Y CAMSHAFT REMOVAL OIL PAN REMOVAL Remove or Disconnect Figures 1 and 26 Remove or Disconnect Figure 27 1 Bolts 86 and thrust...

Page 526: ...PROCKET 93 SPACER CAMSHAFT SPROCKET B8068 Figure 26 Camshaft and Components OIL PUMP REMOVAL Remove or Disconnect Figure 27 1 Bolt 35 2 Oil pump 33 PISTON AND CONNECTING ROD REMOVAL Remove or Disconne...

Page 527: ...ft journal during removal B Push the connecting rod and piston out of the bore C After removal assemble the connecting rod and cap REAR CRANKSHAFT SEAL REMOVAL Remove or Disconnect Figure 30 1 Oil sea...

Page 528: ...al transmission applications a valley drain tube is used at the rear of the block This drain tube prevents fuel or oil that has collected in the valley from draining onto the clutch and flywheel Engin...

Page 529: ...il galley plugs 5 Block heater 6 Block drain bolt if used i Bolt to 25 N m 18 lbs ft CYLINDER BORES Inspect Cylinder bores for scoring and other damage Measure Cylinder out of round and taper Refer to...

Page 530: ...a tion for the proper bore diameter taper and round ness and the rough honing operation removes the boring tool marks Refer to Rough Honing Completely disassemble and clean the block prior to boring R...

Page 531: ...______________ B2 ______________ C 155 mm 6 1 IN C1 __________________ C2 ______________ OUT OF ROUNDNESS CALCULATION A1 A2 __________________ B1 B2 __________________ NOT TO EXCEED 0 02 mm 0 0008 INC...

Page 532: ...and connecting rod Check for scuffing etc Piston for scratches wear etc Connecting rod for failure or piston pin bushing wear Measure the bushing for proper clearance Refer to Measuring Piston Pin to...

Page 533: ...iameter Measure Figures 37 38 and 39 1 Piston pin diameter figure 37 Check against Specifications 2 Piston pin bushing ID Use an inside micrometer figures 38 and 39 3 Piston pin to bushing clearance S...

Page 534: ...d in the ring groove INSTALLING THE PISTON RINGS All compression rings are marked on the upper side of the ring When installing the compression rings make sure the MARKED SIDE IS TOWARD THE TOP OF THE...

Page 535: ...eeler gage as shown in figure 47 Compare with specifications at the rear of this section Figure 47 Measuring Ring Clearance INTAKE AND EXHAUST MANIFOLDS Clean Old pieces of gasket from the gasket surf...

Page 536: ...nstaller Set The outer camshaft bearings must be installed first These bearings serve as guides for the pilot and help center the inner bearings during the installa tion process Be sure to fit the cor...

Page 537: ...are replaced it will be necessary to re time the engine Refer to Front Cover Installation FRONT COVER Clean L Old sealer from the sealing surfaces Inspect Baffle for damage Front cover for cracks and...

Page 538: ...screws Tighten Screws to 16 N m 12 lbs ft Inspect Oil pump operation Turn the drive shaft by hand and check for smooth rotation Figure 51 Removing the Rocker Arm Retainers VALVE TRAIN COMPONENTS IJJ...

Page 539: ...ylinder case above the lifter bore CYLINDER HEAD The 6 5L light duty naturally aspirated engine uses a 39 mm 1 53 inch non stellite exhaust valve Both tur bocharged and heavy duty naturally aspirated...

Page 540: ...ON 6A 2 Cylinder head warpage Use a straightedge and a feeler gage figure 56 If the head is warped more than 0 15 m m 0 006 inch longitudinally or 0 08 mm 0 003 inch transversely replace the cyl inder...

Page 541: ...408 7 Caps 407 intake valves only 8 Rotators 411 exhaust valves only 9 O ring seals 409 and valve keepers 406 A Compress the valve spring using J 8062 figure 53 Compress the spring enough so the lowe...

Page 542: ...3 Adaptor Nut J 29079 18 Adaptor J 29079 13 Manifold Adaptor J 7660 101 Washer Nozzle testing is comprised of the following checks Nozzle opening pressure Leakage Chatter Spray pattern Each test shou...

Page 543: ...stand slowly and note whether chatter noise can be heard 3 If no chatter is heard move the lever faster until it chatters At fast lever movement the nozzle may make a hissing or squealing sound rathe...

Page 544: ...s and stamped 1 2 or 3 on the pan rail The crankshaft is color marked red blue orange or white near the main bearing journal The proper bearing selection is made by using the number on the pan rail Co...

Page 545: ...EMBLY OIL FILTER AND OIL COOLER BYPASS VALVE REPLACEMENT Install or Connect Figure 61 1 Oil filter bypass valve Tap into place using a 16 mm socket 2 Oil cooler bypass valve by pressing into place and...

Page 546: ...o re th e a tta c h in g b o lts a r e in s ta lle d D o n o t u s e th e a tta c h in g b o lts to p u ll th e m a in b e a r in g c a p s in to t h e ir s e a ts a s th is m a y d a m a g e th e b e...

Page 547: ...forced forward measure at the front end of the number 3 main bearing with a feeler gage figure 64 The proper clearance is 0 10 0 25 mm Crankshaft for binding Try turning the crankshaft to check for b...

Page 548: ...to the front cover sealing area shown in figure 66 1 Front cover to the engine Install the bolts 70 Tighten St Bolts 70 to 45 N m 33 lbs ft 2 Crankshaft sensor with new O ring seal Tighten Retaining b...

Page 549: ...g e to th e lift e r s m a y r e s u lt i f th e y a r e d r y w h e n th e e n g in e is s ta rte d 1 Hydraulic lifters to the engine A Prime new hydraulic lifters before installation by working the...

Page 550: ...hich they were removed 1 Connecting rod bearings A Be certain that the bearings are the proper size B Install the bearings in the connecting rod and connecting rod cap 2 Piston and connecting rod to t...

Page 551: ...onnecting rod side clearance Use a feeler gage between the connecting rod and crank shaft figure 72 The correct clearance is 0 17 0 63 mm MARKING TDC ON THE FRONT COVER mMeasure TDC On Front Cover Fig...

Page 552: ...fe r to N o tic e o n p a g e 6A 7 1 2 Bolt 35 Tighten Bolt 35 to 90 N m 65 lbs ft OIL PAN INSTALLATION 4 Install or Connect Figure 76 Apply a 5 mm 3 16 inch bead of RTV sealant GM P N 12345739 to th...

Page 553: ...or Connect Figures 68 and 78 N O T IC E T h e p u s h ro d s m u s t b e in s ta lle d w ith th e m a rk e d o r p a in te d e n d up F a ilu re to d o s o m a y re s u lt in d a m a g e o r p re m a...

Page 554: ...ver with carburetor cleaner or equivalent Install or Connect Figure 79 N O T IC E D o n o t a llo w R T V s e a la n t in to the ro c k e r a rm c o v e r b o lt h o les T h is m a y ca u s e a h y d...

Page 555: ...the top of the engine front cover must be aligned with the marks on the injec tion pump flange figure 80 The engine must be off when the timing is reset a Tighten Nuts 225 to 40 N m 30 lbs ft figure 7...

Page 556: ...intake manifold DIPSTICK TUBE INSTALLATION Install or Connect 1 New O ring seal to the dipstick tube 2 Dipstick to the engine 3 Dipstick bracket bolt 106 53 HOSE 62 CLAMP HOSE 103 GASKET 104 GASKET T...

Page 557: ...0 m m h e x p o rtio n F a ilu re to d o s o w ill re s u lt in d a m a g e to th e in je c tio n n o z z le 1 Injection nozzle with gasket using J 29873 Nozzle to 70 N m 50 lbs ft 2 Fuel return hose...

Page 558: ...A 7 1 3 Intake manifold bolts studs and fuel line clips There are 4 bolts numbers 9 11 13 and 15 exposed to the crankcase and should be sealed with teflon sealer figure 87 Tighten Intake manifold bol...

Page 559: ...ALLATION Install or Connect Figure 88 Tool Required J 39084 Rear Crankshaft Seal Installer Important Coat the crankshaft surface with engine oil and lightly coat the lip of the new oil seal with engin...

Page 560: ...Refer to SECTION OB Replacement of the engine oil and filter is recommended especially if a new camshaft was installed 3 Fill the cooling system with the proper coolant 4 With the shutdown solenoid d...

Page 561: ...33 Glow Plugs 18 Hydraulic Lifter Guide Plate Clamp Bolts 26 19 Intake Manifold Bolts 42 31 Injection Lines 25 19 Injection Nozzles 70 50 Injection Pump Gear Bolts 23 17 Injection Pump Nuts 42 31 Oil...

Page 562: ...ype Ring 2nd 0 039 0 079 Gap2 Top 0 26 0 51 2nd 0 75 1 00 Oil Groove Clearance 0 040 0 090 Gap 0 25 0 51 PISTON PIN Diameter 30 9961 31 0039 Clearance Piston Pin to Piston Bore 0 0101 0 0153 Fit in Ro...

Page 563: ...alled Height 46 Timing Chain Free Play New Chain 12 7 mm 0 500 inch Used Chain 20 3 mm 0 800 inch T2843 SERVICE PISTON AND CYLINDER BORE SPECIFICATIONS Note Cylinders 7 and 8 require 0 013mm 0 0005 ad...

Page 564: ...er Tolerance 038mm 55 050 55 050 55 050 55 050 51 045 118 118 118 118 113 Camshaft Bearing Clearance 025 025 025 025 020 59 17 58 92 58 67 58 42 50 42 Cam Bore Diameter Case 59 12 58 87 58 621 58 37 5...

Page 565: ...IVERSAL CAMSHAFT BEARING REMOVER AND INSTALLER SET 3 NOZZLE SOCKET 4 SEAL INSTALLER 5 NOZZLE TESTER 6 REAR CRANKSHAFT SEAL INSTALLER 7 TORSIONAL DAMPER REMOVER 8 MANIFOLD COVER SET 9 VALVE SPRING COMP...

Page 566: ...NOTES...

Page 567: ...o rre c t to rq u e v a lu e m u s t b e u s e d w h e n in s ta llin g fa s te n e rs th a t re q u ire it If th e a b o v e c o n d itio n s a re n o t fo llo w e d p a rts o r s y s te m d a m a g...

Page 568: ...sensors to determine fuel requirements based on engine operating conditions The fuel is delivered under one of several conditions called modes All the modes are controlled by the ECM PCM Model 220 TB...

Page 569: ...14 O R IN G FUEL RETURN LINE 15 SCREW ISC ACTUATOR ARM ATTACHING 16 ACTUATOR ASSY IDLE SPEED CO NTRO L ISC 17 BODY ASSY THROTTLE 18 SENSO R THROTTLE PO SITIO N TP 19 SCREW TP SENSO R ATTACH IN G 20 SE...

Page 570: ...FUEL METER COVER The fuel meter cover assembly contains the fuel pres sure regulator assembly The regulator has been adjust ed at the factory and should only be serviced as a complete preset assembly...

Page 571: ...a s s e m b lie s in c le a n e r s in c e th e y m a y b e c o m e n o n fu n c tio n al 2 Blow out all passages in the castings with com pressed air Do not pass drill bits or wire through passages...

Page 572: ...x te n d e d e le c tric a lly it m u s t a ls o b e re tra c te d e le c tric a lly B e fo re in s ta llin g a n IA C va lve m e a s u re th e d is ta n c e b e tw e e n th e tip o f th e v a lv e p...

Page 573: ...tant The ISC actuator nose screw must be adjusted after installation Refer to the TBI 220 On Vehicle Service section of the Driveability Emissions and Electrical Diagnosis Manual for the proper model...

Page 574: ...NOTES...

Page 575: ...value must be used when installing fasteners that require it If the above conditions are not followed parts or system damage could result CONTENTS SUBJECT PAGE General Description 6D2A 2 Delco Remy SD...

Page 576: ...has the drive end housing extended to enclose the shift lever and solenoid plunger The solenoid flange mounts to the extension of the drive end housing with sealing compound between the flange and the...

