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GMC T Series 1994 Repair Manual

GMC T Series 1994 Repair Manual

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Page 2 CAUTION To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: Proper service and repair are important to the safety of the service technician^and the safe, reliable operation of all motor vehicles. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part.
Page 3 FOREWORD This service manual contains description, diagnosis, and on-vehicle service for Light Duty S/T Truck models. Procedures involving disassembly and assembly of major components for these vehicles are published in the separate Light Duty Truck Unit Repair Manual (NATP-9437). Fuel and emission-related components, along with wiring diagrams and electronic diagnosis for these models are published in the Driveability, Emissions, and Electrical Diagnosis Manual (NATP-9444).
Page 4 1994 LIGHT DUTY TRUCK UNIT REPAIR MANUAL The Table of C o n te n d on the following page indicates the sections covered in this manual. At th e beginning of each individual section is a Table of Contents which gives the page number on w hich each major /subject begins.
Page 5 TABLE OF CONTENTS The table of contents on this page indicates the sections covered in this manual. At the beginning of each individual section is a table of contents which gives the page number on which each major subject begins. SUBJECT SECTION CONTENTS...
Page 6 GENERAL MOTORS SERVICE MANUAL COMMENTS Technicians and Vehicle Owners & Operators: • Model year and vehicle line If you find an error, omission, or have a suggestion on • Publication book number (if present) any General Motors'Service Manual, we want to hear •...
Page 7: Table Of Contents
SECTION OA GENERAL INFORMATION CONTENTS SUBJECT PAGE Special Tool Ordering Information..........................OA-1 Service Parts Identification Lab el..........................OA-1 Vehicle Identification Num ber............................OA-1 Vehicle Certification L a b e l.............................. OA-1 Engine Identification N um ber............................OA-2 Transmission Identification N um ber..........................OA-3 Model Identification................................OA-3 Metric Fasteners.................................OA-3 Fastener Strength Identification............................
Page 8: Vehicle Identification Num Ber
The payload rating shown on the label is the maxi mum allowable cargo load (including the weight of the driver and all occupants) that the vehicle can carry based on all factory installed equipment on the vehicle. The payload rating is reduced if any accessories or other equipment is added to the vehicle after final date of manufacture.
Page 9: Transmission Identification Number
MFD. BY GENERAL MOTORS CORPORATION IV W M M M PU T UW IM 4649/2109 2100/953 U/k« 26flftp»80 P19S/75R15 T IM S P M /7 5 R 1 5 V ..' 15 X 6 JJ ism fe L j 35/241 Cold M 3 5 /w r i X 4T...
Page 10 VIEW A 1. ENGINE I. D. LOCATION 2. ENGINE I. D. LOCATION (OPTIONAL) V3246 Figure 7—5.0L, 5.7L Engine I.D. Location 1. ENGINE I.D. LOCATION 2. ENGINE I.D. LOCATION (OPTIONAL) V2592 Figure 8—7.4L Engine I.D. Location (International Standards Organization). This was done Important to reduce the number of fastener sizes used and yet retain the best strength qualities in each thread size.
Page 11 VIEW A p n n n j) VIEW C F7554 Figure 10— Hydra-Matic 4L60-E Transmission I. D. Location...
Page 12: New Venture Gear
HYDRA-MAT1C 4L80-E/4L80-EHD TRANSMISSION IDENTIFICATION INFORMATION YPSILANTI, MICHIGAN 3100r4921 Figure 11— Hydra-Matic 4L80-E Transmission I. D. Location BUILD DAY OF MONTH MODEL YEAR 01 = 1ST DAY 1. TRANSMISSION I.D. LOCATION 4 = 1994 15 ■ 15TH DAY 2. TRANSMISSION IDENTIFICATION TAG ---------------1 -------------- SERIAL NUMBER ~ P ri...
Page 13: Fastener Strength Identification
VIEW A V2371 Figure 13— New Venture Gear 4500 Transmission I. D. Location Figure 14— Borg Warner T-5 Transmission I. D. Location PREVAILING TORQUE FASTENER STRENGTH IDENTIFICATION FASTENERS A prevailing torque nut is designed to develop an Most commonly used metric fastener strength proper interference between the nut and bolt threads.
Page 14: Metric-English Conversion
A. PICKUP, REGULAR CAB - SPORTSIDE B. PICKUP, EXTENDED CAB - FLEETSIDE/WIDESIDE C. CHASSIS, REGULAR CAB D. CHASSIS, EXTENDED CAB E. PICKUP, CREW CAB F. UTILITY G. SUBURBAN V2638 Figure 15— C/K Models D. Observe that, before the fastener seats, it J 1 9 3 0 WORD develops torque per the chart in figure 22.
Page 15 G VAN MODELS Vandura (Chevy Van) Rally (Sportvan) Cutaway Van Magnavan (Hi-Cube Van) Extended 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 S/T PICKUP, EXTENDED CAB 4 DOOR S/T UTILITY VEHICLE 2 DOOR S/T UTILITY VEHICLE 2900r4506...
Page 18 CUSTOMARY METRIC — M6.0 • THREAD MAJOR NUMBER OF THREADS THREAD MAJOR DIAMETER DISTANCE BETWEEN DIAMETER IN INCHES PER 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.
Page 19 6 & 6.3 4 ,5 In. Lbs. 1,2, 3, 6, In. Lbs. 7, 8 ,9 .437 .500 .562 .625 .750 .250 .312 .375 4 ,5 In. Lbs. 1,2, 3, 6, In. Lbs. 8, 9 A. M etric Sizes 1. Top Lock Type 6.
Page 20 CONVERSION TABLE to get equivalent to get equivalent Multiply number of: Multiply number of: LENGTH ACCELERATION Inch 25.4 millimeters (mm) Foot/sec2 0.304 8 meter/sec2 (m/s2 ) Foot 0.304 8 meters (m) Inch/sec2 0.025 4 meter/sec2 Yard 0.9144 meters TORQUE Mile 1.609 kilometers (km) Pound-inch...
Page 21 DECIMAL AND METRIC EQUIVALENTS Fractions Decimal In. Metric mm Fractions Decimal In. Metric mm 1/64 0.39688 33/64 0.015625 0.515625 13.09687 1/32 0.03125 0.79375 17/32 0.53125 13.49375 3/64 0.046875 1.19062 35/64 0.546875 13.89062 1/16 0.0625 1.58750 9/16 0.5625 14.28750 1.98437 5/64 0.078125 37/64 0.578125...
Page 22 J1930 CONVERSION CHART From Absolute Pressure Sensor (APS) Manifold Absolute Pressure Sensor (MAPSensor) Accelerator (ACCEL) Accelerator Pedal (AP) Air Cleaner Assembly Air Cleaner (ACL) Air Cleaner Filter Element Air Cleaner Filter (ACL Filter) Air Induction System Air Intake System Air Injection Reaction System (A.I.R. System) Secondary Air Injection System (AIR System) Assembly Line Communication Link (ALCL) Data Link Connector (DLC)
Page 23 J1930 CONVERSION CHART From Knock Sensor Circuit (KS Circuit) Electronic Spark Control Circuit (ESC Circuit) Electronic Spark Control System (ESC System) Knock Sensor System (KS System) Exhaust Gas Recirculation Electronic Vacuum Regula Electronic Vacuuijj Regulator Valve (EVRV) tor Solenoid Valve Engine Calibration Unit (ECU) Programmable Read Only Memory (PROM) Evaporative Emission Control System (EVAP Control...
Page 24 NOTES...
Page 25 SECTION 1 AIR CONDITIONING CONTENTS SUBJECT PAGE HR100T/HR110-MD Air Conditioning Com pressor....................1D1-1 HD6/HR6-HE Air Conditioning Com pressor......................1D2-1 V-5 Air Conditioning Com pressor..........................1D3-1 SD-7H15 Air Conditioning C om pressor........................1D4-1...
Page 27 SECTION 1D1 HR100T/HR110-MD AIR CONDITIONING COMPRESSOR NOTICE: W hen fasteners are rem oved, alw ays reinstall them at the same location from w hich they w ere rem oved. If a fastener needs to be replaced, use the correct part num ber fastener for that application. If the correct part num ber fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 28 1 — CLUTCH HUB KEY 2 — CLUTCH DRIVE 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 —...
