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GMC T Series 1994 Manuals
Manuals and User Guides for GMC T Series 1994. We have
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GMC T Series 1994 manual available for free PDF download: Repair Manual
GMC T Series 1994 Repair Manual (919 pages)
Light Duty Truck Unit
Brand:
GMC
| Category:
Trucks
| Size: 20.17 MB
Table of Contents
Section Oa General Information
7
Table of Contents
7
Vehicle Certification Label
8
Service Parts Identification L Abel
8
Special Tool O Rdering in Form Atio N
8
Engine Identification Number
8
Vehicle Identification Num Ber
8
Metric Fasteners
9
New Venture Gear
12
Model Identification
9
Transmission Identification Number
9
Fastener Strength Identification
13
Prevailing Torque Fasteners
13
Decimal and Metric Equivalents
14
J1930 Word Conversion
14
Metric-English Conversion
14
Section 1D2 Hd6/Hr6-He Air Conditioning Compressor
40
Metric Thread Size Information
42
Minor Compressor Repair Procedures
42
Compressor Clutch Plate and Hub Assembly
42
Compressor Clutch Rotor And/Or Bearing
43
Compressor Clutch Coil
46
Unit Repair
42
Compressor Shaft Seal Replacement
47
Major Compressor Repair Procedures
47
Seal Leak Detection
47
Compressor Pressure Relief Valve
49
Compressor Leak Testing
50
Unit Repair
53
Control Switches
50
Section 1D4 Sd-7H15 Air Conditioning Compressor
64
Inspectio N
65
Disassembly of the Clutch Assembly
65
Assembly of the Clutch Assembly
66
General de Scription
65
Specifications
67
Fastener Tightening Specifications
67
General Specifications
67
Special Tools
68
Unit Repair
70
Section 3B1A Power Steering Gear Unit Repair
72
Automatic Transmission
72
Steering Gear Adjustments
74
Worm Thrust Bearing Preload Adjustment
74
Pitman Shaft Over-Center Preload Adjustment
75
Steering Gear Service
76
Pitman Shaft and Side Cover Replacement
76
Housing End Plug Replacement
77
Adjuster Plug Assembly Replacement
78
Valve Replacement
79
Rack Piston and Worm Shaft Replacement
80
Pitman Shaft Seals and Bearing Replacement
82
Check Valve Replacement
83
Gear Disassembly
85
Adjuster Plug
88
Valve and Stub Shaft
91
Pitman Shaft and Side Cover
92
Primary Rack Piston
93
Pitman Shaft Bearing and Seal Replacement
94
Steering Gear Connectors
94
Gear Reassembly
95
Gear Service Adjustments
98
Specifications
99
Fluid Specification
99
Fastener Tightening Specifications
99
Adjustment Tightening Specifications
99
Section 3B1B Power Steering Pump Unit Repair
101
Unit Repair
101
Drive Shaft Seal Replacement
103
Pump Reservoir Replacement
103
End Plate and Rotating Group Replacement
104
Reservoir Assembly
106
Control Valve Assembly
106
Drive Shaft Seal (Without Disassembly of Pump)
106
Hydraulic Pump Assembly
107
Specifications
108
Fluid Specifications
108
Unit Repair
109
Fastener Tightening Specifications
114
Special Tools
114
Section 4B Rear Axle
115
7 1/2 and 7 5/8-Inch Ring Gear
115
Checking the Axle before Disassembly
116
Disassembly of the Rear Axle
116
Cleaning
119
Inspectio N
119
Axle Housing
119
Differential
120
Pinion and Ring Gear
120
Bearings
120
Shims
120
Assembly of the Rear Axle
120
Pinion Depth Adjustment
120
Differential Case Assembly
121
Side Bearing Preload Adjustment
122
Pinion Installation
123
Backlash Adjustment
124
Gear Tooth Pattern Check
125
Adjustments Affecting Tooth Contact
126
Final Assembly
126
Section 4B2 8 1/2-Inch Ring Gear
131
General D Escription
131
Checking the Axle before Disassem Bly
132
Disassembly of the Rear Axle
132
Cleaning
134
Inspectio N
134
Axle Housing
134
Differential
134
Bearings
135
Pinion and Ring Gear
135
Shims
136
Assembly of the Rear Axle
136
Pinion Depth Adjustment
136
Pinion Installation