Page 577: ...rrent draw and no load speed indicates normal condition of the starter motor 2 Low free speed and high current draw indicates Too much friction Tight dirty or worn bear ings bent armature shaft or loo...

Page 578: ...r end of the armature shaft 5 Field frame 57 from the drive housing 31 and the armature assembly 9 DRIVE END Disassemble Figures 5 6 and 7 1 Armature from the drive housing by tilting the armature to...

Page 579: ...sengaging the Drive Collar from the Shift Lever Fingers 3 Screws 36 attaching the solenoid 3 to the drive housing 4 Lever shaft 43 nut 44 and washer 5 Shift lever 1 and the attached solenoid plunger 2...

Page 580: ...act surface and BAT terminal 25 contact surface for wear Replace if worn DISASSEMBLY OF THE SD 210 AND SD 260 STARTER MOTORS If the motor does not perform to specifications it may need to be disassemb...

Page 581: ...buttons on the drive collar 6 Drive assembly 32 from the armature shaft 9 as follows A Remove the thrust collar 17 from the armature shaft B Drive the pinion stop collar 39 away from the pinion stop r...

Page 582: ...r motor Avoid excessive lubrication Do not lubricate roller bearings They are perma nently lubricated at time of manufacture 2 Armature shaft for runout or scoring Replace the armature assembly if the...

Page 583: ...Brush springs for distortion or discoloring If the springs are weak bent or discolored replace them On the SD 260 replace the frame and field assembly 10 Field coils Look for burned or damaged insulat...

Page 584: ...ct the test lamp between the BAT termi nal and the case The lamp should not light terminal should not be grounded B Connect the test lamp between the S terminal and the case Then connect the test lamp...

Page 585: ...1 Solenoid plunger 2 to the shift lever 1 with the roll pin 40 2 Lever assembly in the drive housing 31 with lever shaft 43 washer and nut 44 Make sure the shift lever pivots freely Important Lightly...

Page 586: ...ft 2 Pinion stop collar 39 with the flat side of the collar toward the drive pinion figure 20 3 New retaining ring 37 onto the armature shaft Slide the ring down the shaft until it seats in the shaft...

Page 587: ...Recess the new bearing 2 mm 0 08 inch into the housing The bearing is pre lubricated so do not add lubricant 5 Identification tag over the hole in the end frame with the fluted end around the bearing...

Page 588: ...0 10700 1114489 10455343 SD 300 65 110 6500 10700 1114577 SOLENOID SWITCHES Switch Pull In Winding Hold ln Winding Part No Volts Amps Volts Amps Volts 1114520 12 23 30 5 13 19 10 1114578 12 26 30 5 13...

Page 589: ...o n d itio n s a r e n o t fo llo w e d p a rts o r s y s te m d a m a g e c o u ld resu lt CONTENTS SUBJECT PAGE General Description 6D2B 2 Starter M otor 6D2B 2 Identification 6D2B 2 Diagnosis 6D2B...

Page 590: ...t and body of the drive assembly should all rotate togeth er If necessary pry the pinion with a screwdriver to turn it Tight bearings a bent armature shaft or a loose pole screw will cause the armatur...

Page 591: ...3 Close the switch and observe the voltmeter Adjust the carbon pile load until the voltmeter reads 10 volts Record the ammeter and RPM readings Open the switch 4 Compare the ammeter and RPM readings...

Page 592: ...st be saved If it is lost it must be replaced with a 2 mm x 10 mm 0 079 inch x 0 394 inch long pin obtained or manufactured locally 5 Frame field and brush holder group A dowel pin 16 and O ring seal...

Page 593: ...17 SEAL O RING FIELD FRAME 18 SCREW SOLENOID 19 ASSEMBLY SOLENOID 20 LEVER SHIFT 21 PLUG DRIVE HOUSING 22 WASHER SHIFT LEVER 23 NUT SHIFT LEVER 24 PLATE IF USED 25 BOLT DRIVE HOUSING SHORT ON SOME MO...

Page 594: ...nd down B Using an open tube slightly larger then the shaft drive the pinion stop 36 toward the clutch drive assembly 34 until it clears the stop rings 26 figure 8 C Pry the stop rings out of the driv...

Page 595: ...BRACKET ARMATURE SUPPORT 28 WASHER FIBER 29 WASHER THIN ONE OR TWO MAY BE USED 30 WASHER THICK 37 BUSHING D E HOUSING 38 SCREW SHIFT LEVER 39 HOUSING DRIVE 40 PLUG BUSHING IF USED V3865 Figure 6 Gear...

Page 596: ...oring or other damage Replace the damaged bushing Refer to Repair Procedures 8 Ball bearings 12 14 and 32 as follows A Hold the armature 13 or drive shaft 31 and slowly rotate the outer bearing race b...

Page 597: ...r e p la c e d w ith n e w b e a r in g s T h e r e m o v a l p r o c e d u r e c a u s e s in te rn a l d a m a g e to th e b e a rin g s Commutator and and or drive end bearings 12 and 14 from the s...

Page 598: ...lco Remy lubricant P N 196094 lubricate the following areas during assembly Avoid using excessive grease Drive end housing bushing in the drive housing Pivot hole and working surface on the ends of th...

Page 599: ...bs in FRAME FIELD AND BRUSH HOLDER GROUP 4 Install or Connect Figures 5 13 and 14 N O T IC E F o r s te p s 3 a n d 4 re fe r to N o tic e o n p a g e 6 D 2B 1 1 Brush springs 11 if removed A Start ea...

Page 600: ...the brush holder assembly 7 with installed brushes over the terminal end of the frame and field assembly 15 B Attach the terminals of the insulated brush leads to the conductors in the frame and fiel...

Page 601: ...ommutator end frame when installed This is the normal installed posi tion of the O ring seal B Carefully roll the O ring seal out of its nor mal installed position up onto the major out er diameter of...

Page 602: ...itch Pull In Winding Hold ln Winding Part No Volts Amps Volts Ohms Amps Volts Ohms 10456454 12 52 59 10 0 17 0 19 12 14 10 0 76 0 81 LUBRICATION Use Delco Remy Gear and Shaft Lubricant No 1960954 or e...

Page 603: ...0 Generator Specifications 6D3A 10 Fastener Tightening Specifications 6D3A 10 Special Tools 6D3A 10 GENERAL DESCRIPTION switches rotor field current on and off at a fixed fre quency of about 400 cycle...

Page 604: ...l is connected to the battery posi tive terminal through the ammeter and that the battery and generator are properly grounded 2 Connect a 30 to 500 ohm resistor between the positive battery terminal a...

Page 605: ...ng 106 from the rotor If you have a slip ring end bearing on the shaft use J 28509 A figure 5 If you have a roller bearing in the slip ring end frame press it out Place the rotor in a vise and tighten...

Page 606: ...117 Outside Collar 227 Rectifier Bridge 30 Screw 128 Retainer 228 Capacitor 31 Grounded Screw 131 Brush Holder 229 Pulley 35 Insulated Screw 216 Drive End Frame 230 Fan 76 BAT Terminal 217 Slip Ring E...

Page 607: ...End Bearing F7083 Figure 5 Removing the Slip Ring End Bearing 14 Washer 216 Drive End Frame 107 Drive End Bearing 221 Rotor 116 Inside Collar 229 Pulley 117 Outside Collar 230 Fan 128 Retainer 306 Fan...

Page 608: ...e bearing is doubtful replace it 6 Windings for burned insulation Replace the rotor or stator if either looks burned Burned insulation appears as very dark or blackened wiring A strong acidic odor wil...

Page 609: ...enerator fails to supply rated output the problem is in the rectifi er bridge stator or regulator If the rotor fails any of the above checks replace it STATOR CHECKS Check the stator with a self power...

Page 610: ...t sink 5 BAT terminal nut 1 with the flat side down to the insulated heat sink figure 8 If the brush holder regulator or connector has been replaced connect it by crimping the connec tors to the other...

Page 611: ...b e a rin g o n th e ro to r sh aft th is b e a rin g m u s t b e re p la c e d w ith a n e w b e a rin g a n y tim e th e tw o h a lv e s o f th e g e n e ra to r a re s e p a ra te d If n o t re p...

Page 612: ...C 80 F Field Current 12 Volts 27 C 80 F AMPS Ampere Rating 1102635 CS 144 2 1 2 4 5 0 5 7 124 10479884 CS 144 2 1 2 4 5 0 5 7 124 FASTENER TIGHTENING SPECIFICATIONS N m Ft Lbs Pulley Nut 100 75 T2532...

Page 613: ...onnects to the distributor cap through a high tension wire The distributor uses an internal magnetic pickup assembly that consists of a permanent magnet pole piece with internal teeth and pickup coil...

Page 614: ...igure 1 Distributor with Sealed Connectors 10 ROTOR 11 COIL PICKUP 13 PIECE POLE 14 MODULE 23 CAP 25 SCREW 26 SHAFT 27 PIN 29 GEAR 30 HOUSING 31 WASHER 33 WASHER TANG 49 RETAINER 50 SHIELD 56 PIN V279...

Page 615: ...B Using a spray type varnish remover clean the drive gear end of the shaft DO NOT allow var nish remover to travel up the driveshaft to the grease pack in the top of the housing N O T IC E F a ilu r e...

Page 616: ...ure 5 step 1 The reading should be infinite If not replace the coil B Connect an ohmmeter to both pickup coil leads as shown in figure 5 step 2 Flex the leads by hand at the coil and the connector to...

Page 617: ...tainer when there is a groove in the center bushing A Place the retainer over the center bushing with the teeth pointing upward B Place a 15 mm 5 8 inch socket head onto the edge of the retainer Keep...

Page 618: ...SPECIAL TOOLS...

Page 619: ...B 1 New Venture Gear 3500 5LM60 Manual Transmission 7B1 1 New Venture Gear 4500 Manual Transmission 7B2 1 Borg Warner T5 Manual Transmission 7B3 1 Transfer Case 7D New Process 233 Transfer Case 7D1 1...

Page 620: ...NOTES...

Page 621: ...Turbine Shaft Seals 7A 14B 36 Lo and Reverse Clutch Parts 7A 14B 12 Reverse Input Clutch Assembly 7A 14B 37 Inner Manual Linkage 7A 14B 13 Reverse Input Clutch Backing Plate Manual Shaft Seal Replacem...

Page 622: ...washer and thrust bearing surfaces may appear to be polished This is a normal condition and should not be considered damage lg Clean Thoroughly clean the exterior of the trans mission Remove or Disco...

Page 623: ...3 1 Install J 33037 as shown with apply pin 13 2 Install servo cover retaining ring 29 to secure tool 3 Apply 11 N m 98 lb in torque 4 If white line A appears in gage slot B pin length is correct 5 U...

Page 624: ...ESCRIPTION 12 SPRING SERVO RETURN 13 PIN 2ND APPLY PISTON 14 RING RETAINER 2ND APPLY PISTON 15 RETAINER SERVO CUSHION SPRING 16 SPRING SERVO CUSHION 17 PISTON 2ND APPLY 18 RING OIL SEAL 2ND APPLY PIST...

Page 625: ...g 30 4 Output shaft sleeve 690 and output shaft O ring seal 691 Not all models use an output shaft sleeve and seal ILL NO DESCRIPTION 8 CASE TRANSMISSION 30 SEAL CASE EXTENSION TO CASE 31 EXTENSION CA...

Page 626: ...Body And Wiring Harness Figures 9 through 14 0 Remove or Disconnect Figures 9 and 10 1 Electrical connections from components 2 TCC Solenoid bolts 68 and solenoid assembly 66 with O ring seal 65 and w...

Page 627: ...4 5 Bolts 77 and plate 53 6 Spacer plate 48 and spacer plate gaskets 47 and 52 7 Spring 46 piston 44 and pin 43 Seven checkballs are located under the valve body and one is located in the case The lar...

Page 628: ...4 CLUTCH EXHAUST 5 OVERRUN CLUTCH FEED 6 OVERRUN CLUTCH CONTROL 8 1 2 UPSHIFT 12 FORWARD CLUTCH ACCUM RH0112 4L60 E 38 PLUG TRANSMISSION CASE ACCUM BLEED 40 RETAINER AND BALL ASSEMBLY 3RD ACCUM 91 NO...