Page 29 SERVICE PROCEDURES MINOR REPAIR PROCEDURES, W hen servicing the com pressor, rem ove only the necessary com ponents that prelim inary diagnosis indicates are HR100T & HR110-MD in need of service. Refer to Figure 2 for inform ation relative to COMPRESSOR parts nomenclature and location.
Page 30 • C om pressor m ounting holes are metric. Use proper metric bolts with holding fixture J 25008-A . T hread the Clutch Plate and Hub A ssem bly Remover J 33013-B , into the hub. Hold the body o f the Remover with a w rench and turn the center screw into the R em over body to rem ove the Clutch Plate and Hub assem bly (Fig.
Page 31 If the pulley rim m ounting screws were rem oved in Step Using a center punch w ith a 45° angle point, stake 2, only the Clutch Rotor and Bearing assem bly will be 1.1 -1,4mm (.0 4 5 -0 5 5 " deep) the bearing in three places 120°...
Page 32 Reinstall Clutch Plate and Hub assem bly as described in “C om pressor Clutch Plate and H ub” Replacem ent procedures. 1 -J 25031 CLUTCH ROTOR AND/OR BEARING — GUIDE 6 POLE CLUTCH 2 -J 25031 Remove or Disconnect ROTOR & BEARING Rem ove the clutch plate and hub assem bly as described PULLER...
Page 33 19. Shift the rotor and bearing assem bly on the J 21352-A Support Block to give full support o f the hub under the staking pin location. A heavy duty rubber band may be used to hold the stake pin in the guide (Fig. 19), and the stake pin should be properly positioned in the guide alter each im pact on the pin.
Page 34 Slide the pulley rim off the Rotor and H ub assem bly The Pulley Rim and the Clutch Coil (Fig. 23) are replaceable at this point. Poly-Groove Drive Remove or Disconnect Rem ove the clutch plate and hub assem bly as described previously.
Page 35 Poly-Groove Drive |+ » | Install or Connect Place the clutch coil assem bly on the neck o f the front head with clutch coil term inals in line w ith m ark described in Step 2 o f the rem oval procedure. Place the pulley rotor and bearing assem bly on the neck of the front head and seat the clutch coil and pulley rotor in place using Rotor and Bearing Installer J 26271- A...
Page 36 COMPRESSOR SHAFT SEAL Shaft Seal Design T he shaft seal is a lip seal, one piece design. Seal Leak Detection A shaft seal should not be changed because of an oil-line on the hood insulator. O nly change a shaft seal when a leak is detected by evidence o f oil sprayed in large am ounts and then only after actual refrigerant leakage is found by using an approved leak D etector such as J 39400 or equivalent.
Page 37 1 -L E A K TEST ADAPTER J 9625-A 2 -H IG H PRESSURE C U T O F F SWITCH NO TICE: HIG H PRESSURE CUT-OFF SWITCH INSULATO RS ARE CO LORED Fig. 28 Removing and Installing Shaft Seal Seat Fig.
Page 38 D isconnect both Gage Adapters J 5420 from the Test Plate J 9 6 2 5 -A . Add 90 ml (3 oz.) new 525 viscosity refrigerant oil to the 1 - R E D I N S U L A T O R com pressor assembly.
Page 39 [_22j 13.— J 23128-A SEAL REMOVER AND INSTALLER SNAP RING PLIERS (#23 INTERNAL) 1. - - J 4245 14.— J 24092 PULLEY HUB ADAPTER SET 2 . - - J 5403 SNAP RING PLIERS (#21 INTERNAL) (USED WITH J 8433) 3 .
Page 40 SECTION 1D2 HD6/HR6-HE AIR CONDITIONING COMPRESSOR NOTICE: W hen fasteners are rem oved, alw ays reinstall them at the same location from which they were rem oved. If a fastener needs to be replaced, use the correct part num ber fastener for that application. If the correct part num ber fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 41 1 — CLUTCH DRIVER 2 — ROTOR BEARING RETAINER 3 — PULLEY BEARING 4 — PULLEY 5 — CLUTCH COIL ASSEMBLY 6 — SHAFT SEAL PARTS 7 — PUMP ASSEMBLY 8 — SWITCH O-RING 9 — SYSTEM CONTROL SWITCH 1 0 — HIGH PRESSURE RELIEF VALVE 11 —...
Page 42: Metric Thread Size Information
METRIC THREAD SIZE INFORMATION m easured and recorded. This PAG lubricant should then be discarded and an equal am ount of new PAG lubricant added to Com pressor to mounting bracket bolts. the com pressor. Front M 10 x l .5 - 6H The service com pressor is shipped with 240 ml (8 oz.) of Rear M8 x 1.25 - 6H...
Page 43: Compressor Clutch Rotor And/Or Bearing
NOTICE: fully If the center screw is threaded onto the end of the com pressor shaft, or if the body of the installer is held and the center screw is rotated, the key will wedjie and will break the clutch hub. CLUTCH PLATE AND HUB ASSY [ | ] CLUTCH PULLEY ROTOR SHAFT KEYWAY...
Page 44 J 33020 PULLEY ROTOR AND BEARING PULLER G60120-1D2-EK-R1 Fig. 8 Removing Pulley Rotor and Bearing Assembly (T l J 6 0 8 3 PLIERS |~2| PULLEY ROTOR j T ) RETAINING RING G60060-1D2-C-R1 Fiq. 6 Installing-Removing Pulley Rotor & Bearing Assembly Retaining Ring PULLEY ROTOR E l J 33020 (LESS...
Page 45 J 3 3 01 9-1 BEARING STAKING G UIDE RUBBER BAND f i l J 33019-2 BEARING STAKING PIN _________________________ ________ G60150-1D2-EK-R1 Fig. 11 Staking Bearing In Rotor Hub Bore |T | J 21352-A [Z ] J 9481-A BEARING SUPPORT BLOCK INSTALLER G 60140-1D2-C-R1 Fig.
Page 46: Compressor Clutch Coil
J 8433-3 SCREW U ] J 33023-A PULLER PILOT [ U J 33026-2 THROUGH BOLTS PULLEY ROTOR [ | ] J 33017 PULLEY ROTOR AND BEAR- ING INSTALLER [ I ] J 8433-1 CROSS BAR G60170 1D2-C-R1 Fig. 13 Installing Pulley Rotor and Bearing Assembly Fig.
Page 47: Major Compressor Repair Procedures
W h e n c oil is fully s e a te d on the f ro n t h e a d , use a 1/8" d i a m e t e r drift p u n c h a n d s t a k e the front h e a d at th ree p l a c e s 12 0 d e g r e e s a p a r t (F ig .
Page 48 Remove or Disconnect Recover the refrigerant using J 39500-G M . Loosen and reposition com pressor in m ounting brackets, if necessary. Remove clutch plate and hub assem bly from com pressor as described in m inor repairs. Remove the shaft seal retainer ring, using snap ring pliers J 5403 (Fig.
Page 49: Compressor Pressure Relief Valve
In sta ll th e n e w seal r e t a i n e r r in g w i t h its flat sid e a g a i n s t th e S e a l, u s in g S n a p - R i n g P liers J 5 4 0 3 . S e e F i g u r e 21. U s e th e s l e e v e f ro m Q - r i n g in s t a l l e r J 3 3011 to p r e s s in on the se a l r e ta in e r r in g so th at it s n a p s in to its g r o o v e .
Page 50: Control Switches
CONTROL SWITCHES If an e x te r n a l leak is p r e s e n t , p e r f o r m th e n e c e s s a r y c o rre c ti v e m e a s u r e s a n d r e c h e c k fo r le a k s t o m a k e Figure 20 c e rta in the leak h a s b e e n c o r r e c t e d .
Page 51 [E l 1 — J 5403 SNAP RING PLIERS 13 — J 33013 HUB & DRIVE PLATE REMOVER & INSTALLER 2 — J 6083 SNAP RING PLIERS 14 — J 39500-G M R134a A/C REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 3 — J 29886 DRIVER HANDLE SYSTEM (ACR4) 4 —...
Page 52 SECTION 1D3 V5 AIR CONDITIONING COMPRESSOR NOTICE: W hen fasteners are rem oved, alw ays reinstall them at the same location from w hich they w ere rem oved. If a fastener needs to be replaced, use the correct part num ber fastener for that application. If the correct part num ber fastener is not available, a fastener o f equal size and strength (or stronger) m ay be used.