137
Differential Case Assembly
138
Side Bearing Pre-Load Adjustment
139
Backlash Adjustment
140
Gear Tooth Pattern Check
141
Adjustments Affecting Tooth Contact
141
Fastener Tightening Specifications
144
Specifications
144
Section 4B3 9 1/2-Inch Ring Gear
147
Checking the Axle before Disassem Bly
148
Disassembly of the Rear Axle
148
Cleaning
151
Inspection
151
Axle Housing
167
Bearings
167
Differential
167
Pinion and Ring Gear
167
Shims
167
Assembly of the Rear Axle
168
Differential Case Assembly
169
Pinion Installation
169
Backlash Adjustment
170
Side Bearing Preload Adjustment
170
Final Assembly
171
Gear Tooth Pattern Check
171
Adjustments Affecting Tooth Contact
171
Specifications
173
Fastener Tightening Specifications
173
Spacer and Shim S Pecifications
173
Spacer and Shim Specifications
173
Lubrication
173
Special Tools
174
Section 4B5 Dana Model 80 (11-Inch Ring Gear)
175
Inspection
180
Axle Housing
180
Differential
180
Pinion and Ring Gear
180
Assembly of the Rear Axle
181
Differential Case Assembly
181
Determining Total Shim Pack Size
182
Pinion Depth Adjustment
182
Pinion Installation
183
Assembling the Differential into the Axle Housing
185
Checking Backlash
185
Bearings
181
Shims
181
Adjustm Ents Affecting Tooth Contact
186
Final Assembly
186
Gear Tooth Pattern Check
186
Lubrication
188
Fastener Tightening Specifications
188
Available Shim Sizes
188
Specifications
188
Pinion Bearing and Differential Bearing Preload Specification
188
Ring Gear Bolts
188
Special Tools
189
Section 4B7 Locking Differential
191
Locking Differen Tia Ls
192
Cam Unit Disassembly 7 1/2, 7 5/8, and 8 1/2-Inch
192
Cam Unit Disassembly - 9 1/2-Inch
192
Cleaning and Inspection
193
Cam Unit Assembly - 9 1/2-Inch
194
Adjustment of the Differential
194
Assembly of the Differential
195
71 /2, 7 5/8, 8 1/2 and 9 1/2-Inch Ring G Ear
192
101/2-Inch Ring G Ear
195
Disassembly of the Differential
195
Cleaning and Inspection
197
Cam Unit Assembly
197
Adjustment of the Differential
197
Assembly of the Differential
199
Thrust Block Sizes
200
Reaction Block Thrust Washers
200
Fastener Tightening Specifications
200
Lubrication
200
Rig Ht Side Gear Thrust Washer
200
Reaction Block Size - 10 1/2-Inch
200
Specifications
200
Special Tools
201
Section 4C Front Axle
203
Disassembly
205
Cleaning
210
Axle Housing
210
Differential
210
Ring and Pinion Gear
210
Bearings
210
Thrust Washers, Shims and Adjuster S Leeves
210
Shift Mechanism
210
Assembly of the Axle
211
Differential Case Assembly
211
Pinion Bearing Cup Installation
211
Pinion Depth Adjustm Ent
211
Pinion Installation
213
Adjusting Backlash
214
Differential Assembly Installation
214
Gear Tooth Contact Pattern Check
215
Gear Tooth Nomenclature
215
Test
215
Adjustments Affecting Tooth Contact
215
Final Assembly
217
Drive Axle Assembly
219
Outer Deflector Ring
219
ABS Sensor Ring
219
Outer Joint S Eal
219
Outer Jo in T Assembly
223
Inner Tr Ipo T Seal
224
Specifications
226
Fastener Tightening Specifications
226
Lubrication
226
Special Tools
227
Section 4C2 8 1/4 and 9 1/4-Inch Ring Gear
229
Assembly of the Axle
238
Pinion Bearing Cup Installation
238
Pinion Depth a Djustm Ent
238
Pinion Installation
239
Differential Assembly Installation
241
Differential Case Assembly
241
Adjusting Backlash
243
Measuring Backlash
243
Gear Tooth Contact Pattern Check
243
Gear Tooth Terms
243
Test
244
Adjustments Affecting Tooth Contact
244
Axle Tube Assembly
244
Assembly
244
Output Shaft Shim Selection
244
Section 4C3 All Wheel Drive Front Axle 7 1/4-Inch Ring Gear
259
Insp Ectio N
260
Disassembly of the a X le
260
Disassembly
260
Thrust Washers, Shims, and Adjuster S Leeves
264
General Description