Page 629: ...11 inch bolt and locknut or J 25025 7A 2 Install J 25022 A or J 34725 as shown 3 Install J 24773 A as shown 4 Install dial indicator A Set to zero B Pull up on J 24773 A C End play should be 0 13 to 0...

Page 630: ...through 20 Tools Required J 29837 Output Shaft Support Fixture J 34627 Snap Ring Pliers Remove or Disconnect Figures 18 and 20 1 Reverse input clutch 605 and input clutch 621 together Grasp the turbin...

Page 631: ...T INPUT CARRIER TO REACTION SHAFT RH0119 4L60 E Reaction Gear Set Figure 21 Q j Remove or Disconnect 1 Input internal gear 664 and reaction carrier 666 2 Reaction sun shell 670 and thrust washer 669 3...

Page 632: ...TERNAL REACTION GEAR 692 BRG REACTION GEAR SUPPORT TO CASE 693 RING LO AND REVERSE CLUTCH RETAINER 694 SPRING ASSEMBLY LO AND REVERSE CLUTCH 695 PISTON LO AND REVERSE CLUTCH 697 DEFLECTOR OIL HIGH OUT...

Page 633: ...tuator assembly 85 and inside detent lever 88 89 3 78 PLUG STEEL CUP 79 SHAFT PARKING BRAKE PAWL 80 SPRING PARKING PAWL RETURN 81 PAWL PARKING BRAKE 82 SEAL MANUAL SHAFT 83 RETAINER MANUAL SHAFT 84 SH...

Page 634: ...ge transmission fluid characteristics and cause undesirable shift conditions and or filter clogging Case Assembly g Clean Thoroughly with solvent Air dry Do not wipe with cloth Figure 26 Case Vent Ass...

Page 635: ...se If leakage is observed replace the third accumulator retainer and ball assembly Replacement Procedure Third Accumulator Retainer and Ball Assembly Figures 29 and 30 Tools Required 6 3 mm 4 Screw Ex...

Page 636: ...27 Figure 29 Leak Check 3rd Accumulator Figure 30 Third Accumulator Retainer and Ball Asm Installation Lo and Reverse Clutch Piston Figures 31 and 32 Tools Required J 34627 Snap Ring Remover Installer...

Page 637: ...8 into the case Coat the plug with Loctite sealant or equivalent and install it with a hammer and punch Reaction Internal Gear and Carrier Assembly Figures 34 35 and 36 y Inspect Reaction internal gea...

Page 638: ...SE TRANSMISSION 681 CARRIER ASSEMBLY REACTION 683 BEARING ASSEMBLY THRUST REACTION CARRIER SUPPORT 685 SUPPORT INTERNAL REACTION GEAR 692 BRG REACTION GEAR SUPPORT TO CASE RH0133 4L60 E Figure 35 Capt...

Page 639: ...an evenly distributed load to the top of the lo and reverse support assembly 679 Light pressure approximately 22 N or 5 lbs on the lo and reverse support assembly 679 will provide the correct dimensi...

Page 640: ...r plate 682B from selection procedure 3 Lo and reverse clutch plates 682 into case lugs Start with a composition plate and alternate with steel Index with the splines of the reaction carrier and the c...

Page 641: ...e finish Support assembly for Cracks or damaged lugs Install or Connect Figures 42 43 and 44 1 Roller clutch assembly 678 into the cam and support assembly 679 2 Support and roller assembly into the c...

Page 642: ...e Index the four locating ears into the inner race 4 Reaction sun gear shell 670 onto the reaction sun gear 5 Bronze thrust washer 669 onto the reaction sun gear shell Index tangs into the shell Input...

Page 643: ...ernal Gear and Reaction Shaft Transmission Output Speed Sensor Rotor Figure 47 Tools Required J 21427 01 Speedometer Gear Puller Adapter J 8433 Speedometer Gear Puller J 36352 6 C Washer J 36352 4 Rot...

Page 644: ...thrust bearing To check the captive thrust bearing in the carrier for wear place a bushing or an output shaft sleeve on the bearing race do not contact the pinion gears and turn it with the palm of yo...

Page 645: ...ut clutch assembly 621 on the bench with the turbine shaft through the bench hole 2 The 3 4 clutch plate retainer ring 656 and the backing plate 655 3 The 3 4 clutch plates 654 4 Five 3 4 clutch boost...

Page 646: ...ly into the ring grooves Check valve retainer and ball assembly 617 for Damage The ball must move freely in the retainer The retainer must be tight in the turbine shaft Feed passages for Obstructions...

Page 647: ...54A PLATE ASSEMBLY 3RD AND 4TH CLUTCH FIBER 625 RING 3RD AND 4TH CLUTCH APPLY 654B PLATE 3RD AND 4TH CLUTCH STEEL 626 SPRING ASSEMBLY 3RD AND 4TH CLUTCH 655 PLATE 3RD AND 4TH CLUTCH BACKING SEL 627 RE...

Page 648: ...nd a cause is not found during diagnosis or disassembly replacement of the retainer and checkball assembly may be required Figure 54 USED WITH USED WITH 298mm CONVERTER 245mm CONVERTER A SHAFT TURBINE...

Page 649: ...om the piston hub Lubricate the seals with Transjel J 36850 or equivalent 2 The 3 4 clutch piston 623 into the input housing as shown Use care not to damage the seals Figure 58 Input Housing and 3 4 P...

Page 650: ...bricate with Transjel J 36850 or equivalent 3 Forward clutch piston 630 into the forward clutch housing Use care not to damage the outer lip seal 4 The 3 4 clutch spring assembly 626 onto the 3 4 clut...

Page 651: ...rrun clutch plates 645 for Com position plate dam aged tangs delamination or excessive wear Steel plate damaged tangs wear or heat damage Input sun gear bearing assembly 637 for Wear Flatness Damaged...

Page 652: ...642 FORWARD SPRAG ASSEMBLY 643 RETAINER RINGS SPRAG ASSEMBLY 644 RACE FORWARD CLUTCH OUTER RH0160 4L60 E Figure 65 Forward Clutch Sprag Assembly h Assemble Figures 66 6 7 an d 68 1 Forward clutch spr...

Page 653: ...ure y Assemble Forward clutch sprag assembly into the input clutch housing Index the overrun clutch hub into the overrun clutch plates Inspect Figures 69 and 70 Forward 649 and 3 4 clutch plates 654 f...

Page 654: ...plate 648 into the input clutch housing Index as shown The remaining forward clutch plates 649 into the input clutch housing Start with a steel plate and alternate with composition Forward clutch sele...

Page 655: ...5 and retainer ring 656 Chamfered side up 3 4 CLUTCH INFORMATION CHART PLATETYPE THICKNESS QUANTITY REQUIRED ALLMODELS STEPPED APPLY PLATE 5 60mm 220 1 t FLAT STEEL CLUTCH PLATES 1 78mm 070 1 FLAT STE...

Page 656: ...Figure 74 3 4 Backing Plate Selection Chart Turbine Shaft Seals Figure 76 Tools Required J 36418 1 Seal Installer J 36418 2A Seal Sizer Assemble 1 Install four turbine shaft oil seal rings 619 using J...

Page 657: ...1 SEAL OVERRUN CLUTCH INNER AND OUTER 653 PLATE 3RD AND 4TH CLUTCH APPLY STEPPED 632 PISTON OVERRUN CLUTCH 654A PLATE ASSEMBLY 3RD AND 4TH CLUTCH FIBER 634 SPRING ASSEMBLY OVERRUN CLUTCH 654B PLATE 3R...

Page 658: ...1 J 25018 A UNDER J 23327 1 RH0174 4L60 E Figure 79 Reverse Input Retainer Ring Removal jy Inspect Figures 78 and 80 Backing plate 613 for Damage Distortion or flatness Burrs or surface finish damage...

Page 659: ...load to the clutch pack in the direction shown in Figure 81 Medium pressure approximately 89 N or 20 lbs on the backing plate applied by hand on five evenly distributed points will obtain the backing...

Page 660: ...E 621 HOUSING AND SHAFT ASSEMBLY INPUT RH0180 4L60 E Figure 84 Reverse Input Clutch Reverse Input and Input Clutches Figures 85 86 and 87 Assemble Figures 85 and 86 1 Selective thrust washer 616 onto...

Page 661: ...n hole 2 Band anchor pin 41 into the case Index the pin into the 2 4 band Figure 88 2 4 Band Assembly Installed Oil Pump Assembly Figures 89 and 91 Remove or Disconnect 1 Thrust washer 601 2 Pump cove...

Page 662: ...1 Pressure regulator valve assembly 216 221 and converter clutch apply valve assembly 222 226 for Chips burrs distortion plugged oil passage and free movement in bore Remove burrs with lapping compoun...

Page 663: ...BOOST VALVE RETAINING 222 RING OIL PUMP CONVERTER CLUTCH VALVE RETAINING 223 VALVE STOP 224 VALVE CONVERTER CLUTCH 225 SPRING CONVERTER CLUTCH VALVE INNER 226 SPRING CONVERTER CLUTCH VALVE OUTER 227...

Page 664: ...h in the slide with the pivot pin The oil seal ring must face downward into the pump pocket 4 Slide seal 209 and support 208 5 Vane guide ring 210 6 Rotor guide 211 onto the rotor Retain with Transjel...

Page 665: ...screwdriver through a bolt hole and into a hole in the bench Tighten Attaching bolts to 24 N m 18 lb ft Retain with Transjel J 36850 or equivalent 4 Install two oil seal rings 233 using J38735 3 and J...

Page 666: ...e Adaptor 245 mm J 34725 End Play Checking Fixture Adaptor 298 mm J 25025 7A Post or 278 mm 11 inch Bolt and Nut Dial indicator j Measure Figures 99 through 102 1 Remove an oil pump to case bolt and i...

Page 667: ...80 084 68 2 21 2 31 mm 087 091 69 2 38 2 48 mm 094 098 70 2 55 2 65 mm 100 104 71 2 72 2 82 mm 107 111 72 2 89 2 99 mm 113 118 73 3 06 3 16 mm 120 124 74 RH0192 4L60 E Figure 101 End Play Chart CORREC...

Page 668: ...accum ulator spring 54 and 3 4 accumulator spring 46 for distortion or damage Spacer plate 48 and gaskets 47 and 52 for damage Checkballs 61 for damage Manual detent spring 63 for damage Oil filter 72...

Page 669: ...ase the chance of a valve not operating 1993 MODELS 1 2ACCUMULATOR SPRINGCOLOR 3 4 ACCUMULATOR SPRINGCOLOR CHD CJD KCD ORANGE LT GREEN WHITE OR PLAIN VIOLET CAD CBD KAD MJD MND ORANGE LT GREEN WHITE O...

Page 670: ...0 bore plug 359 and forward abuse valve train 357 and 358 10 Manual valve 340 11 3 2 control solenoid retainer clip 379 and solenoid 394 12 Bore plug retainer 395 bore plug 381 and 3 2 control valve t...

Page 671: ...black connector should be installed on the tab farthest from the valve body B Install or Connect 1 Parking bracket 86 P x l Tighten Bolts to 31 N m 23 lb ft 2 The 1 2 accumulator piston seal 55 onto...

Page 672: ......

Page 673: ...VE 2 3 SHUTTLE 370 SPRING 1 2 ACCUMULATOR VALVE 371 VALVE 1 2 ACCUMULATOR 372 SLEEVE 1 2 ACCUMULATOR VALVE 373 PLUG BORE 374 VALVE ACTUATOR FEED LIMIT 375 SPRING ACTUATOR FEED LIMIT VALVE 376 PLUG BOR...

Page 674: ...0112 4L60 E 63 SPRING ASSEMBLY MANUAL DETENT 88 LEVER INSIDE DETENT 89 LINK MANUAL VALVE 340 VALVE MANUAL RH0110 4L60 E Figure 112 Manual Valve Link Figure 111 Valve Body Checkball Locations A M 6 X 1...

Page 675: ...e Pan and Filter Assembly 2 4 Servo Assembly Figures 116 through 120 Tools Required J 33037 Band Apply Pin Tool Vernier calipers Scale J 22269 01 Piston Compressor J 29714 Servo Cover Compressor Iffi...