Page 53: Unit Repair
suction pressure will be above the control point; the valve will rotation acts as an oil separator, w hich rem oves som e o f the oil m aintain bleed from crankcase suction: from the crankcase-suction bleed, rerouting it to the crankcase crankcase-suction pressure differential;...
Page 54 1 — SHAFT NUT 2 — CLUTCH DRIVER 3 — ROTOR BEARING RETAINER 4 — PULLEY BEARING 5 — PULLEY ROTOR 6 — CLUTCH COIL ASM. 7 — SHAFT SEAL PARTS 8 — SERVICE COMPRESSOR WITHOUT CLUTCH 9 — COMPRESSOR CONTROL VALVE ASM.
Page 55 1 - J 34992 COMPRESSOR HOLDING FIXTURE 2 - CLUTCH PLATE AND HUB ASM. 3 - J 33022NUT SOCKET 4 - J 33027-A CLUTCH HUB HOLDING TOOL 5 - J 34992 THUMB SCREW _______________________________________________________ 520006-1D3-R1 Fig. 4 Removing Shaft Nut Fig.
Page 56 1 - J 8083 PLIERS 2 - PULLEY ROTOR 3 - RETAINING RING _______________________________ 520010-1D3-R1 520012-1D3-R1 Fig. 8 Removing Pulley Rotor & Bearing Assembly Fig. 10 Removing Pulley Rotor and Bearing Assembly Retaining Ring Hold the center screw w ith a w rench. Tighten the hex portion o f the installer J 3 3 0 1 3 -B body to press the hub onto the shaft.
Page 57 1 - J 33020 (LESS PULLEY ROTOR FORCING SCREW) “FACE DOWN” INVERTED AND USED TO SUPPORT HUB OF J 8398-A BEARING ROTOR FOR BEARING REMOVER REMOVAL, PULLER J 8092 DRIVER TANGS ENGAGED IN ROTOR SLOTS HANDLE 520013-1D2-R1 Fig. 11 Pulley Rotor Bearing Removal NOTICE: Install pulley rotor and bearing puller guide J 33023-A Do Not support the rotor by resting the...
Page 58 1 - J 33019 BEARING STAKING GUIDE 2 - RUBBER BAND 3 - J 33019 BEARING STAKING Fig. 13 Staking Bearing In Rotor Hub Bore 1 - J 8433-3 SCREW 2 - J 8433-1 PULLER CROSS BAR 3 - J 33025 PULLER LEG 4 - J 33023-A PULLER PILOT 5 - CLUTCH COIL ASSEMBLY 6 - MARK COIL TERMINAL LOCATION...
Page 59 MAJOR V5 COMPRESSOR REPAIR PROCEDURES W hen replacing the shaft seal assem bly (Fig. 20), pressure relief valve or rear head m ounted pressure sw itches (Fig. 21), even if the com pressor rem ains on the vehicle during the operation, it will be necessary to discharge the system of refrigerant.
Page 60 1-P R E S S U R E R E L IE F V A L V E 1 - F R O N T H E A D S U R FA C E 3 -C L U T C H 2 -D IS C H A R G E P O R T C O IL 3 -S U C T IO N PO RT...
Page 61 Fig. 22 Removing or Installing Shaft Seal Retaining Ring R em ove any excess oil resulting from installing the new COMPRESSOR CONTROL SWITCHES seal parts from the shaft and inside the com pressor neck. Install the clutch plate and hub assem bly as described in Remove or Disconnect m inor repair procedures.
Page 62 SEAL J 34614 SEAL PROTECTOR 520021-1D3-R1 Fig. 25 Lip seal Installed on Seal Protector Using J 5403 snap ring pliers, install valve retaining ring with high point o f curved sides against valve housing. Be sure retaining ring is properly seated in ring groove. Leak test referring to “C om pressor Leak Testing”...
Page 63 1 — J 5403 SNAP RING PLIERS 14 — J 33013-B HUB & DRIVE PLATE REMOVER AND INSTALLER 2 — J 6083 SNAP RING PLIERS 15 — J 33017 PULLEY & BEARING ASSEMBLY 3 — J 8092 DRIVER HANDLE INSTALLER PULLER BAR 4 —...
Page 64 SECTION 1D4 SD-7H15 AIR CONDITIONING COMPRESSOR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 65: Disassembly Of The Clutch Assembly
1. NUT, A/C COMPRESSOR SHAFT 2. CLUTCH, A/C COMPRESSOR 3. SHIM, A/C COMPRESSOR 4. KEY, A/C COMPRESSOR CLUTCH 5. ROTOR, A/C COMPRESSOR 6. COIL, A/C COMPRESSOR 7. SCREW, COIL LEAD WIRE 8. CLAMP, COIL LEAD WIRE 9. RING, A/C COMPRESSOR SNAP 10.
Page 66: Assembly Of The Clutch Assembly
Figure 8— Removing the Coil Snap Ring ----- J 29886 J 38467 < ASSEMBLY OF THE F9443 CLUTCH ASSEMBLY Figure 9— Installing the Rotor Pulley -► 4- Install or Connect (Figures 2, 3, and 9) 1. Clutch coil and snap ring retainer. Tools Required: •...
Page 67: Specifications
NOTICE: Refer to “Notice” on page 1D4-1. 2. Rotor pulley to the front housing hub and align. • Place J 38467 into the bearing cavity with the outer edge on the rotor bearing outer race (figure 6. Shaft hex nut. •...
Page 68: Special Tools
SPECIAL TOOLS J 37828 J 8433 J 29886 J 38467 J 37825 J 37827 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 2901 r4920...
Page 69 NOTES...
Page 70: Unit Repair
SECTION 3 STEERING CONTENTS SUBJECT PAGE Power Steering Gear Unit R e p a ir..........................3B1A-1 Power Steering Pump Unit Repair........................... 3B1B-1 Manual Steering Gear Unit Repair..........................3B2A-1...
Page 71 STEERING...
Page 72: Automatic Transmission
SECTION 3B1A POWER STEERING GEAR UNIT REPAIR NOTICE: Repair the steering gear in a clean, dust-free location, using clean tools and equipment. Dirt or grit will damage the machined surfaces and result in leaking or damage to the steering gear assembly. If broken components or foreign materials are found while disassembling the gear, the hydraulic system should be disassembled, inspected, cleaned, and flushed.
Page 74: Steering Gear Adjustments
Key No. Part Name Key No. Part Name 1 - RING, RETAINING 32 SEAL, DOUBLE LIP 2 - PLUG 33 WASHER, BACKUP 3 - SEAL, O-RING 35 RING, RETAINING 5 - RING, TEFLON 36 WASHER, LOCK 6 - SEAL, O-RING 37 NUT 7 - COVER, SIDE 38 SEAL...
Page 75: Pitman Shaft Over-Center Preload Adjustment
PITMAN SHAFT OVER-CENTER PRELOAD Turn adjuster plug (55) counterclockwise until hole in adjuster plug (55) is aligned with the second mark ADJUSTMENT on the housing (20) (see Figure 6). Figures 7 thru 9 Install adjuster plug lock nut (48). Remove steering gear from vehicle. Refer to “Power Steering Gear Replacement”...
Page 76: Steering Gear Service
STEERING GEAR SERVICE Adjust PITMAN SHAFT AND SIDE COVER Over-center torque by turning the pitman shaft REPLACEMENT adjuster screw clockwise until the correct preload Figures 1 and 2 torque is obtained. Add 0.7-1.1 N*m (6-10 lb. in.) torque to the Remove or Disconnect previously measured worm bearing preload torque.
Page 77: Housing End Plug Replacement
HOUSING END PLUG REPLACEMENT Disassemble ❖ Figure 10 Adjuster lock nut (8). Remove or Disconnect Bolts (10). • Rotate stub shaft (40), using a 12-point socket, Steering gear from vehicle. Refer to “Power to center gear. Steering Gear Replacement” in Section 3B. Side cover (7), gasket (11), and pitman shaft (12) as an assembly.