260
Differential Case Assem Bly
266
Pinion Bearing Installation
266
Pinion Installation
266
Differential Case Installation
268
Adjusting B Acklash
268
Gear Tooth Contact Pattern C H Eck
270
Test
270
ABS Sensor Ring
272
Inner Tripo T Seal
277
Assem Bly of the Ax le
266
Pinion Depth a Djustm Ent
266
Outer Deflecto R Rin G
272
Drive Axle Assem Bly
272
Final Assem Bly
272
Outer Joint Assem Bly
277
Outer Jo Int Seal
277
Specifications
279
Available Shim Sizes
279
Fastener Tightening Specifications
279
Lubrication
279
Pinion Preload and B Acklash
279
Special Tools
280
Section 5 Brakes
281
General Description
282
Master Cylinders
282
Composite Master Cylinder
282
Cast Iron Master C Ylin D
284
Bendix Master C Ylin D
285
Fastener Tightening Specifications
286
Unit Repair
295
Unit Repair
298
Specific Ations
286
General Information
302
Piston Selection (2.2L E Ng Ines)
307
Piston Selection (All Except 2.2L Engines)
307
Assembly
307
Camshaft Bearings
309
Camshaft Bearing Replacement (2.2L Engines)
309
Camshaft Bearing Replacement (All Except 2.2L Engines)
309
Hydraulic Lifters
310
Valve Lifter Leakdown Rate Test (Flat-Type Lifters Only)
310
Disassembly
311
Cleaning and Inspection
311
Repair
313
Valve Grinding
313
Valve Seat Grinding
313
Measuring Main Bearing Clearance
314
Measuring Connecting Rod Bearing Clearance
315
Thread Repair
316
Section 6A2 2.2L L4 Rpo Ln2, Vin 4
319
General Description
320
Accessory Removal
321
Cleaning
321
Draining the Engine
321
Engine Lubrication
321
Exhaust Manifold
321
Intake Manifold
321
Valve Train
321
Coolant Inlet Removal
327
Coolant Outlet, Thermostat and Adapter Removal
327
Coolant Pump Removal
327
Exhaust Manifold Removal
327
Intake Manifold Removal
327
Oil Fill Tube Removal
327
Oil Filter, Connector and By-Pass Valve Removal
327
Crankshaft Pulley Hub Removal
328
Crankshaft Pulley Removal
328
Crankcase Front Cover Oil Seal Removal
329
Crankshaft Sprocket Removal
330
Rocker Arm and Pushrod Removal
330
Timing Chain, Tensioner and Camshaft Sprocket Removal
330
Valve Rocker Arm Cover Removal
330
Cylinder Head Removal
331
Oil Pan Removal
331
Oil Pump Removal
331
Valve Lifter Removal
331
Flywheel Removal
332
Oil Pump Drive Removal
332
Piston and Connecting Rod Removal
332
Camshaft Removal
333
Cleaning, Inspection and Repair
333
Crankshaft Removal
333
Cylinder Block
333
Crankshaft
335
Main and Rod Bearings
338
Camshaft
340
Cylinder Head
341
Exhaust Manifold
341
Intake Manifold
341
Valve Lifters
345
Oil Pump Overhaul
346
Thread Repair
348
Assembly of Engine
349
Crankshaft Installation
349
Crankshaft Rear Oil Seal Installation
349
Prior to Assembly
349
Camshaft Installation
350
Flywheel Installation
350
Piston and Connecting Rod Installation
350
Automatic Transmission
350
Oil Pan Installation
352
Oil Pump Drive Installation
352
Oil Pump Installation
352
Cylinder Head Installation
353
Rocker Arm and Pushrod Installation
353
Valve Lifter Installation
353
Crankshaft Sprocket Installation
354
Timing Chain, Tensioner and Camshaft Sprocket Installation
354
Valve Rocker Arm Cover Installation
354
Coolant Pump Installation
355
Crankcase Front Cover Oil Seal Installation
355
Crankshaft Pulley Hub Installation
355
Crankshaft Pulley Installation
355
Coolant Inlet Installation
356
Coolant Outlet, Thermostat and Adapter Installation
356
Exhaust Manifold Installation
356
Intake Manifold Installation
356
Oil Fill Tube Installation
358
Start-Up Procedures
358
Fastener Tightening Specifications
359
Special Sealers, Adhesives, Thread Lockers and Lubricants
359
Engine Specifications
361
Special Tools
363
Section 6A3 4.3L V6 Rpo Lb4, Vin Z
365
General Description
367
Engine Construction
367