Page 676: ...s in the seal groove Springs for distortion Pin for wear or burrs f f Important Check servo bore in the case for any wear which may cut the servo seals j Measure Figure 117 1 Measure piston 17 dimensi...

Page 677: ...stall J 22269 01 A Compress the retainer past the snap ring groove in the 2nd apply piston B Install the retainer ring 14 4 The 2nd apply piston 17 onto the apply pin 13 Retainer goes toward the shoul...

Page 678: ...3 or J 25016 Seal Installer J 21426 Seal Installer J 38417 Speed Sensor Rem over and Installer 0 Install or Connect 1 O ring seal 691 on the output shaft sleeve 2 Output shaft sleeve 690 on the output...

Page 679: ...sembly Figure 126 Tool Required J 35138 Torque Converter End Play Checking Tool j Inspect The torque converter assembly must be replaced for any of the following conditions Evidence of damage to the p...

Page 680: ...possible B Replace the oil filter and pan gasket C Fill to proper level Refer to Section 7A The converter bolt hole threads are damaged Correct with thread insert Refer to Section 6A V Important Flush...

Page 681: ...CLUTCH PLANETARY REVERSE CLUTCH A S S E M B L Y G EARSET CLUTCH A S S E M B L Y REACTION O U T P U T P LANETARY SHAFT GEARSET T O R Q U E TURBINE CONVERTER SHAFT A S S E M B L Y S TATOR I 2 4 ROLLER...

Page 682: ......

Page 683: ...Y PIN 68 BOLT HEX WASHER HEAD SOLENOID 23 WASHER SERVO APPLY PIN 69 SWITCH ASSEMBLY TRANSMISSION PRESSURE 24 RING RETAINER APPLY PIN 70 BOLT PRESSURE SWITCH ASSEMBLY 25 PISTON 4TH APPLY 71 SEAL FILTER...

Page 684: ...629 633 632 631 634 635 645A 645B 636 638 639 642 643 644 641 646 648 649A 649B 650 651 r 653 654A 654B 655 656 658 661 662 663 664 665 666 667 668 669 670 671 672 673 674 675 676 677 678 679 677 681...

Page 685: ...WARD HSG ASSEMBLY CAM 623 PISTON 3RD AND 4TH CLUTCH 678 CLUTCH ASSEMBLY LO AND REVERSE ROLLER 624 SEAL 3RD AND 4TH CL INNER AND OUTER 679 SUPPORT ASM LO AND REVERSE CLUTCH 625 RING 3RD AND 4TH CLUTCH...

Page 686: ......

Page 687: ...VE 2 3 SHUTTLE 370 SPRING 1 2 ACCUMULATOR VALVE 371 VALVE 1 2 ACCUMULATOR 372 SLEEVE 1 2 ACCUMULATOR VALVE 373 PLUG BORE 374 VALVE ACTUATOR FEED LIMIT 375 SPRING ACTUATOR FEED LIMIT VALVE 376 PLUG BOR...

Page 688: ...A L V E S LO CATED IN TH E V A LV E BO D Y FORWARD ABUSE ACCUM VALVE 3 2 DOWNSHIFT LO OVERRUN ACTUATOR FEED LIMIT 1 2 SHIFT VALVE REV ABUSE 3 4 SHIFT VALVE 2 3 SHUTTLE VALVE 3 2 CONTROL RH0209 4L60 E...

Page 689: ...SPRINGS LOCATED IN THE PUMP PRESSURE CONV CL REGULATOR VALVE SPRINGS LOCATED IN THE VALVE BODY 3 4 SHIFT...

Page 690: ...OIL PUMP REVERSE BOOST VALVE 222 RETAINING RING OIL PUMP CONVERTER CLUTCH VALVE 224 223 RETAINING VALVE STOP 224 VALVE CONVERTER CLUTCH 225 SPRING CONVERTER CLUTCH VALVE INNER 226 SPRING CONVERTER CLU...

Page 691: ...ON OUTER 624 SEAL 3RD AND 4TH CL INNER AND OUTER 27 SEAL O RING 2 4 SERVO COVER 629 SEAL FORWARD CLUTCH INNER AND OUTER 30 SEAL CASE EXTENSION TO CASE 631 SEAL OVERRUN CLUTCH INNER AND OUTER 34 SEAL A...

Page 692: ...616 WASHER THRUST SELECTIVE 637 BEARING ASSEMBLY INPUT SUN GEAR 657 BUSHING INPUT SUN GEAR FRONT 659 BUSHING INPUT SUN GEAR REAR 663 BEARING ASSEMBLY THRUST INPUT CARRIER TO REACTION SHAFT 665 BUSHIN...

Page 693: ...ASSEMBLY TO CASE 2 M6 1 0 x 12 0 11 N m 8 LB FT MANUAL SHAFT TO INSIDE DETENT LEVER 1 M10 1 50 NUT 31 N m 23 LB FT TRANSMISSION OIL PAN TO CASE 16 M8 1 25 x 19 3 11 N m 8 LB FT LINE PRESSURE PLUG 1 1...

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 699: ...ly 4L80 E 11 Unit Assembly 4L80 E 47 Direct Clutch Assembly 4L80 E 11 Rear Unit End Play Check 4L80 E 47 Intermediate Clutch Assembly 4L80 E 11 Intermediate Clutch Assembly Direct Center Support and G...

Page 700: ...3 with 8 mm socket 4 Pump Body Seal Assembly 201 p 7 Install or Connect 1 Holding fixture J 8763 02 and J 38655 onto transmission NOTICE Overtightening of tool could cause case damage and inhibit disa...

Page 701: ...Twenty one bolts 35 using 10 mm socket from valve body assembly manual detent spring and roller assembly 41 5 Three wiring clips 33 fluid level indicator stop 43 one bolt 36 using 10 mm socket lube pi...

Page 702: ...FLUID PRESS 41 SPRING ASSEMBLY MANUAL DETENT 43 STOP FLUID LEVEL INDICATOR DIPSTICK 44 BODY ASSEMBLY CONTROL VALVE 51 HOUSING ACCUMULATOR 75 SCREEN PWM SOLENOID 76 BOLT SPECIAL RH0103 4L80 E FRONTAND...

Page 703: ...LY SELECTIVE 74 SPRING REAR ACCUMULATOR BAND APPLYPIN CHECK Figures 7 8 and 9 Tools Required J 21370 10 Gage Pin J 38737 Band Apply Pin Checking Tool j Measure 1 Place J 21370 10 in the servo bore 2 P...

Page 704: ...09 4L80 E Output shaft O ring seal 675 some models for damage Figure 10 Removing Case Extension Assembly PARKING LOCK PAWLAND ACTUATOR ASSEMBLY Figures 11 and 12 NOTICE Do not apply excessive force pr...

Page 705: ...0 ACTUATOR ASSEMBLY PARKING LOCK 711 LEVER AND PIN ASSEMBLY INSIDE DETENT 712 NUT HEX HEAD 713 BRACKET PARKING LOCK 714 BOLT HEX HEAD M6 X 1 25 X 20 0 707 PLUG PARKING PAWL SHAFT HOLE SHAFT PARKING LO...

Page 706: ...0 559 mm 0 004 to 0 022 inch Retain this measurement for future reference 5 Remove tools T Important During reassembly Front End Play Check must be repeated to verify accuracy of selective washer THIC...

Page 707: ...LY Figures 17 and 18 Tool Required J 37789 Pump Remover E Remove or Disconnect 1 O ring turbine shaft 2 NOTICE Pump assembly can not be removed without damage to the O ring when in place 2 Seven bolt...

Page 708: ...unit assembly 504 and turbine shaft 502 2 Recheck Fourth Clutch Bolt 26 Torque should be 15 N m minimum 133 lb in minimum 3 Fourth clutch bolt 26 using 40T torx head socket NOTICE Discard bolt do not...

Page 709: ...or top of direct clutch housing fthT OTMnnnflr 601 BEARING ASM THRUST CARRIER FORWARD CLUTCH 602 HOUSING ASSEMBLY FORWARD CLUTCH R H 0120 4L80 E DIRECTCLUTCH ASSEMBLY Figure 22 Tool Required J 38733...

Page 710: ...do not reuse Damage could result to the Center Support Housing 2 Snap ring 633 tapered 3 Attach tool J 38868 to main shaft 662 4 Center support assembly 634 641 and gear unit assembly 642 672 using t...

Page 711: ...sembly lube It is recommended that TRANSJEL J 36850 or the equivalent of petroleum jelly be used during assembly NOTICE Do not use any type of grease to retain parts during assembly of this unit Greas...

Page 712: ...8 Excess gasket material left on surfaces 2 Case extension 19 for Cracks Porosity Scored bushing 77 3 All threaded holes for Damage Heli coil to repair damage 4 Air check all fluid passages See Diagno...

Page 713: ...11 Pipe vent 9 12 PWM solenoid screen 75 13 Rear lube seal 13 and snap ring 14 Replace rear lube seal 13 with J 38693 if necessary 14 Manual shaft seal 707 ffi Clean All components m Important Use on...

Page 714: ...Damaged bushing Output carrier assembly 661 for Wear Damaged lugs Pinion gear damage Washer wear Pinion gear and pocket thrust surfaces damage Inspect Excess pinion washer wear end play should be 0 22...

Page 715: ...SSEMBLY SUN GEAR GEAR SUN DRUM AND CARRIER ASSEMBLY REACTION WASHER PINION THRUST BRONZE WASHER PINION THRUST STEEL ROLLER NEEDLE BEARING PINION PLANET PIN PLANET PINION BAND ASSEMBLY REAR BRAKE RING...

Page 716: ...and sun gear shaft 649 for Nicked scored or worn bushings 676 Damaged splines or teeth Cracks CENTER SUPPORT ASSEMBLY Figures 33 through 36 Tools Required J 6116 01 Rear Gear Assembly Holding Fixture...

Page 717: ...Center Support and Intermediate Clutch Piston h h Assemble Figures 33 35 and 36 1 Lubricate new inner and outer clutch piston seals 637 and 638 and seal pockets in housing with DEXRON IIE transmission...

Page 718: ...on fluid 6 Output shaft 671 into output carrier assembly 661 634 RING SNAP INTERMEDIATE CLUTCH 635 SPRING AND RETAINER ASM INTERMEDIATE CLUTCH 636 PISTON INTERMEDIATE CLUTCH 637 SEAL INTERMEDIATE CLUT...

Page 719: ...SSEMBLY SUN GEAR 651 DRUM AND CARRIER ASSEMBLY REACTION 660 RING OUTPUT SPEED SENSOR RH0137 Figure 39 Installing Spacer Ring and Roller Clutch Assembly 7 Snap ring 672 in groove of output carrier asse...

Page 720: ...rough 49 Tools Required J 8001 Dial Indicator Set J 21362 Seal Protector inner J 23327 Spring Compressor J 25018 A Adapter Mechanical Press J 38695 Spiral Snap Ring Installer J 38732 Seal Protector ou...

Page 721: ...s of inside diameter Spline damage 3 Clutch housing 623 for Cracks Wear Proper opening of oil passages Checkball 537 4 Clutch plates 611 and 618 for Wear Burned Flaking Scoring Pitting 5 Backing plate...

Page 722: ...clutch hub install tool J 38695 in hub hole rotate counterclockwise while pressing down until snap ring is in place 5 Dished plate 609 into direct clutch housing 623 Inner diameter dish down 6 Plate...

Page 723: ...rect passage This condition is normal Apply 80 psi of air pressure to direct passage to actuate piston and move clutch plates 4 Piston travel should be 3 07 to 4 72 mm 0 121 to 0 186 inch 5 Remove dir...

Page 724: ...holes Damaged thrust faces 613 Clutch surface 615 INSPECT CHECKBALL SOME MODELS 685 605 606 607 608 601 BEARING ASM THRUST CARRIER FORWARD CLUTCH 602 HOUSING ASSEMBLY FORWARD CLUTCH 603 SEAL CLUTCH CE...