Page 78: Adjuster Plug Assembly Replacement
Notice: ADJUSTER PLUG ASSEMBLY Needle bearing m ust be installed with REPLACEMENT identification on bearing facing tool to prevent damage to bearing. Figures 1,2, 11 thru 14 Needle bearing (53) to adjuster plug (55) using Tools Required: J 6221. J 7624 Spanner Wrench Lip seal (52) to adjuster plug (55) using J 6221.
Page 79: Valve Replacement
VALVE REPLACEMENT Notice: Pack the small cavity between seals (51 and 52) Figures 1, 2, 15 thru 18 with white petroleum grease before installing adjuster plug (55). When installing adjuster plug, be careful not to cut the ♦ 4 Remove or Disconnect seals.
Page 80: Rack Piston And Worm Shaft Replacement
Stub shaft (40) to valve spool, if necessary and RACK PISTON AND WORM SHAFT insert pin. REPLACEMENT • Notch in stub shaft cap must fully engage Figures 1,2, 19 thru 22 valve body pin and seat against valve body Tools Required: shoulder.
Page 81 Rack piston plug (27). • Make sure that all rack piston balls (25) are • Insert J 21552 into bore of rack piston (26). reinstalled in the rack piston. Improper rack Hold J 21552 tightly against worm shaft piston ball installation may result in personal while turning the stub shaft counterclockwise.
Page 82: Pitman Shaft Seals And Bearing Replacement
Rack piston (26) to worm shaft (13) from J 21552, Clean using J 8947 to compress seals. • Hold J 21552 tightly against worm shaft and • Exposed end of pitman shaft (12) and turn stub shaft clockwise until rack piston housing (20).
Page 83: Check Valve Replacement
CHECK VALVE REPLACEMENT Remove or Disconnect • Steering gear from vehicle. Refer to “Power Steering Gear Replacement” in Section 3B. Disassemble Notice: Use care not to damage threads of housing when removing check valve. • Check valve (18) by prying from housing with a small screwdriver.
Page 85: Gear Disassembly
Key No. Part Name Key No. Part Name 1 - NUT, PRELOAD ADJUSTER 27 RING, VALVE BODY 28 BODY, VALVE 2 - BOLT, HEX HEAD (SIDE COVER) 3 - COVER ASSEMBLY, HOUSING SIDE 29 SEAL, O-RING (SPOOL) 30 SPOOL, VALVE 4 - SEAL, O-RING (SIDE COVER) 5 - GEAR ASM., PITMAN SHAFT 31 SHAFT, STUB...
Page 86 O-ring seal (11). Important • Turn the stub shaft counterclockwise until the rack piston (50) covers the crossover hole Do not remove the plug (8) from the rack (see Figure 4). piston (7) during this procedure. Remove Important only for replacement. •...
Page 87 Rack piston (50) and balls (49). Pitman shaft (5) from housing (6). Tap in end of shaft. Nut (14) (see Figure 8). Adjuster plug (19). Use tool J 7624 or equivalent (see Figure 9). Valve (28) and worm shaft (33) as an assembly with both races (34) and bearing (35).
Page 88: Adjuster Plug
ADJUSTER PLUG Figures 1, 10 thru 22 Retainer (25). Pry the retainer at the two raised areas (see Figure 12). Tools Required: Spacer (24). J 4245 Internal Snap Ring Pliers, Race (23). J 8524-1 Bearing Seal Installer Bearing (22). J 8524-2 Bearing Remover Race (21).
Page 89 Inspect Spacer (24) for wear or cracks. Races (23, 21) for wear or scoring. Adjuster plug (19) threads for wear. Bearing (22) for wear or scoring. Needle bearing (18) for wear, pitting, or scoring (see Figure 14). Replace if necessary. +*+ Assemble New needle bearing (18), if required.
Page 90 Retaining ring ( 15), use tool J 4245 (see Figure 17). • Lubricate new seal (20) with power steering fluid. New seal (20). • Lubricate the thrust bearing assembly with power steering fluid. Large race (21) on the adjuster hub. Bearing (22).
Page 91: Valve And Stub Shaft
VALVE AND STUB SHAFT Figures 20 thru 25 Important Valve assembly malfunction is uncommon, except during seal replacement. Do not service the valve unless indicated to do so. Disassemble ❖ Seal (32) in the shaft cap end. Stub shaft (31) from the valve body (28) (Figure 20). •...
Page 92: Pitman Shaft And Side Cover
Assemble • Lubricate new rings (27) and seals (26). New seals (26) in the ring grooves. New rings (27) in the grooves over the seals (26). • Lubricate valve spool seal (29). Seal (29) over the valve spool. • Lubricate the valve spool and the valve body (28).
Page 93: Primary Rack Piston
PRIMARY RACK PISTON Figure 1 and 29 Tool Required: J 21552 Rack Pinion Arbor Inspect Worm (33) and rack piston (50) grooves and all balls (49) for scoring. Replace as a matched assembly. Seal (9) and ring (10) for wear. Ball return guide halves (46) for cracks and damage.
Page 94: Steering Gear Connectors
PITMAN SHAFT BEARING AND STEERING GEAR CONNECTORS SEAL REPLACEMENT Figure 1 and 29 Figure 30 Tool Required: J 6217 Valve Connector Seat Installer Tools Required: J 4245 Internal Snap Ring Pliers Important J 24655 Bearing Installer and Remover J 8092 Handle •...
Page 95: Gear Reassembly
GEAR REASSEMBLY Figures 31 thru 39 Tool Required: Shaft Seal Protector 6222-A J 7624 Spanner Wrench J 7754-01 Torque Wrench Assemble ❖ • Lubricate the worm (33), bearing (35), and races (34) with power steering fluid. Race (34), bearing (35), and race (34) over the end of the worm (33).
Page 96 • Turn the stub shaft (31) clockwise to thread the rack piston onto the worm (33) while holding tool J 21552 against the end of the worm. • Remove tool 21552 after the rack piston is completely threaded on the worm. •...
Page 97 Pitman shaft preload, as follows (see Figure 39): Attach tool J 7754-01 and a 12-point socket on the stub shaft splines. Center the steering gear by: • Counting the number of turns while turning the stub shaft (31) counter-clockwise until bottomed.
Page 98: Gear Service Adjustments
GEAR SERVICE ADJUSTMENTS Turn stub shaft one half turn (180°) right or left from center. Install torque wrench vertical on stub shaft. Tools Required: Turn torque wrench 20° left or right of vertical. J 7754-01 Torque Wrench Take torque reading while turning torque wrench back to vertical.
Page 99: Specifications
SPECIFICATIONS FLUID SPECIFICATION or Equivalent meeting GM Specification 9985010. F A S T E N E R TIG H TEN IN G S P E C IF IC A T IO N S 708 Power Steering Gear Steering Gear Adjuster Lock N ut..................49 N*m (36 lb.
Page 100 SPECIAL TOOLS 3. J 7624 1. J 6219 2. J 4245 5. J 21552 4. J 8947 6. J 6221 10. J 34196-4 7. J 6278 8. J 22912-01 9. J 24655 11. J 35509 12. J 6217 13. J6222-A 14.
Page 101: Unit Repair
SECTION 3B1B POWER STEERING PUMP UNIT REPAIR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 103: Drive Shaft Seal Replacement
Key No. Part Name Key No. Part Name 1 - SEAL, O -R IN G 17 - RING, SHA FT R E T A IN IN G 2 - VA LVE ASM , C O N T R O L 1 8 - VANE, PUM P 3 - SEAL, O -R IN G 20 - RING , PUM P...
Page 104: End Plate And Rotating Group Replacement
END PLATE AND ROTATING GROUP Important REPLACEMENT Figures 1, 2 and 4 • Use new seals when assembling pump. ♦ 4 Remove or Disconnect Assemble Power steering pump from vehicle. Refer to Lubricate O-ring seals (1,10,35 and 40) with power “Power Steering Pump Replacement”...
Page 105 KEY NO. PART NAME KEY NO. PART NAME 1 - CAPSTICK ASM, RESERVOIR 16 - FITTING, O-RING UNION 2 - RESERVOIR ASM, HYD PUMP (TYPICAL) 25 - PLATE, THRUST 3 - CLIP, RESERVOIR RETAINING (LH) 26- RING, PUMP 5 - CLIP, RESERVOIR RETAINING (RH) 27 - VANE 6 - PIN, PUMP RING DOWEL 28 - ROTOR, PUMP...