Balance Shaft
367
Cylinder Block
367
Cylinder Heads
367
Intake Manifold
367
Pistons and Connecting Rods
367
Valve Train
367
Engine Lubrication
367
Disassembly of the Engine
378
Tools and Shop Equipment
378
Accessory Removal
378
Draining the Engine
378
Egr Valve Removal
378
Exhaust Manifold Removal
378
Rocker Arm Cover Removal
378
Intake Manifold Removal
378
Valve Train Component Removal
378
Cylinder Head Removal
379
Torsional Damper Removal
379
Oil Pan Removal
379
Oil Pump Removal
380
Front Cover Removal
380
Camshaft Removal
380
Balance Shaft Removal
380
Piston and Connecting Rod Removal
380
Flywheel Removal
382
Crankshaft Rear Oil Seal Removal
382
Crankshaft Rear Oil Seal Retainer Removal
383
Crankshaft Removal
383
Main Bearing Removal (Without Removing C Rankshaft)
384
Cleaning, Inspection, and Repair
384
Cylinder Bore
384
Piston and Connecting Rod Assembly
385
Intake and Exhaust Manifolds
385
Camshaft
386
Camshaft Bearings
386
Timing Chain and S P Ro Ckets
386
Crankshaft Sprocket Replacement
386
Oil Pan and Rocker Arm Covers
387
Valve Train Components
388
Pushrods, Rocker Arms, Balls, and Nuts
388
Hydraulic Lifters
389
Cylinder Head
389
Rocker Arm Stud Replacement
389
Assembly
390
Thermostat and Coolanto Utlet
391
Crankshaft and Bearings
391
Assembly of the Engine
392
Prior to Assembly
392
Crankshaft and Main Bearing Installation
392
Inspecting Crankshaft End Play
392
Crankshaft Rear Oil Seal Retainer Installation
393
Crankshaft Rear Oil Seal Installation
393
Balance Shaft Installation
394
Camshaft, Timing Chain, and Sprocket Installation
394
Front Cover Installation
394
Torsional Damper Installation
394
Piston and Connecting Rod Installation
395
Connecting Rod Bearing Selection
395
Oil Pump Installation
397
Oil Pan Installation
397
Cylinder Head Installation
398
Valve Train Component Installation
398
Valve a Djustm Ent
400
Intake Manifold Installation
400
Rocker Arm Cover Installation
401
Exhaust Manifold Installation
401
Flywheel Installation
401
Engine Accessory Installation
402
Engine Setup and Testing
402
Special Tools
406
Section 6A4 4.3L V6 Rpo L35, Vin W
407
Engine Construction
409
Cylinder Block
409
Cylinder Heads
409
Crankshaft
409
General Description
409
Accessory Removal
416
Cleaning
416
Coolant Pump Removal
416
Draining the Engine
416
Exhaust Manifold Removal
416
Rocker Arm Cover Removal
416
Tools and Shop Equipment
416
Egr Valve Removal
417
Lower Intake Manifold Removal
417
Valve Train Component Removal
417
Cylinder Head Removal
419
Oil Pan Removal
419
Torsional Damper Removal
419
Camshaft Removal
420
Flywheel Removal
420
Front Cover Removal
420
Oil Pump Removal
420
Timing Chain and Camshaft Sprocket Rem Oval
420
Balance Shaft Removal
421
Piston and Connecting Rod Removal
421
Crankshaft Rear Oil Seal Removal
423
Crankshaft Rear Oil Seal Retainer Removal
423
Crankshaft Removal
423
Cleaning, Inspection, and Repair
424
Cylinder Bore
425
Main Bearing Removal (Without Removing Crankshaft)
424
Piston and Connecting Rod Assembly
426
Upper and Lower Intake and Exhaust Manifolds
426
Camshaft
427
Camshaft Bearings
427
Tim in G Chain and Sprockets
427
Crankshaft Sprocket Replacement
427
Oil Pan and Rocker Arm Covers
428
Valve Train Components
429
Pushrods, Rocker Arms, Balls, and Nuts
430
Cylinder Head Disassembly
430
Cleaning and Inspection of Cylinder Head Components
430
Rocker Arm Stud Replacement
431
Hydraulic Lifters
430
Cylinder Head Assembly
431
Thermostat and Coolant O Utlet
431
Crankshaft and Bearings
432
Crankshaft Rear Oil Seal Retainer
432
Assembly of the Engine
433
Crankshaft and Main Bearing Installation
433
Flywheel
433
Prior to Assembly
433
Camshaft Installation
434