Page 725: ...ure 51 1 Dished clutch plate 609 Inside dish down 2 Steel plates 610 0775 thickness and plate assemblies 611 Starting with steel plate first 3 Direct clutch hub 615 in forward clutch housing 602 4 Sna...

Page 726: ...T STEEL PLATES NO OF DISHED PLATES NO OF COMPOSITION PLATES NO OF WAVED STEEL PLATES PISTON TRAVEL CHECK THICKNESS 1 97MM 0775 1 37MM 054 2 03MM 080 1 54MM 0605 3 07 4 27MM 0 121 0 186 ALL MODELS EXCE...

Page 727: ...n 528 5 Place housing 529 on bench resting on piston 528 and piston spacer 6 Push and rotate down on housing do not force until piston is through housing exposing snap ring groove 7 Remove housing sea...

Page 728: ...523 Measurement should be 1 016 to 2 540 mm 0 040 to 0 100 inch OVERDRIVE UNIT ASSEMBLY Figure 59 Disassem ble Snap ring 522 Turbine shaft 502 Overrun carrier assembly 514 from housing 504 1 2 3 523...

Page 729: ...ates 508 and 509 three steel and three fiber 4 Compress spring and retainer assembly 506 using J 23327 and J 38734 adapter 5 Snap ring 507 6 Remove tools 7 Spring and retainer assembly 506 8 Piston 50...

Page 730: ...utch plates 508 and 509 3 of each backing plate 510 6 Snap ring 511 j Measure Figure 62 1 Feeler gage between backing plate and snap ring 2 Clearance should be between 0 838 to 2 38 mm 0 033 to 0 094...

Page 731: ...er clutch assembly 512 3 Pinion assembly 518 4 Thrust bearing assembly 513 5 Carrier 514 for Cracks Damage Wear i h Assemble 1 Needle bearing 517 and pinions 518 2 Washers 515 and 516 on pinion 518 9...

Page 732: ...haft seals 501 and 503 Assemble Figures 68 and 69 1 Place seal installer J 38736 onto shaft 2 Push seals 501 and 503 over and down the installer until they are in place using pusher tool One at a time...

Page 733: ...G SNAP 512 ROLLER CLUTCH ASSEMBLY OVERDRIVE 513 BEARING ASSEMBLY THRUST CARRIER OVERRUN CLUTCH 514 CARRIER ASSEMBLY OVERDRIVE 515 WASHER PINION THRUST 516 WASHER PINION THRUST STEEL 517 ROLLER NEEDLE...

Page 734: ...ating surfaces Cross channel leaks 3 Pump body bolt threads for Damage 4 Oil seal 201 bushing 202 for Wear Damage Pump Cover Figure 70 y Inspect 1 Pump gear face for Wear Scoring 2 Stator shaft spline...

Page 735: ...E VALVE 217 VALVE TCC ENABLE 218 WASHER THRUST SELECTIVE 219 RING OIL SEAL _____ 220 BOLT M 8X 1 25 X 40 5 221 RING SNAP 223 VALVE TCC 224 SPRING TCC VALVE 225 PLUG TCC VALVE BORE 226 RING RETAINER RE...

Page 736: ...CC Enable Valve Spring Rod Location F 1 Assemble Figures 73 and 74 Tools Required J 21368 Alignment Band J 38739 Oil Pump Seal Ring Installer Sizer and Pusher J 25025 1 Guide Pins J 37789 Pump Install...

Page 737: ...59 3 Ring 56 piston pin 55 and piston 57 REARSERVO ACCUMULATOR Figure 76 Disassemble Retaining clip 64 from rear band apply pin 73 and inspect 3 1 2 3 Inspect Rear Accumulator piston 68 and Rear Serv...

Page 738: ...REAR SERVO 63 GASKET REAR SERVO COVER 64 CLIP RETAINING BOTTOM 65 PISTON REAR SERVO 66 RING OIL SEAL ACCUM PISTON OUTER 67 RING OIL SEAL ACCUM PISTON INNER 68 PISTON REAR ACCUMULATOR 69 SEAL REVERSE S...

Page 739: ...ensator valve 409 and spring 410 2 Snap ring 402 from outside housing pin 408 snap ring 402 piston 407 and spring 49 3 3rd clutch piston 405 and spring 50 4 Seals 404 and 406 l2 l Clean All components...

Page 740: ...ULATOR 53 BOLT ACCUM HOUSING TO VALVE BODY RH0171 4L80 E Figure 77 Control Valve Assembly Accumulator Housing 49 SPRING 4TH CLUTCH ACCUM PISTON 50 SPRING 3RD CLUTCH ACCUM PISTON 51 HOUSING ACCUMULATOR...

Page 741: ...OLENOID RETAINING 308 VALVE 3 4 SHIFT 323 SOLENOID ASSEMBLY PWM 309 SPRING SHIFT VALVE RETURN 2 3 AND 3 4 324 VALVE TCC REGULATOR APPLY 310 BOLT SOLENOID 1 2 AND 2 3 SHIFT PRESSURE 325 SPRING TCC REGU...

Page 742: ...Start accumulator housing bolts finger tight starting with bolt 52 and work towards opposite end Tighten sequence Figure 79 Tighten Bolts 52 and 53 to 11 N m 97 lb in 7 Remove guide pin J 25025 5 P A...

Page 743: ...ve the T handle forcing screw from the base 2 Place J 39195 base into the torque converter J 39195 will bottom itselfon the face of the stator 3 Insert the T handle forcing screw and hand tighten NOTE...

Page 744: ...king lock bracket 713 with two bolts 714 Tighten Bolts 714 to 24 N m 18 lb ft REAR BAND AND SELECTIVE THRUST WASHER Figure 85 Install or Connect 1 Selective thrust washer 674 determined by Rear End Pl...

Page 745: ...ition align bolt hole in center support 640 with hole in case 7 and carefully lower gear unit center support assembly into case using J 38868 4 Beveled snap ring 633 Flat side down using J 28585 The e...

Page 746: ...t clutch passage through case 7 Apply pressure on J 23093 seating the center support splines counterclockwise against the case splines Push tool toward rear servo bore 2 New case to center support bol...

Page 747: ...nd 632 with J 24396 Leave tool in place 7 Apply air through center support bolt hole to engage intermediate clutch 8 Remove tool J 24396 9 Continue applying air to hold clutch plates in place 10 Direc...

Page 748: ...ATE CLUTCH RETAINER 630 PLATE INTERMEDIATE CLUTCH BACKING 631 PLATE ASSEMBLY INTERMEDIATE CLUTCH 632 PLATE INTERMEDIATE CLUTCH RH0181 4L80 E Figure 92 Installing Intermediate Clutch Plates and Front B...

Page 749: ...er 218 onto top of overrun housing and straight edge to pump to cage surface The two surfaces should be flush FOURTH CLUTCH PLATES hhh Install or Connect Figures 97 and 98 1 Fourth clutch plates 525 a...

Page 750: ...assembly is fully installed J 37789 2 3 4 5 6 218 219 SEAL O RING TURBINE SHAFT TURBINE HUB BOLT AND SEAL ASSEMBLY PUMP TO CASE PUMP ASSEMBLY COMPLETE SEAL OIL PUMP TO CASE GASKET PUMP COVER TO CASE...

Page 751: ...inch 5 Remove tools and correct end play if necessary 6 Install O ring 2 on turbine shaft 7 Install seal assembly 201 using J 38694 if necessary THICKNESS INCH STRIPE 057 061 BLUE 073 077 RED 089 093...

Page 752: ...10 Gage Pin J 38737 Band Apply Pin Checking Tool Measure 1 Place J 21370 10 in the servo pin bore 2 Position J 38737 over the bore with the hex nut facing the parking pawl linkage 3 Fasten with two se...

Page 753: ...arts 64 73 in servo bore 3 New gasket 63 cover 62 and six 10 mm bolts 61 using 10 mm socket Tighten Bolts 61 to 24 N m 18 lb ft 61 BOLT REAR SERVO COVER 62 COVER REAR SERVO 63 GASKET REAR SERVO COVER...

Page 754: ...ing 10 mm socket 8 Six bolts 76 using 8 mm socket into transmission fluid pressure switch assembly 40 9 Lube pipe 39 long end into case short end into valve body 10 Lube pipe clip 37 with short bolt 3...

Page 755: ...Seal 32 inside of case 7 2 Filter assembly 31 3 Bottom pan seal 29 4 Magnet 30 into bottom pan 5 Pan 29 6 Seventeen bolts 27 using 10 mm socket j l Tighten Bolts 27 to 24 N m 18 lb ft CASE EXTENSION...

Page 756: ...BE PIPE 40 SWITCH ASM A TRANS FLUID PRESS 43 STOP FLUID LEVEL INDICATOR DIPSTICK 311 2 3 SHIFT SOLENOID AND O RING ASSEMBLY 313 1 2 SHIFT SOLENOID AND O RING ASSEMBLY 320 PRESSURE CONTROL SOLENOID 323...

Page 757: ...ELIX SEAL ASSEMBLY CASE EXTENSION 21 BOLT HEX HD M 1 0 X 1 5X30 0 675 SEAL O RING OUTPUT SHAFT RH0109 4L80 E Figure 113 Installing Case Extension Assembly 22 SENSOR ASM A TRANS INPUT SPD AND VEH SPD 2...

Page 758: ...RH0194 4L80 E...

Page 759: ...ENSION 65 PISTON REAR SERVO 21 BOLT HEX HD M10 X 1 5 X 30 0 66 RING OIL SEAL ACCUM PISTON OUTER 22 SENSOR ASM A TRANS INPUT SPD AND VEH SPD 67 RING OIL SEAL ACCUM PISTON INNER 23 BOLT METRIC HEX 68 PI...

Page 760: ...LUG ORIFICED CUP 1 229 RETAINER PRESSURE REGULATOR SPRING 209 PLUG CUP 2 230 SPRING PRESSURE REGULATOR 211 PIN COILED SPRING 3 231 VALVE PRESSURE REGULATOR 212 PLUG CONVERTER LIMIT VALVE BORE 232 PLUG...

Page 761: ...OID RETAINING 308 VALVE 3 4 SHIFT 323 SOLENOID ASSEMBLY PWM 309 SPRING SHIFT VALVE RETURN 2 3 AND 3 4 324 VALVE TCC REGULATOR APPLY 310 BOLT SOLENOID 1 2 AND 2 3 SHIFT PRESSURE 325 SPRING TCC REGULATO...

Page 762: ...E CUT 50 SPRING 3RD CLUTCH ACCUM PISTON 405 PISTON 3RD CLUTCH ACCUMULATOR 51 HOUSING ACCUMULATOR 406 SEAL 859 SQUARE CUT 53 BOLT ACCUM HOUSING TO VALVE BODY 407 PISTON 4TH CLUTCH ACCUMULATOR 402 RING...

Page 763: ...DRIVE 515 WASHER PINION THRUST 516 WASHER PINION THRUST STEEL 517 ROLLER NEEDLE BEARING 518 PINION OVERDRIVE PLANET 519 PIN OVERDRIVE PINION 520 RETAINER PINION PIN 521 RING SNAP 522 RING SNAP TURBINE...

Page 764: ......

Page 765: ...619 PISTON DIRECT CLUTCH 663 RACE THRUST BEARING TO SUN GEAR 622 SEAL CLUTCH CENTER 664 BEARING NEEDLE THRUST RR INTERNAL GEAR 623 HOUSING DIRECT CLUTCH 665 RACE THRUST BEARING TO RR INTERNAL GEAR 624...

Page 766: ...SHAFT 711 LEVER AND PIN ASSEMBLY INSIDE DETENT 705 SPRING PARKING PAWL RETURN 712 NUT HEX HEAD 706 STUD PARKING PAWL RETURN SPRING 713 BRACKET PARKING LOCK 707 SEAL ASSEMBLY MANUAL SHIFT SHAFT 714 BOL...

Page 767: ...STATOR SHAFT FRONT 664 BEARING NEEDLE THRUST RR INTERNAL GEAR 234 BUSHING STATOR SHAFT REAR 676 BUSHING SUN GEAR SHAFT 512 ROLLER CLUTCH ASSEMBLY OVERDRIVE 677 BUSHING OUTPUT SHAFT 513 BEARING ASSEMB...