Page 106: Reservoir Assembly
RESERVOIR ASSEMBLY Install or Connect Figure 1 Flow control spring (12). Control valve assembly (13). <-+l Remove or Disconnect O-ring (15) on fitting (16). Fitting (16) into hydraulic pump housing Pump assembly from vehicle, if necessary for assembly (10). access. Retaining clips (3) and (5) from reservoir assembly (2) and housing (10).
Page 107: Hydraulic Pump Assembly
HYDRAULIC PUMP ASSEMBLY Adjust Figures 1, 4 thru 7 Pressure plate (31). Tool Required: Pump ring (26). J 7728 Shaft Oil Seal Installer Vanes (27). Thrust plate (25). Disassemble Drive shaft (7). scoring, pitting or chatter marks. If noted, Retaining ring (37) using punch in access hole (see replace appropriate parts.
Page 108: Specifications
Drive shaft subassembly into pump housing (10). Vanes (27) into pump rotor (28). Pump ring (26), with holes positioned correctly onto dowel pins (6), in pump housing (10) (see Figure 6). Lubricate new O-ring (32) with power steering fluid. • O-ring (32) into groove in pump housing (10).
Page 109: Unit Repair
SECTION 3B2A MANUAL STEERING GEAR UNIT REPAIR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 110 Worm Bearing A djuster Locknut Worm Bearing Adjuster Lower Worm Bearing Cup Lower Worm Bearing Lower Bearing Retainer Ball 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 A djuster Shim...
Page 111 1. REMOVE AND INSTALL WORM SHAFT SEAL GEAR ASSEMBLED REMOVE INSTALL 1. Wrap 0.1 mm to 0.2 mm 1. Install parts as shown. “ I 2. REMOVE AND INSTALL PITMAN SHAFT AND SIDE COVER REMOVE INSTALL 1. Center steering gear. 1.
Page 112 3. REMOVE AND INSTALL WORMSMAFT 4. DISASSEMBLE AND ASSEMBLE WORM AND BALL NUT BEARING ADJUSTER REMOVE INSTALL DISASSEMBLE ASSEMBLE 1. Loosen lock nut. Use punch Install parts as shown. Pry lower bearing retainer Press cup into adjust against edge of slot. out with screwdriver.
Page 113 6. REMOVE AND INSTALL PITMAN SHAFT 7. ADJUST WORM BEARING PRELOAD SEALS AND BEARING 1. Tighten worm bearing adjuster until it bottoms then REMOVE INSTALL loosen one-quarter turn. 2. Carefully turn the wormshaft all the way to end of travel 1.
Page 114: Fastener Tightening Specifications
SPECIFICATIONS ADJUSTMENT Adjustment Torque to Turn Worm Shaft In. Lbs. Worm Bearing........................0.6-1.0 Over Center Preload......................0.5-1.2 4-10 In Excess of Worm Bearing Preload Total Steering Gear Preload....................16 max. FASTENER TIG H TEN IN G SPECIFICATIONS SAGINAW MODEL 5 3 5 Manual Steering Gear Ft.
Page 115: 7 1/2 And 7 5/8-Inch Ring Gear
SECTION 4B REAR AXLE CONTENTS SUBJECT PAGE 7 1/2 and 7 5/8-Inch Ring G ear........................... 4B1-1 8 1/2-Inch Ring G ear............................... 4B2-1 9 1/2-Inch Ring G ear............................... 4B3-1 10 1/2-Inch Ring G ear..............................4B4-1 Dana Rear A xles................................4B5-1 Locking Differentials............................... 4B7-1 SECTION 4B1 7 1/2 AND 7 5/8-INCH RING GEAR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were...
Page 116: Checking The Axle Before Disassembly
CONTENTS (cont’d) SUBJECT PAGE Spacer and Shim Specifications.......................... 4B1-14 Lubrication...................................4B1-14 Special T o o ls ..................................4B1-15 GENERAL DESCRIPTION 3. The case for metal chips and shavings. Determine The corporate 7 1/2 and 7 5/8-inch ring gear rear axle where these chips and shavings came from, such uses a conventional ring and pinion gear set to transmit as a broken gear or bearing cage.
Page 117 2 7 ^ J ® ^ - ^ § > 21 22 25 /? 2123 : / \ J y z k j I / j JL /f „ 19. Shim 1. Brake Drum 20. Pinion and Ring Gear Set 2.
Page 118 Figure 3— Pinion Shaft Lock Bolt 7. Bearing using J 2619-01 and J 22813-01 (figure 4). • Make sure the tangs of the tool engage the bearing outer race. 8. Differential pinion and side gears. A. Roll the pinion gears out of the case with the pinion thrust washers.
Page 119: Cleaning
Figure 10— Pinion Collapsible Spacer 15. Ring gear from the differential. • Drive the ring gear off with a brass drift if nec essary. Inspect • Drive pinion bearing preload and record for use when reassembling the pinion (figure 9). •...
Page 120: Differential
• The housing for cracks. Replace the housing if any SHIMS cracks are found. Inspect • The housing for foreign material such as metal chips, dirt, or rust. Refer to “ Cleaning." • Shims for cracks and chips. Damaged shims DIFFERENTIAL should be replaced with an equal size service shim.
Page 121: Differential Case Assembly
EXAMPLE: If the indicator needle moved coun terclockwise 1.70 mm (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 to 0.050 inch) range.
Page 122: Side Bearing Preload Adjustment
A. Dial indicator and arbor positioned on the gage block. B. Measurement after the arbor is moved off of the gage block. ^ F4682 Figure 15— Checking Pinion Depth 10. Differential side bearings using J 25299, J 8092, SIDE BEARING PRELOAD ADJUSTMENT and J 8107-2 (figure 17).
Page 123: Pinion Installation
• Production shims are cast iron and are not to be A. Tighten the lock bolt on the side of the tool. reused. Measure the production shims and spacers B. Leave the tool in place. one at a time and add the measurements together 4.
Page 124: Backlash Adjustment
B. Remove J 8614-01. Using an inch-pound torque wrench, check the pinion preload by rotating the pinion with the wrench (figure 23). Preload 4.32 MM (0.170-INCH) SERVICE SPACER should be at or below 2.7 to 3.6 N-m (24 to 32 Total Thickness of Total Thickness of lbs.
Page 125: Gear Tooth Pattern Check
5. Install the differential bearing caps and bolts. GEAR TOOTH PATTERN CHECK Tighten Checking the ring gear to pinion tooth pattern is done • Bolts to 75 N.m (55 lbs. ft.). only after setting up the axle according to the methods in this section.
Page 126: Adjustments Affecting Tooth Contact
If the thickness of the right shim is increased (along with decreasing the left shim thickness), backlash will increase. If the thickness of the left shim is increased (along with decreasing the right shim thickness), backlash will decrease. FINAL ASSEMBLY NOTICE: For steps 6, 7, and 8, refer to "No...
Page 127 CONDITION: CONDITION: • BACKLASH CORRECT. • BACKLASH CORRECT. • PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT. IS TOO FAR AWAY FROM RING GEAR. HEEL HEEL ffSI DRIVE SIDE COAST SIDE DRIVE SIDE COAST SIDE (CONVEX) (CONCAVE) (CONVEX) (CONCAVE) CORRECTION: CORRECTION: INCREASE THE PINION SHIM THICKNESS.
Page 128 SPECIFICATIONS SPACER A N D S H IM S P E C IF IC A T IO N S 7 1/2 AND 7 5/8-IN C H RING GEAR AXLE Lbs. Ft. Fastener Axle Cover B o lts ....... Bearing Cap Bolts......Filler P lu g ...........
Page 129 SPECIAL TOOLS J 7817 8. d l £ 22813-01 23911 J 7818 25299 J 8107-2 25320 J 8614-02 8 0 9 2 J 8614-02 8001 J 22888 23771 J 5590 1. Front Pinion Bearing Cup Installer 2. Rear Pinion Bearing Cup Installer 3.
Page 130 NOTES...
Page 131: General D Escription
SECTION 4B2 8 1/2-INCH RING GEAR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 132: Checking The Axle Before Disassem Bly
8. Pinion gear(21) and side gears (22). The axle is sealed at each axle shaft end, at the differential pinion, and at the differential case cover. • Roll the pinion gears out of the case with the All corporate axles are identified by the alphabetic pinion thrust washers (20).