Crankshaft Rear Oil Seal Installation
434
Crankshaft Rear Oil Seal Retainer Installation
434
Balance Shaft Installation
435
Timing Chain and Sprocket Installation
436
Front Cover Installation
437
Piston and Connecting Rod Installation
437
Connecting Rod Bearing Selection
437
Torsional Damper Installation
437
Oil Pan Installation
439
Oil Pump Installation
439
Cylinder Head Installation
440
Valve Train Component Installation
440
Lower Intake Manifold Installation
441
Rocker Arm Cover Installation
442
Upper Intake Manifold Installation
442
Coolant Pump Installation
443
EGR Valve Installation
443
Engine Accessory Installation
443
Exhaust Manifold Installation
443
Flywheel Installation
443
Engine Setup and Testing
444
Engine Specifications
445
Special Tools
448
6A5 V8 Engines
449
Engine Identification
451
Automatic Transmission
455
Disassembly of the Engine
461
Accessory Removal
461
Exhaust Manifold Removal
462
Oil Pump Removal
464
Flywheel Removal
467
Crankshaft Rear Oil Seal Retainer Removal (5.0L and 5.7L Engines)
467
Automatic Transmission
472
Cleaning, Inspection, and Repair
473
Cylinder Bores
474
Piston Selection
475
Camshaft
476
Camshaft Bearings
477
Hydraulic Lifters
480
Cylinder Head
480
Disassembly
480
Cleaning and Inspection
481
Rocker Arm Stud Replacement (5.0L and 5.7L Engines)
481
Crankshaft and Bearings
484
Crankshaft Rear Oil Seal Retainer (5.0L and 5.7L Engines)
485
Assembly of the Engine
485
Crankshaft and Main Bearing Installation
485
Undersize Main Journals (5.0L and 5.7L Engines)
486
Crankshaft Rear Oil Seal Installation (7.4L Engines)
487
Camshaft, Timing Chain, and Sprocket Installation
488
Front Cover Installation
489
Torsional Damper Installation
489
Piston and Connecting Rod Installation
490
Connecting Rod Bearing Selection
490
Installation
490
Oil Pump Installation
491
Oil Pan Installation
492
Cylinder Head Installation
492
Valve Train Component Installation
493
Valve Adjustm Ent
494
Intake Manifold Installation
496
L Engines
496
Rocker Arm Cover Installation
496
Exhaust Manifold Installation
496
Coolant Pump Installation
497
Engine Accessory Installation
498
Engine Setup and Testing
498
Specifications
501
6A7 6.5L Diesel
507
Automatic Transmission
528
Automatic Transmission
619
Section 7A-14B Hydra-Matic 4L60-E Automatic Transmission Unit Repair
621
Automatic Transmission
621
General Service Information
622
Servo Pin Length
623
Speed Sensor and Case Extension
625
Band, Reverse Input Clutch
630
Reaction Gear S
631
Inner Manual Linkage
633
Component Repair and Transmission Reassembly
634
Ball a Ssem Bly
635
Replacement Procedure - Third Accumulator Retainer and Ball Assembly
635
Retainer and Ball Assembly Leak Check Procedure
635
Lo and Reverse Clutch Piston
636
Carrier a Ssem Bly
637
Lo and Reverse Clutch Spacer Plate Selection
638
Reaction Internal Gear and Support
638
Lo and Reverse Clutch Support Assembly
641
Reaction S Haft
642
Input Internal Gear and Output Shaft
643
Input Clutch Assembly
645
Check Valve Retainer and Ball Assembly - Replacement Procedures
646
Forward Clutch Sprag Assembly
652
Clutch Air Check
655
Reverse Input Clutch Backing Plate Selection
659
Reverse Input and Input Clutches
660
Oil Pump Body
661
Speed Sensor and Case Extension
678
Torque Converter Assembly
679
Automatic Transmission
699
Automatic Transmission
832
Automatic Transmission
843
Automatic Transmission
846
Automatic Transmission
855
Automatic Transmission
857
Automatic Transmission
861
Automatic Transmission
869
Automatic Transmission
873
Automatic Transmission
891
Automatic Transmission
900
Automatic Transmission
904
Automatic Transmission
918
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