Page 768: ...SEAL ASSEMBLY CASE EXTENSION RING OIL SEAL RING OIL SEAL ACCUM PISTON OUTER RING OIL SEAL ACCUM PISTON INNER SEAL REVERSE SERVO PISTON HELIX SEAL ASSEMBLY PUMP BODY RING OIL SEAL SEAL 1 615 SQUARE CUT...

Page 769: ...N 15 MIN ACCUMULATOR HOUSING TO VALVE BODY SCREW 11 97 8 MIN 71 MIN FOURTH CLUTCH SCREW 16 12 15 MIN 133 MIN PAN TO CASE SCREW 24 18 15 MIN 133 MIN EXTENSION HOUSING TO CASE SCREW 34 25 27 MIN 20 MIN...

Page 770: ...SPECIAL TOOLS...

Page 771: ...SPECIAL TOOLS CONT...

Page 772: ......

Page 773: ...ainshaft and Synchronizers 7B1 Countershaft 7B1 Reverse Idler G ear 7B1 Front and Rear Housings 7B1 Shift Shaft Rail and Fork assemblies 7B1 Shift Lever Housing 7B1 Assembly 7B1 Input Shaft Bearing Re...

Page 774: ...G 134 NUT HEX JAM 136 HOUSING ASSEMBLY SHIFT LEVER 200 HOUSING FRONT 204 BOLT HEX HEAD 206 RETAINER INPUT SHAFT BEARING 209 SEAL INPUT SHAFT BEARING RETAINER OIL 210 RING SNAP SELECTIVE 213 RING INPUT...

Page 775: ......

Page 776: ......

Page 777: ...200 HOUSING FRONT 201 BEARING ASSEMBLY COUNTERSHAFT 202 RACE COUNTERSHAFT BEARING 203 BEARING COUNTERSHAFT 300 HOUSING REAR 2WD 302 RETAINER OUTPUT SHAFT BEARING 2WD 303 RETAINER OUTPUT SHAFT BEARING...

Page 778: ...g pilot with a rubber mallet B Save the input bearing retainer washer 9 Snap ring 210 and shim 212 10 Position transmission horizontally 11 Front housing to rear housing bolts 312 figure 10 12 Drive d...

Page 779: ...a g e th e re a r h o u s in g s h ift s h a ft b e a rin g 309 c a u s in g in c re a s e d s h ift e ffo rt 21 Shift shaft 108 shift shaft socket assembly 114 anti rotation bracket 112 biasing spri...

Page 780: ...MAINSHAFT DISASSEMBLY Disassemble Figures 16 through 21 Tools Required Hydraulic Press J 36513 Gear and Bearing Separator Plate 1 Snap ring 6 figure 16 N O T IC E O p tio n a l m e th o d in fig u re...

Page 781: ...RD A N D F O U R T H SHIFT 3707r5193 Figure 14 Gears and Shift Forks B Leave the synchronizer rings 2 on the first second synchronizer assembly 19 to pre vent the synchronizer detent balls 9 from pop...

Page 782: ...R GEAR DISASSEMBLY Disassemble Figure 23 1 Snap ring 47 2 Thrust washer 48 3 Reverse gear 49 4 Bearing assembly 50 FRONT HOUSING DISASSEMBLY Disassemble Figures 1 2 24 through 27 Tools Required J 3618...

Page 783: ...DLE 18 GEAR ASSEMBLY 2ND SPEED 23 SHAFT OUTPUT 2WD 24 SHAFT OUTPUT 4WD 3707r5129 2 RING SYNCHRONIZER 17 BEARING ASSEMBLY SPEED GEAR NEEDLE 19 SYNCHRONIZER ASSEMBLY 1 2 22 GEAR 1ST SPEED 23 SHAFT OUTPU...

Page 784: ...TH SPEED GEAR NEEDLE MG5 31 GEAR ASSEMBLY 5TH SPEED MG5 3707r5131 2 RING SYNCHRONIZER 17 BEARING ASSEMBLY SPEED GEAR NEEDLE 23 SHAFT OUTPUT 2WDI 24 SHAFT OUTPUT 4WDI 25 GEAR ASSEMBLY REVERSE SPEED 26...

Page 785: ......

Page 786: ...s 2 Shift rail front housing bushing 228 using J 36800 and J 23907 figure 24 3 Clutch fork pivot assembly 219 using J 36510 and J 6125 1B figure 25 A Put an additional nut 3 8 16 thread onto J 36510 a...

Page 787: ...mover 2WD models only 1 Rear housing shift shaft bearing 309 using J 23907 with pilot bearing puller figure 28 A Position puller legs behind bearing lip B Tighten C Slide hammer out If the bearing lip...

Page 788: ...e bolts 306 output shaft bearing retainer 303 and bearing assembly 33 using brass drift 4WD models only figure 29 4 Slip yoke seal 319 using J 26941 and J 23907 figure 30 2WD models only 5 Gasket mate...

Page 789: ...these conditions exist 4 Bearing races 202 for scoring wear or overheat ing If scuffed nicked or burred conditions cannot be removed with a soft stone or crocus cloth replace the component Fifth gear...

Page 790: ...are serviced as an assembly only 1 Shaft for wear or scoring 2 Forks 100 101 and 102 for wear scoring or dis tortion The edges will turn black in color This is a normal condition 3 Shift lever and blo...

Page 791: ...ller Seal Replacement 1 Rubber seal lip with pliers Exposing the metal lip A Install J 29369 2 below metal lip of seal B Expand to finger tight C Turn five additional turns D Install J 23907 into J 29...

Page 792: ...16 lbs ft 3 Two dowel pins 321 Drive until flush 4 Slip yoke oil seal 319 using J 36503 figure 37 2WD models only Fill between the seal lips with chassis grease FRONT HOUSING ASSEMBLY Assemble Figure...

Page 793: ...onto hub 12 21 or 28 Check scribe marks for correct positions Remove spiral lock ring 27 for easier assem bly fifth reverse only 2 Spring 10 into key 11 Assembly into the hub 3 Position assembly as i...

Page 794: ...nizer rings 2 using J 36183 J 36184 J 22912 01 and hydraulic press Check scribe marks for correct positions Important The groove on the outside of the sleeve MUST GO TOWARDS THE SECOND SPEED GEAR to p...

Page 795: ...4WD 30 BEARING ASSEMBLY 5TH SPEED GEAR NEEDLE MG5 31 GEAR ASSEMBLY 5TH SPEED MGS 3707r5134 2 RING SYNCHRONIZER 17 BEARING ASSEMBLY SPEED GEAR NEEDLE 19 SYNCHRONIZER ASSEMBLY 1 2 22 GEAR 1ST SPEED 23 S...

Page 796: ...GEAR NEEDLE 18 GEAR ASSEMBLY 2ND SPEED 23 SHAFT OUTPUT 2WD 24 SHAFT OUTPUT 4WD 3707r5136 2 RING SYNCHRONIZER 6 RING SNAP 7 SYNCHRONIZER ASSEMBLY 3 4 13 GEAR ASSEMBLY 3RD SPEED 14 BEARING ASSEMBLY 3RD...

Page 797: ...2WD SHAFT ASSEMBLY MAIN 4WD 3707r5147 1 Pilot bearing 3 into input shaft 1 figure 46 A Turn the smaller diameter of the bearing cabe toward the input shaft B Retain with TRANSJEL J 36850 or equiva len...

Page 798: ...ole in the case B Rotate back and fourth while pulling down C Pull up on J 36515 10 while installing rear housing Important Bring the housing straight down If resistance is felt at about 7 mm 1 4 in t...

Page 799: ...seal protector J 36502 2A onto output shaft 16 Output shaft oil seal 320 using J 36502 figure 51 4WD models only A Fill between the seal lip with chassis grease B Remove seal protector J 36502 2A Impo...

Page 800: ...se opening Thin side of plate as viewed from the top should be installed towards the left side of the transmission 30 Shift tower 136 and bolts 204 figure 33 a Tighten Shift tower bolts to 10 N m 89 l...

Page 801: ...ission Fluid or the equivalent 44 Oil fill plug 222 Tighten Oil fill plug 222 to 60 N m 44 lbs ft Figure 53 Installing External Components SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS N m Lbs Ft...

Page 802: ...EAR PULLER ADAPTER 7 SEPARATOR PLATE OF EQUIVALENT 8 SLIDE HAMMER WITH PILOT BEARING PULLER 9 GEAR PULLER 10 HEAT GUN OR EQUIVALENT 11 2WD OUTPUT SHAFT OIL SEAL REMOVER 12 INPUT SHAFT BEARING RETAINER...

Page 803: ...REMOVER 22 CLUTCH FORK PIVOT REMOVER INSTALLER J 36825 23 OIL FILL DRAIN PLUG HEX BIT 17 MM 24 GEAR AND BEARING SEPARATOR PLATE 25 ASSEMBLY PALLET WITH COUNTER SHAFT ADAPTER 26 2WD OUTPUT SHAFT BEARIN...

Page 804: ...NOTES...

Page 805: ...Bearing Replacement 7B2 8 Seal Replacement 7B2 8 Shift Cover 7B2 9 Unit Assem bly 7B2 10 Specifications 7B2 13 Fastener Tightening Specifications 7B2 13 Lubrication Specifications 7B2 13 Special Tool...

Page 806: ......

Page 807: ...56 TRUNION TRANSMISSION 29 RETAINER REAR OIL 3707r5169 Figure 2 Transmission Shift Mechanism and Case Components Legend 15 Overdrive gear assembly Slide overdrive fork 137 as far rearward as possible...

Page 808: ......

Page 809: ...7 BEARING MAIN DRIVE GEAR PILOT 98 GEAR MAIN DRIVE 99 CONE DRIVE GEAR BEARING 100 BEARING COUNTERSHAFT REAR 101 PIN 102 SHAFT TRANSMISSION COUNTER 103 KEY COUNTER GEAR 104 GEAR THIRD COUNTER 105 GEAR...

Page 810: ...Disassemble Figures 3 4 and 8 Inspect Parts for damage and wear Oil the bearings and check for roughness 1 Pilot bearing 97 2 Bearing 99 using suitable puller Clean All parts in a suitable solvent Im...

Page 811: ...e gear 58 and rotor 57 if equipped 2WD models only Do not let mainshaft fall to the floor 3 58 GEAR MAINSHAFT OVERDRIVE 59 BEARING MAINSHAFT REAR 60 WASHER THRUST 61 GEAR REVERSE SPEED 69 SHAFT MAIN V...

Page 812: ...l Replacement in this section 2 Retaining ring 21 3 Bearing 20 from extension 18 or 23 Install or Connect Figures 1 and 2 Tool Required J 38807 Extension Housing Bearing Installer 1 Bearing 20 into ex...

Page 813: ...Important Figure 14 Do not disassemble the shift cover Individual compo nents of the shift cover are not serviced If the shift cover is damaged or worn it must be replaced as a complete assembly Figu...

Page 814: ...lever retaining pin Hold overdrive shift lever back out of the way using a rubber band figure 15 Ensure the notches that retain the overdrive fork 137 are to the outside of the case 4 Countershaft fr...

Page 815: ...nd countershaft thrust washer 124 17 Overdrive gear assembly 129 onto overdrive shift rail 139 Bearings 125 spacer 126 synchronizer ring 133 and clutch gear 134 into overdrive gear assembly 129 if rem...

Page 816: ...te Dri Loc 201 or equivalent to the bolts and retorque 23 Vibration damper 30 using J 39314 figure 20 4WD models only Move synchronizer sleeves to lock transmission into two gears at once 24 Mainshaft...

Page 817: ...clockwise surfaces Install boot seal 32 Shift lever stub 1 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Item N m Lbs Ft Countershaft Retainer Plate to Case Bolt 35 26 Main Drive Gear Retainer to...

Page 818: ...ALLER COUNTERSHAFT BEARING CONE INSTALLER 2 EXTENSION HOUSING SEAL INSTALLER 2WD MODELS 3 INPUT SHAFT SEAL INS1ALLER 4 OUTPUT SHAFT NUT SOCKET 4WD MODELS 5 EXTENSION HOUSING BEARING INSTALLER 2WD MODE...