Page 133 1. HOUSING, AXLE 2. CONNECTOR, REAR VENT HOSE 3. PLUG 4. SPACER, PINION BEARING 5. BEARING, PINION INNER 6. SHIM, PINION INNER 7. GEAR SET, RING AND PINON 24. CASE, DIFFERENTIAL 8. BEARING, DIFF 25. NUT, HEX 9. SHIM, DIFF BEARING ADJ 26.
Page 134: Cleaning
Figure 2— Pinion Shaft Lock Bolt 22. Bearing cups (5 and 39) from the axle housing using a hammer and punch. • Work the cups out of the housing evenly, mov ing the punch back and forth between one side of the cup and the other.
Page 135: Pinion And Ring Gear
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 Figure 7— Removing the Pinion Flange tain proper system balance. •...
Page 136: Shims
PINION DEPTH ADJUSTMENT SHIMS Tools Required: Inspect J 8001 Dial Indicator Gage Set J 21777-1 Arbor J 21777-29 Gage Plate • Shim s for cracks and chips. Dam aged shims J 21777-35 Rear Pilot Washer should be replaced with an equal size service J 21777-42 Front Pilot Washer shim.
Page 137: Pinion Installation
reading of 0.84 mm (0.033 inch), NOT 1.70 mm (0.067 inch). 16. Check the pinion face for a pinion adjustment mark. This mark indicates the best running position for the pinion from the nominal setting. • If the pinion has no plus or minus marked on it, use the nominal pinion setting to select a shim.
Page 138: Differential Case Assembly
• The bearing cups should have been installed in B. Remove J 8614-01. Using an inch-pound torque “ Pinion Depth Adjustment.” wrench, check the pinion preload by rotating the pinion with the wrench. Preload should be at or 1. The pinion inner bearing (5) using J 8609-01. below 2.3 to 2.8 N-m (20 to 25 lbs.
Page 139: Side Bearing Pre-Load Adjustment
4. Pinion thrust washers (20). Tighten • Rotate the pinion gears toward the differential • The ring gear bolts in sequence to 120 N-m (90 opening enough to slide in the pinion thrust lbs. ft.). washers. • Make sure the mating surfaces of the differen 7.
Page 140: Backlash Adjustment
4. Insert J 22779 between the axle housing and left 9. Measure J 22779 in three places using a microme bearing cup (figure 21). ter. Average the readings (figure 23). 5. Move the tool back and forth in the bore while 10.
Page 141: Gear Tooth Pattern Check
4. Place the indicator stem at the heel end of a tooth. be used as an initial check, or instead of checking pin ion depth and backlash adjustments. This check is only • Set the dial indicator so the stem is in line with to be used to verify the correct adjustment of the gear the gear rotation and perpendicular to the tooth set after setup.
Page 142 CONDITION: CONDITION: • BACKLASH CORRECT. • BACKLASH CORRECT. • PINION DEPTH IN C O R R E C T-PIN IO N GEAR • PINION DEPTH CORRECT. IS TO O FAR AWAY FROM RING GEAR. HEEL HEEL DRIVE SIDE COAST SIDE DRIVE SIDE COAST SIDE (CONVEX)
Page 143 Backlash is adjusted by the side bearing adjusting shims that move the case and ring gear assembly clos er 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), backlash will increase.
Page 144: Specifications
SPECIFICATIONS FASTENER TIG H TEN IN G SPECIFICATIONS Lbs. Ft. Fastener Axle Cover B o lts ......................... Bearing Cap Bolts........................Filler P lu g ..........................,... Ring Gear Bolts........................... SPACER AND SHIM SPECIFICATIONS Spacer and Shim Sizes Size Differential Side Bearing S pacer....................0.170-inch Differential Side Bearing Shim K its.....................
Page 145 SPECIAL TOOLS ^ ^ ^ ^ 3 J 8092 J 22399 J 8001 J 22761 J 8609-01 J 22779 “ ' j 8614-01 te s s s ll) J 5590 J 8107-4 1. Front Pinion Bearing Cup Installer 11. Differential Side Bearing Installer 2.
Page 146 NOTES...
Page 147 SECTION 4B3 9 1/2-INCH RING GEAR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 148: Checking The Axle Before Disassem Bly
The differential allows the wheels to turn at different 7. Bearing (5) using J 2619-01 and J 22813-01. rates of speed while the axle continues to transmit the • The tangs of the tool should engage the bear driving force. This prevents tire scuffing on turns and ing outer race.
Page 149 1. DRUM, REAR BRAKE 2. BOLT, WHEEL 3. SHAFT, AXLE 4. SEAL, REAR AXLE SHF (OIL) 27. CASE. DIFFERENTIAL 5. BEARING, REAR WHEEL 16. LOCK, DIFF BRG ADJ NUT 6. NUT, PINION FLANGE 17. NUT, DIFF BRG ADJ 28. SHAFT, DIFF PINION 7.
Page 150 Figure 2— Pinion Shaft Lock Bolt Figure 3— Removing the Differential Case J 8107-3 Figure 6— Removing the Drive Pinion Nut B. Replace the axle housing cover (25) 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).
Page 151: Cleaning
• The bearing cup bores for nicks or burrs. Remove any that are found. • The housing for cracks. Replace the housing if any are found. • The housing for foreign material such as metal chips, dirt, or rust. Refer to “ Cleaning.” DIFFERENTIAL Inspect •...
Page 152 Figure 9— Removing the Pinion Rear Bearing Figure 11— Installing the Rear Pinion Bearing Cup SHIMS J 21777-8 Rear Pilot Washer J 21777-42 Front Pilot Washer Inspect J 21777-43 Stud Assembly— Bolt J 21777-85 Gage Plate • Shim s for cracks and chips. Damaged shims J 21777-86 Side Bearing Disc should be replaced with an equal size service shim.
Page 153 7. Tighten the stud nut until a torque of 1.6 to 2.2 N-m 11. Position the gage shaft assembly in the carrier so the dial indicator rod is centered on the gaging (15 to 25 lbs. in.) is obtained to keep the gage area of the gage block.
Page 154 PINION INSTALLATION (Figures 1, 15 through 18) 6. The pinion flange (8) to the pinion by tapping it with a soft-faced hammer until a few threads show +«- Install or Connect through the pinion flange. Tools Required: NOTICE: Refer to "Notice” on page 4B3-1. J 22388 Pinion Oil Seal Installer J 22804-1 Pinion Oil Seal Spacer 7.
Page 155 • If the preload torque is below the preload val ues given above, continue tightening the nut in small increments. Check the preload after each tightening. Each tightening increases the bear ing preload by several pounds. If the bearing preload is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
Page 156 8. D ifferential side bearings (22) using J 29710, Tighten J 8107-3, and J 8092 (figure 21). • Place J 8107-3 into the differential on the side • Bolts (20) to 80 N-m (60 lbs. ft.). opposite the bearing installation to protect the 6.
Page 157 NOTICE: For steps 6, 7, and 9, refer to “No FINAL ASSEMBLY tice on page 4B3-1. " Tools Required: J 8092 Driver Handle Important J 23765 Axle Shaft Bearing Installer J 23771 Axle Shaft Seal Installer J 23911 Pinion Oil Seal Installer •...
Page 158 2. Apply gear marking compound (GM P/N 1052351) ADJUSTM ENTS AFFECTING or equivalent to all ring gear teeth using a medi- TOOTH CONTACT um-stiff brush. When properly used, the area of Two adjustments can be made that affects tooth con pinion tooth contact will be visible when hand load tact pattern;...
Page 159 CONDITION: CONDITION: • BACKLASH CORRECT. • BACKLASH CORRECT. • PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT. IS TOO FAR AWAY FROM RING GEAR. HEEL HEEL HEEL HEEL \m w d > > — — DRIVE SIDE COAST SIDE DRIVE SIDE COAST SIDE (CONVEX) (CONCAVE)
Page 160 SPECIFICATIONS FASTENER TIG H TENING SPECIFICATIONS 1/2-INCH RING GEAR AXLE Fastener Lbs. Ft. Adjusting Nut Lock B o lt......................Axle Cover B o lts ......................... Bearing Cap B olts........................Filler P lu g ............................. Pinion Shaft Lock B o lt....................... Ring Gear Bolts..........................
Page 161 SPECIAL TOOLS J 8107-3 J 8092 J 8001-M J 22804-1 J 24429 J 29710 J 22888 J 22912-01 J 24433 J 5590 £ J 22388 J 7817 Q »r J 8614-01 1. D ifferential Side Bearing Plug 2. Pinion Oil Seal Spacer Figure 53 for these tools: Refer to 3.
Page 162 NOTES...
Page 163 SECTION 4B4 10 1/2-INCH RING GEAR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 164 11. Ring gear bolts (36) and washers (35). The differential allows the wheels to turn at different rates of speed while the axle continues to transmit the NOTICE: Do not pry the ring gear from the driving force. This prevents tire scuffing on turns and case.
Page 165 15. Pinion Pilot Bearing 16. Axle Vent Tube 17. Axle Housing 18. Differential Side Bearing 19. Bearing Adjusting Nut 20. Bearing Cap 21. Adjusting Nut Lock 22. Bolt 23. Gasket 24. Cover 25. Bolt 26. Brake Line Clip 27. W asher 28.
Page 166 Figure 5— Removing the Pinion Flange Figure 6— Pressing the Drive Pinion from the Cage...
Page 167: Axle Housing
• 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 for cracks and scoring. • All parts for wear and replace if necessary. PINION AND RING GEAR •...
Page 168: Assembly Of The Rear Axle
7. Pinion oil seal (5) using J 24433 and J 8092. ASSEMBLY OF THE REAR AXLE 8. Pinion flange oil deflector (4) and pinion flange (3) PINION ASSEMBLY to the pinion splines. 9. Washer (2) and pinion nut (1). Install or Connect (Figures 1 and 9 through 13) -►4"...
Page 169: Pinion Installation
Each tightening increases the bearing preload by several pounds. If the bearing preload is exceeded, the pinion will have to be removed, and a new collapsible spacer installed. • Once the preload has been obtained, rotate the pinion several times to ensure that the bearings have seated.
Page 170: Side Bearing Preload Adjustment
7. Differential side bearings (18) using J 24429 and B. Tighten the right adjusting nut firmly to force the J 8092. case into solid contact with the left adjusting A. Place J 8107 into the differential on the side nut. Rotate the pinion several times to seat the opposite of bearing installation to protect the bearings.
Page 171: Final Assembly
6. If the reading is too low, remove the adjusting nut locks, and loosen the left nut one slot. Then tighten the right nut one slot. • The side bearing preload will not change as long as the adjusting nut is tightened an equal amount to the nut which was loosened.
Page 172 CONDITION: CONDITION: • BACKLASH CORRECT. . BACKLASH CORRECT. • PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT. IS TOO FAR AWAY FROM RING GEAR. HEEL HEEL DRIVE SIDE COAST SIDE DRIVE SIDE COAST SIDE (CONVEX) (CONCAVE) (CONVEX) (CONCAVE) CORRECTION: CORRECTION: INCREASE THE PINION SHIM THICKNESS.
Page 173: Specifications
SPECIFICATIONS FASTENER TIG H TEN IN G SPECIFICATIONS 1/2-INC H RING GEAR AXLE (CORPORATE) Fastener Lbs. Ft. Adjusting Nut Lock B o lts..Axle Cover B o lts ....Bearing Cap B olts....Filler P lu g ........ Pinion Cage to Axle Housing Ring Gear Bolts......
Page 174: Special Tools
SPECIAL TOOLS J 8614-01 J 8092 J 22888 J 24433 J 8608 J 24429 1. Pinion Flange Remover 2. Side Bearing Remover 3. Rear Pinion Bearing Cup Installer 4. Driver Handle 5. Rear Pinion Bearing Cone Installer 6. Side Bearing A djustm ent Spanner J 22912-01 7.
Page 175 SECTION 4B5 DANA MODEL 80 (11-INCH RING GEAR) NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 176 J 29721-70 Side Bearing Adapters between the bearings and the differential case. To move C-4171 Universal Handle the ring gear, shims are removed from one side and an C-4307 Bearing Cup Remover (Rear) equal amount added to the other. Differential side bear D-128 Dial Indicator Set or Equivalent ing preload is set by the axle housing.
Page 177 1. AXLE HOUSING 19. BOLT 2. RING GEAR AND PINION SET 20. BEARING 3. INNER PINION BEARING 21. SHIM 4. SHIMS 22. DIFFERENTIAL CASE 6. PRELOAD SHIMS 23. RING GEAR BOLT 7. BEARING 24. PINION GEAR 8. SLINGER 25. SIDE GEAR 9.
Page 178 Figure 3— Spreading the Differential Case Figure 4— Removing the Differential...
Page 179 F4764 F4768 Figure 12— Removing the Bearing Cups Figure 13— Removing the Pinion Inner Bearing 8. Bearings (20) using J 8107-3, J 29721, and J 29721-70 (figure 5). • Mark the bearings left and right, and place them with their corresponding bearing caps. 9.
Page 180: Inspection
11. Ring gear (2) from the case using a soft-faced CLEANING hammer. Do not steam-clean drive parts that have ground and A. Ring gear (2) from the vise. polished surfaces such as gears, bearings, and shafts. B. Put the case back in the vise. All parts should be disassembled before cleaning.
Page 181: Bearings
8. Ring gear to the case (2). BEARINGS A. Align the holes in the case with the holes in the Inspect ring gear. B. Press the ring gear onto the case. Bearings for smooth rotation after oiling them. Bearing rollers for wear. Bearing cups for wear, cracks, brinelling, and scor...
Page 182: Determining Total Shim Pack Size
4. Install the arbor and discs into the axle housing. DETERMINING TOTAL SHIM PACK SIZE 5. Install D-116-1 onto D-6255 against the arbor. 1. Assemble the case (22) to the axle housing. The 6. Place D-115 onto the height block (figure 18). pinion must not be installed.
Page 183: Pinion Installation
Figure 19— Dial Indicator On The Arbor C. A negative (-) pinion marking indicates that the distance between the ring gear centerline and the pinion head must decrease by the number of thousandths marked on the pinion. This means that the shim pack will increase by the same number of thousandths.
Page 184 Figure 23— Tightening Pinion Nut F4720 Figure 26— Installing Differential Bearings Figure 24— Checking Pinion Preload B. Remove J 8614-01. Using an inch-pound 6. Preload shims (6). torque wrench, check the pinion preload by • It is very important to place shims on pinion rotating the pinion with the wrench (figure gear stem in proper sequence.
Page 185: Assembling The Differential Into The Axle Housing
7. Remove the indicator and the differential case from the axle housing. 8. Remove the master bearings from the differential case. 9. Using the total shim pack size determined earlier, (Refer to “ Determining Total Shim Pack Size” ) sub tract the reading found in step 6 from the total reading.
Page 186: Gear Tooth Pattern Check
4. To adjust the backlash, the differential case must be removed from the housing, the differential bear ings removed, and the proper number of shims moved from one side to the other. 5. Make the final gear pattern check. GEAR TOOTH PATTERN CHECK Checking the ring gear to pinion tooth pattern is done only after setting up the axle according to the methods...
Page 187 CONDITION: CONDITION: • BACKLASH CORRECT. • BACKLASH CORRECT. • PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT. IS TOO FAR AWAY FROM RING GEAR. HEEL HEEL rfS/ jjra r DRIVE SIDE COAST SIDE DRIVE SIDE COAST SIDE (CONVEX) (CONCAVE) (CONVEX) (CONCAVE) CORRECTION: CORRECTION:...
Page 188: Specifications
SPECIFICATIONS FASTENER TIG H TEN IN G SPECIFICATIONS Lbs. Ft. Axle Cover Bolts..........................Bearing Cap Bolts.......................... Drive Pinion Nut Model 8 0 ............................. Fill P lu g ............................RING GEAR BOLTS Model Lbs. Ft. 8 0 ..............................AVAILABLE SHIM SIZES Differential Bearing Adjusting Shim....................