Page 819: ...and Spacers 7B3 9 Front and Rear Bearings 7B3 9 Synchronizer Blocker Rings 7B3 9 Synchronizer Keys and Springs 7B3 10 Extension Housing Oil Seal and Bushing Replacement 7B3 10 Drive Gear Bearing Retai...

Page 820: ...type interlock blocks the other shafts when one is moved PRECAUTIONS Certain precautions should be followed when repair ing the transmission Unless proper care is taken the components may be damaged R...

Page 821: ...26 from the mainshaft 14 figure 9 Mark the front bearing retainer and the case for alignment 17 Front bearing retainer bolts 95 18 Front bearing retainer 96 19 Front bearing race 99 and the shim pack...

Page 822: ...3707r5079...

Page 823: ...COUNTERSHAFT BEARING 51 BEARING COUNTERSHAFT 52 GEAR CLUSTER COUNTERSHAFT 53 RACE REAR COUNTERSHAFT 54 SHIM COUNTERSHAFT BEARING ADJUSTMENT 55 RETAINER COUNTERSHAFT 56 BOLT COUNTERSHAFT RETAINER 57 GE...

Page 824: ...Speed and Reverse Shift Lever Retaining Clip 63 RETAINER 64 RING SNAP 3707r5086 Figure 7 Fifth Gear Synchronizer Retainer 62 SYNCHRONIZER FIFTH SPEED 65 FUNNEL OILING 73 FORK FIFTH SPEED SHIFT 3707r51...

Page 825: ...SE TRANSMISSION 3707r5081 Figure 9 Fifth Gear Snap Ring 98 SHIM MAIN DRIVE GEAR BEARING 99 RACE MAIN DRIVE GEAR BEARING 3707r5109 Figure 10 Main Drive Gear Shim Pack Figure 12 Mainshaft Removal Figure...

Page 826: ...BEARING DRIVE GEAR 100 GEAR MAIN DRIVE 101 BEARING PILOT 3707r5159 Figure 19 Main Drive Gear Bearings 12 Mainshaft rear bearing assembly 23 and 24 13 First gear 22 14 Needle bearing 21 and sleeve 20...

Page 827: ...pecified Fifth gear blocker ring is brass and can be checked visually for wear and damage I Important Make certain the blocker rings are correctly identified before assembly The first second synchroni...

Page 828: ...Remove or Disconnect Figure 26 Tool Required J 8092 Driver Handle J 23062 14 Extension Housing Bushing Remov er and Installer 1 Seal 88 2 Sealing compound from the flange of the extension housing 31...

Page 829: ...etainer 95 L Inspect 1 Retainer nose for scoring wear or cracks espe cially at the flange 2 Replace the retainer if it is worn or damaged Install or Connect Figure 28 Tool Required J 37375 Bearing Ret...

Page 830: ...e plug with sealing com pound 2 Fit the inserts 11 and the fork plates 12 into the shift forks 3 First and second largest shift fork 10 Fit the shift rail into the cover rear bore Hold the shift fork...

Page 831: ...8092 and a press figure 31 Install or Connect Figures 1 2 32 and 33 Tools Required J 37357 Countershaft Bearing and Race Remover and Installer J 22912 01 Bearing and Gear Puller J 8092 Universal Driv...

Page 832: ...ng J 25234 and a press Lubricate fifth gear splines with petroleum jelly Carefully align the mainshaft and gear splines If splines are improperly aligned damage could occur when the gear is pressed on...

Page 833: ...bearing race 24 9 Drive drive gear in case 100 Make sure rollers thrust bearing and washer are in place Be sure to engage the third fourth synchronizer sleeve and blocker ring 10 Front bearing race 9...

Page 834: ...olts 93 to 30 N m 22 lbs ft 24 New pin 84 into the offset lever 85 and shift rail 6 25 Damper sleeve in offset lever 83 Turn transmission on end and mount a dial indica tor J 8001 on the extension hou...

Page 835: ...tainer Bolts 20 15 Drain Plug 27 20 Drive Gear Bearing Retainer Bolts 20 15 Extension Housing Bolts 30 22 Fill Plug 27 20 Pivot B olt 27 20 Transmission Cover Bolts 13 115 LUBRICATION SPECIFICATIONS C...

Page 836: ...ON HOUSING SEAL INSTALLER 4 BEARING AND GEAR PULLER 5 EXTENSION HOUSING BUSHING REMOVER AND INSTALLER 6 FRONT AND REAR BEARING INSTALLER 7 HOLDING FIXTURE 8 INSTALLER 9 COUNTERSHAFT BEARING AND RACE R...

Page 837: ...l s iz e a n d s tre n g th o r s tro n g e r m a y b e u s e d F a s te n e rs th a t a re n o t re u s e d a n d th o s e re q u irin g th re a d lo c k in g c o m p o u n d w ill b e c a lle d out...

Page 838: ...the drive chain The plane tary gear assembly consists of a 4 pinion planetary car rier and an annulus gear that provide the four wheel drive low range when engaged The reduction ratio is 2 72 1 in thi...

Page 839: ...ousing bolts 7 4 Pump retainer housing 8 from the rear case half 17 5 Speedometer tone wheel 11 from the mainshaft 19 6 Case bolts 3 from the case halves Note the two longer case bolts and washers go...

Page 840: ......

Page 841: ...DE SHIFT 87 RETAINER SNAP RING 26 CONNECTOR OIL PICK UP TUBE 55 SECTOR SHIFT 88 PIN MODE FORK GUIDE 27 WASHER 56 BUSHING SHIFT RAIL 89 CUP SHIFT FORK SPRING 28 RING MAIN DRIVE SYCHRONIZFR 57 BRACKET R...

Page 842: ...NING AND INSPECTION Clean 1 Bearings Remove all old lubricant and dirt 2 Shafts 3 Sprockets 4 Chain 5 Oil feed ports and channels in each case half Apply compressed air to each oil feed port and chann...

Page 843: ...e front case half 45 using J 8092 and J 33833 4 Retainer 40 5 Bearing 6 to the pump retainer housing 8 using J 33833 and J 8092 figure 10 6 Bearing 84 into the input gear 38 using J 36372 and J 8092 7...

Page 844: ...u m p failu re N O T IC E F o r s te p s 3 15 17 a n d 19 R e fe r to N o tic e o n p a g e 7D 1 1 1 Planetary input gear assembly 38 through the input bearing 40 into the annulus gear 62 using a soft...

Page 845: ...xtension housing bolts Tighten Bolts to 31 N m 23 lbs ft EXTERNAL COMPONENTS Install or Connect Figures 3 and 4 N O T IC E F o r a ll th e fo llo w in g s te p s re fe r to N o tic e o n p a g e 7D 1...

Page 846: ...ncoder Motor Bolts 18 13 Fill and Drain Plugs 47 35 Front Output Yoke Nut 149 110 Input Shaft Bearing Retainer Bolts 19 14 Mainshaft Extension Housing Bolts 31 23 Poppet Screw 15 11 Pump Housing Bolts...

Page 847: ...DLE 8 BEARING INSTALLER 3 BEARING REMOVER 9 BEARING INSTALLER 4 BEARING REMOVER 10 SEAL INSTALLER 5 OUTPUT SHAFT BEARING REMOVER 11 EXTENSION HOUSING SEAL INSTALLER 6 ADAPTER 12 BEARING INSTALLER 7 BE...

Page 848: ...NOTES...

Page 849: ...1 is a part time four wheel drive unit Torque input in four wheel high and low ranges is undif ferentiated The range positions are selected by a floor mounted gearshift lever The Model 241 has a two p...

Page 850: ...ing seal 47 3 Speedometer sensor 9 and O ring seal 85 4 Poppet screw 68 O ring seal 69 poppet spring 71 and poppet plunger 70 MAINSHAFT EXTENSION AND OIL PUMP HOUSING Remove or Disconnect Figures 3 an...

Page 851: ...nt case half 45 10 Retainer ring snap ring 41 from input gear 38 11 Bearing retainer snap ring 39 12 Planetary carrier 36 and input gear 38 from the annulus gear using a soft faced hammer 13 Input bea...

Page 852: ......

Page 853: ...39 Retainer Snap Ring 40 Input Bearing 41 Retainer Snap Ring 42 Input Bearing Retainer Seal 43 Input Retainer Bolt 44 Input Bearing Retainer 45 Front Case Half 46 4WD Actuator Switch 47 O Ring Seal 4...

Page 854: ...zer Assembly F5391 65 63 51 Range Fork 52 Mode Fork Spring 54 Mode Fork 55 Sector With Shaft 63 Shift Lever Nut 65 Lever F5389 Figure 5 Mode Fork and Shaft Assembly Figure 6 Shift Rail Assembly 12 Oil...

Page 855: ...xcessive wear 8 Synchronizer hub and sleeve for cracks chips spalling or excessive wear 9 Pads on mode fork and range fork for wear and distortion 10 Oil pump gears and case halves for wear spalling c...

Page 856: ...RNAL COMPONENTS Assemble Figures 15 through 19 1 Spring retainers 32 to the synchronizer hub 31 2 Synchronizer hub 31 to the synchronizer sleeve 29 along with the three struts 30 Align the previously...

Page 857: ...22 and chain 58 are installed into the front case half as a unit 13 Driven gear retainer snap ring 23 to front output shaft 21 14 Mode shift fork 54 onto shift rail 48 15 Mode shift fork assembly 54...

Page 858: ...ump housing bolts Pump bolts 7 are shouldered 25 Output bearing retainer snap ring 5 to the main shaft 19 26 Rear extension housing 4 and extension bolts 3 to the pump retainer housing 8 Apply RTV GM...

Page 859: ...17 Rear Case Half 18 Oil Pump Pick Up Tube 26 Connector Dowel Pin Location Pump Pick Up Screen F5434...

Page 860: ...F5435...

Page 861: ...O Ring Seal 23 Retainer Snap Ring 72 Front Output Shaft Seal 24 Front Output Rear Bearing 73 Deflector 27 Washer 74 Front Out Flange 28 Main Drive Synchronizer Stop Ring 75 Rubber Sealing Washer 29 Sy...

Page 862: ...73 1 SLIDE HAMMER 2 DRIVER HANDLE 3 BEARING REMOVE 4 OUTPUT SHAFT BEARING REMOVER 5 OUPUT SHAFT BEARING REMOVER 6 SLIDE HAMMER 7 BEARING INSTALLER REMOVER 8 FRONT AND REAR OUTPUT SHAFT BEARING INSTALL...

Page 863: ...nsfer case is a chain driven four position unit It provides four wheel drive high and low ranges a two wheel high range and a neutral posi tion This model is a part time four wheel drive unit Torque i...

Page 864: ...nshaft through the synchronizer Torque is transmitted through the drive sprocket to the driven sprocket by the connecting drive chain Since the front output shaft is splined to the driven sprocket tor...

Page 865: ...o the case 1 Oil pump 12 pickup tube 18 O ring 14 and pump pickup filter 35 from the rear case half fig ure 5 2 Fork shift spring 3 Mainshaft 19 chain 58 and driven sprocket 22 from the front case hal...

Page 866: ......

Page 867: ...ift Fork 55 Sector With Shaft 56 Bushing 57 Range Fork Pin 58 Chain 59 Retainer Snap Ring 61 Front Output Bearing 62 Annulus Gear 63 Shift Lever Nut Prev Torque 64 Washer 65 Shift Lever 66 Washer Plas...

Page 868: ...Rear Case Half 18 Oil Pump Pickup Tube 35 Oil Filter F5851 Figure 5 Oil Pump Pickup Tube and Screen 48 Shift Rail 51 Range Fork 52 Mode Fork Spring 54 Mode Fork 55 Sector With Shaft 63 Shift Lever Nut...

Page 869: ...Synchronizer hub and sleeve for cracks chips spalling or excessive wear 9 Pads on mode fork and range fork for wear and distortion 10 Oil pump gears and case halves for wear spalling cracks and damage...

Page 870: ...Main drive synchronizer stop ring 28 to the syn chronizer sleeve 29 and the synchronizer hub 31 4 Drive sprocket 20 to mainshaft 19 5 Synchronizer assembly to mainshaft 19 6 Snap ring 83 to mainshaft...

Page 871: ...eve 31 Synchronizer Hub 48 Shift Rail 54 Mode Fork F5432 Figure 14 Synchronizer Hub Assembly and Mode Fork N O T IC E D o n o t d a m a g e th e O rin g d u rin g a s s e m b ly a s th is c o u ld re...

Page 872: ...31 N m 23 lbs ft EXTERNAL COMPONENTS Install or Connect Figures 3 and 4 N O T IC E F o r s te p s 1 th ro u g h 4 re fe r to N o tic e o n p a g e 7D 3 1 1 Selection plunger 70 poppet spring 71 O ring...

Page 873: ...110 Input Shaft Bearing Retainer Bolts 19 14 Mainshaft Extension Housing Bolts 31 23 Poppet Screw 15 11 Pump Housing Bolts 31 23 Shift Selector Lever Nut 31 23 Shift Selector Vacuum Switch 24 17 Vehi...

Page 874: ...DLE 8 BEARING INSTALLER 3 BEARING REMOVER 9 BEARING INSTALLER 4 BEARING REMOVER 10 SEAL INSTALLER 5 OUTPUT SHAFT BEARING REMOVER 11 EXTENSION HOUSING SEAL INSTALLER 6 ADAPTER 12 BEARING INSTALLER 7 BE...

Page 875: ...in g c o m p o u n d w ill b e c a lle d o ut T h e c o rre c t to rq u e v a lu e m u s t b e u s e d w h e n in s ta llin g fa s te n e rs th a t re q u ire it If th e a b o v e c o n d itio n s a...

Page 876: ...ate The information on this tag is neces sary for servicing information If the tag is removed or becomes dislodged during service operations be sure to keep the identification tag with the unit POWER...

Page 877: ...lves Note these are self tapping screws and aluminum shavings are common upon removal 5 Rear case half 46 from the front case half 31 Using a suitable tool pry between the two pry bosses to separate t...

Page 878: ...F9167...

Page 879: ...ring 40 Front Output Bearing Snap Ring 42 Front Output Shaft Seal 43 Front Input Bearing Snap Ring 44 Front Input Bearing 45 Rear Output Bearing 46 Rear Case 47 Rear Output Shaft Seal 48 Shift Lever 4...

Page 880: ...I T t r 4 REAR OUTPUT OUTPUT BEARING SNAP RING 23 MAINSHAFT F6602 Figure 6 Removing the Output Bearing Snap Ring 5 Clutch Coil Wire Connector 6 Clutch Coil Nut F6603...

Page 881: ...oil Housing Snap Ring 11 Clutch Coil Housing 23 Mainshaft F6604 Figure 8 Removing the Clutch Coil Housing 15 FrontOutput Shaft Snap Ring 16 FrontOutput Shaft 17 Flat Washer F6606 Figure 10 Removing th...

Page 882: ...16 FrontOutputShaft 18 DrivtQNr 19 DrivenGm t 20 DriveChain 22 FrontOutputBearing V2836...

Page 883: ...25 InputCarrierAMwmbly 26 OilPumpPickup V2837 Figure 12 Removing the Mainshaft and Oil Pump 30 AnnulusGear Snap Ring 31 FrontCase 32 AnnulusGear F6610 Figure 14 Removing the Annulus Gear Snap Ring 31...

Page 884: ...apRing F6617 Figure 16 Removing the Carrier Assembly Snap Ring 25 InputCarrierAssembly 35 PowerTakeOff Drive Gear F6618 36 36 Retainer Clip 37 Sector Shaft 38 Cam 39 Detent 48 Shift Lever 49 Detent Ro...

Page 885: ...ner bolts 63 and oil pump retainer 69 from the oil pump rear cover 64 figure 25 2 Oil pump body 66 and pickup tube assembly from the mainshaft 23 3 Oil pump pins 67 and oil pump spring 68 from the mai...

Page 886: ...haft 26 Strainer 63 Oil Pump Retainer Bolts 64 Oil PumpRearCover 66 Oil PumpHousing 67 Oil PumpPins 68 Oil PumpSpring 69 Oil PumpRetainer 70 Oil Pump FrontCover 71 PickupTube RetainerClip 72 PickupTub...

Page 887: ...ines for excessive wear spalling cracks distortion or corrosion 5 Retainer rings for excessive wear distortion or damage 6 Case halves for damaged or warped mating sur faces cracks porosity or damaged...

Page 888: ...nspect I Oil pump operation on the mainshaft The main shaft must turn freely within the oil pump If binding occurs loosen the four bolts and retor que SYNCHRONIZER HUB ASSEMBLY Assemble Figure 24 1 Co...

Page 889: ...6 to 10 N m 89 lbs in 29 Clutch coil wire through the rear case and clutch coil wire connector 5 to the clutch coil wire 30 RTV sealer GM P N 1052366 to the case sealing surfaces and the rear case hal...

Page 890: ...F9168...

Page 891: ...Bearing 58 Front Output Flange 23 Mainshaft 59 Speedometer Pick up Switch 24 Oil Pump Assembly 60 Four Wheel Indicator Switch 25 Input Carrier Assembly 61 Rear Bearing Retainer Bolts 28 Range Fork 62...

Page 892: ...2 J 37668 7 8 9 10 J 8092 J 5590 J 29369 1 J 2619 01 1 Bearing and Gear Puller 2 Puller 3 Snap Ring Pliers 4 Bearing Remover Installer 5 Bearing Remover Installer 6 Seal Installer 7 Driver Handle 8 In...

Page 893: ...W4472 Transfer Case 7D5 1 Identification 7D5 2 Power Flow 7D5 2 Disassembly 7D5 3 External Components 7D5 3 Internal Components 7D5 3 Bearings and Seals 7D5 7 Cleaning and Inspection 7D5 8 Assembly 7D...

Page 894: ...is transmitted through the input shaft to the planet carrier assembly Torque flow continues through the ring gear to the rear output shaft Torque is trans mitted from the planet carrier assembly to th...

Page 895: ...Sun gear shaft 18 sun gear shaft bearing 33 drive sprocket spacer 16 drive sprocket 17 vis cous clutch 20 and sun gear shaft thrust washer 21 as an assembly from the planet carrier assembly 22 6 Plane...

Page 896: ...ut Shaft 20 Viscous Clutch 21 Sun Gear Shaft Thrust Washer 22 Planet Carrier Assembly 23 Planet Carrier Assembly Thru 24 Output Shaft Assembly 25 Extension Housing Bolts 27 Output Shaft Bearing Snap F...

Page 897: ...27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Input Shaft Viscous Clutch Sun Gear Shaft Thrust Washer Planet Carrier Assembly Planet Carrier Assembly Thrust Washer Output Shaft Assembly Extension Hous...

Page 898: ...ocket 17 Drive Sprocket 19 Input Shaft 20 Viscous Clutch 30 Gear Ring 33 Sun Gear Shaft Bearing F7566 24 Output Shaft Assembly 27 Output Shaft Bearing Snap Ring 28 Output Shaft Bearing 37 Speedometer...

Page 899: ...bearing 35 from the front cover 11 using J 2619 01 and J 29369 1 figure 11 5 Output shaft oil seal 36 from the extension hous ing 8 6 Using J 22912 01 press the sun gear shaft bearing 33 from the sun...

Page 900: ...uid or GM P N 9985286 Assemble Figures 12 through 17 1 Viscous clutch 20 drive sprocket 17 drive sprocket spacer 16 and the sun gear shaft bear ing 33 onto the sun gear shaft 18 figure 12 2 Input shaf...

Page 901: ...ont Cover 34 Output Shaft Bearing Snap Ring 35 Output Shaft Bearing F7606 Figure 16 Installing the Front Output Shaft Front Bearing Snap Ring 10 10 Rear Case Half 39 Output Shaft Rear Bearing F7607 Fi...

Page 902: ...embly into the planet carrier assembly planet gears 22 and align the viscous clutch teeth 20 to the ring gear spline 30 figure 22 30 22 7 2 3 21 Sun Gear Shaft Thust Washer 22 Planet Carrier Assembly...

Page 903: ...lts 9 to the rear case half 10 4 Output Shaft 12 Front Output Shaft Spacer F7636 Figure 24 Installing the Front Output Shaft Spacer Tighten Front cover bolts 9 to 42 N m 30 ft lbs 19 Front output shaf...

Page 904: ...Dexron HE Automatic Transmission Fluid T2380 SPECIAL TOOLS J 22912 01 J 23907 J 2619 01 7 8 9 J 37668 J 38216 P sa GM P N 1052366 4 J 29369 1 J 7079 2 10 11 J 38427 J 38423 J 38212 12 K ra re i m J 80...

Page 905: ...oviding four wheel drive high and low ranges a two wheel high range and a neutral position The BW4470 is a part time four wheel drive unit Torque input in four wheel drive is undifferentiated The rang...

Page 906: ...uses the input gear to rotate the planetary pinions inside the annulus gear causing the planetary carrier range shift hub and mainshaft to rotate at a gear reduction of 2 69 1 DISASSEMBLY EXTERNAL COM...

Page 907: ...7 Shift rail 9 range fork 28 and shift hub 29 from the input carrier assembly 25 figure 13 18 Annulus gear snap ring 30 from the front case 31 figure 14 19 Annulus gear 32 from the front case 31 figur...

Page 908: ......

Page 909: ...ring 40 Front Output Bearing Snap Ring 42 Front Output Shaft Seat 43 Front Input Bearing Snap Ring 44 Front Input Bearing 45 Rear Output Bearing 46 Rear Case 47 Rear Output Shaft Seal 48 Shift Lever 4...

Page 910: ...4 REAR OUTPUT OUTPUT BEARING SNAP RING 23 MAINSHAFT F6602 Figure 6 Removing the Output Bearing Snap Ring 5 Clutch Coil Wire Connector 6 Clutch Coil Nut F6603...

Page 911: ...oil Housing Snap Ring 11 Clutch Coil Housing 23 Mainshaft F6604 Figure 8 Removing the Clutch Coil Housing 15 FrontOutput Shaft Snap Ring 16 FrontOutput Shaft 17 Flat Washer F6606 Figure 10 Removing th...

Page 912: ...Driven Gear 20 Drive Chain 66 Oil Pump Body 70 Oil Pump Cover F6607 Figure 11 Removing the Drive Chain 23 Mainshaft 24 Oil Pump Assembly 25 Input Carrier Assembly F6608 9 Shift Rail 28 Range Fork 29...

Page 913: ...0 Annulus Gear Snap Ring 31 FrontCase 32 AnnulusGear F6610 Figure 14 Removing the Annulus Gear Snap Ring 31 Front Case 32 AnnulusGear F6616 Ring 25 inputCarrierAssembly 35 PowerTakeOff Drive Gear F661...

Page 914: ...J 2619 01 46 Rear Case 85 Front Output Shaft Rear Bearing F7659 Figure 21 Removing the Front Output Shaft Rear Bearing...

Page 915: ...and sleeve for cracks chips spalling or excessive wear 9 Pads on the mode fork and the range fork for wear or distortion 10 Oil pump gears housing and mainshaft for wear spalling cracks and damage Rep...

Page 916: ...832 6 Front input bearing snap ring 44 to the front case 31 using J 8092 and J 29169 figure 27 7 Front input bearing snap ring 43 to the front case 31 8 Sector 38 detent spring 39 and detent roller 49...

Page 917: ...th e E C M If it is re m o ve d it m u s t b e re p la c e d w ith a n e w p a rt a n d th e o ld p a r t s h o u ld b e d is c a rd e d U s e ca re n o t to d a m a g e it u p o n in s ta lla tio n 3...

Page 918: ...2 5 22 Speed Sensor Bolt 16 12 Vent 14 120 Yoke Nut Rear Output 170 125 LUBRICATION SPECIFICATIONS Capacity 3 1 L 3 3 q Type Recommended Dexron HE Automatic Transmission Fluid T2689 SPECIAL TOOLS 1 2...

Page 919: ......