Page 189: Special Tools
SPECIAL TOOLS D 116-2 J 8092 D 115-3 J 5590 D 116-1 J 8614-01 D 115 J 23690 D 136/D 346 J 29721 D 6255 J 24385-01 C 4204 J 29721-70 <0<S> C 4171 J 8107-03 J 7818 1. MASTER DISCS (MILLER) 10.
Page 190 NOTES...
Page 191 SECTION 4B7 LOCKING DIFFERENTIAL NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 192: Cam Unit Disassembly 7 1/2, 7 5/8, And 8 1/2-Inch
6. W ASHER, PINIO N THRU ST 7. GEAR, PINION 15. W ASHER , W AVE A. GEAR, RING 7 1 / 2 - INCH 8. W ASHER, SIDE GEAR TH R U S T 16. PLATE, CAM B. GEAR RING 8 1 /2 - IN C H 9.
Page 193: Cleaning And Inspection
F4800 F4802 Figure 5— Checking Cam Gear Backlash Figure 3— Removing the Retaining Ring Figure 6— Measuring Side Gear Spread Figure 4— Removing the Thrust Sleeve 1. Guide clips (20). 2. Side thrust sleeve (14) using J 22910-01. • Press the sleeve from the side gear (figure 4). 3.
Page 194: Cam Unit Assembly - 9 1/2-Inch
• Differential case for cracks and scoring. 2. Place the pinion gears (7) and side gear thrust • Thrust sleeve for excessive wear. Do not replace washers into the differential. the thrust sleeve unless necessary. Inspect the • Align them with the pinion shaft hole. side gear bore for scoring.
Page 195: Assembly Of The Differential
Thrust Block Clearance Adjustment 5. Right side gear (10). 6. Thrust block (17), pinion thrust washer (6), and Install or Connect (Figures 1, 6, and 7) pinion gear (7). A. Place the pinion gears into the differential 180 1. Left thrust washer (13) to the differential. degrees apart.
Page 196 31. Differential Case Halves 37. Plates 43. Governor and Latching Bracket 32. Screw 44. Plates 38. Pinion Thrust Washer 33. Cam Plate 39. Pinion Gear 45. Side Gear Thrust Washer 34. Guide Clip 40. Side Cam Gear 46. Side Gear 35.
Page 197: Cleaning And Inspection
5. Guide clips (34) to the plates. CLEANING AND INSPECTION • Use a chassis grease in the clips to hold them Clean in place on the plates. A. If the side gear or thrust sleeve has been • All parts with an approved solvent. replaced, measure and record the overall length of the gear to the back of the thrust Inspect...
Page 198 4. Install the yoke firmly to the differential case half Left Side Gear Backlash Adjustment (figure 14). 1. Assemble the clutch plates. 5. Loosen the nut, and index one pinion gear tooth to • Alternate the plates as shown in figure 12. point downward (perpendicular to the case half 2.
Page 199: Assembly Of The Differential
Measure 1. The distance from the side gear face to the case half face (figure 16). A. The thickness of the straight edge must be sub tracted from the reading. B. Add the measurement of both sides together. This is the side gear spread. 2.
Page 200: Specifications
SPECIFICATIONS FASTENER TIG HTENING SPECIFICATIONS Fastener Lbs. Ft. Differential Lockscrew 7 1/2, 7 5/8, and 8 1/2 -in c h ............... 36 9 1/2-inch....................... 50 THRUST BLOCK SIZES Color Code 7 1/2, 7 5/8-Inch 8 1 /2-Inch 9 1/2-Inch Purple..
Page 201: Special Tools
SPECIAL TOOLS fo ( f / J ) J 22 9 1 2 -0 1 J 2 6 2 5 2 1. Rear Pinion Bearing Cone Remover 2. Locking D ifferential Governor Remover F4804...
Page 202 NOTES...
Page 203 SECTION 4C FRONT AXLE CONTENTS SUBJECT PAGE 7 1/4-Inch Ring G ear...............................4C1-1 8 1/4 and 9 1/4-Inch Ring G ear........................... 4C2-1 All Wheel Drive Front Axle 7 1/4-Inch Ring G e a r....................4C3-1 SECTION 4C1 7 1/4-INCH RING GEAR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
Page 204 CONTENTS (cont’d) SUBJECT PAGE Drive Axle A ssem b ly..............................4C1-17 Outer Deflector R in g ..............................4C1-17 ABS Sensor Ring...............................4C1-17 Outer Joint S eal................................. 4C1-17 Outer Joint A ssem b ly.............................. 4C1-21 Inner Tripot S e a l................................ 4C1-22 S p ecificatio n s.................................4C1-24 Fastener Tightening Specifications........................4C1-24 Available Shim Sizes..............................
Page 205: Disassembly
19. Bearing cups (33) and sleeves (32) from the case. DISASSEMBLY • Turn the sleeves (32) using J 33792 until the Disassemble (Figure 1 through 15) cups are pushed out of the case (figure 8). 20. Bearings (30) from the sleeves (32). Use J 21551 Tools Required: (figure 9).
Page 206 F5785 '...
Page 207 1. Shaft 16. Spring 31. Insert 46. Nut 2. Deflector 17. Shift Shaft and Fork 32, Sleeve 47. Plug 3. Seal 18. Bolt 33. Side Bearing 48. Bushing 4. Bearing 19. Lock Tab 34. Bolt 49. Vent Hose 5. Tube 20.
Page 208 30. Bearing 32. Sleeve J-21551 F1782 Figure 6— Separating the Carrier Case Halves Figure 9— Remove the Sleeve Bearing 18. B olt 29. Carrier Case 19. Lock Tab 32. Sleeve F1780 Figure 7— Removing the Lock Tabs F5788 Figure 10— Removing the Pinion Nut...
Page 209 Figure 11— Remove the Pinion Flange F4759 Figure 14— Removing the Differential Side Bearing F4696...
Page 210: Cleaning
CLEANING AND INSPECTION • The sealing surface of the pinion flange for nicks, CLEANING burrs, or rough tool marks which would cause dam Do not steam clean drive parts having ground and age to the seal’s inside diameter and result in an polished surfaces such as gears, bearings, and shafts.
Page 211: Assembly Of The Axle
ASSEMBLY OF THE AXLE DIFFERENTIAL CASE ASSEMBLY PIN IO N BEARING CUP INSTALLATION -H - Install or Connect (Figures 1, 2 and 16) Install or Connect (Figures 1, 2, 17 and 18) Tool Required: J 33790 Side Bearing Installer Tool Required: 1.
Page 212 B. Button Moved Out of Bearing Bore F5791...
Page 213: Pinion Installation
• Set the dial indicator at ZERO, then position it 7. Deflector (43), flange (44), washer (45) and nut (46). in J 33838. Push the dial indicator downward A. Apply PST sealant (GM P/N 1052080) or equiv alent to the pinion gear threads and on both until the needle rotates approximately 3/4 turns sides of the washer.
Page 214: Differential Assembly Installation
2. Tighten the left sleeve (32) to 140 N-m (100 lbs. ft.) DIFFERENTIAL ASSEMBLY using J 33792 (figure 24). INSTALLATION 3. Mark the location of the adjusting sleeves in rela tion to the carrier halves (figure 25), so the notches Install or Connect (Figures 1, 2, 23, 24 and 25) in the adjusting sleeves can be counted when turned.
Page 215: Gear Tooth Contact Pattern Check
ously outlined. It is a method to verify the correct running position of the ring gear and the drive pinion. Gear sets which are not positioned properly may be noisy, have a short life, 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.
Page 216 CONDITION: CONDITION: • BACKLASH CORRECT. • BACKLASH CORRECT. • PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT. IS TOO FAR AWAY FROM RING GEAR. HEEL HEEL HEEL HEEL ris/ \ J / DRIVE SIDE COAST SIDE DRIVE SIDE COAST SIDE (CONVEX) (CONCAVE) (CONVEX)
Page 217: Final Assembly
2. Right carrier case (29). The position of the drive pinion is adjusted by 3. Bolts (28). increasing or decreasing the shim thickness between the pinion head and the inner race of the rear bearing. The shim is used in the differential to compensate for manufacturing tolerances.
Page 218 Figure 32— Installing the Thrust Washer Figure 33— Checking the Shift Mechanism B. Apply sealer (GM P/N 1052357) or equivalent Tighten to the carrier. 20. Tube assembly (5) to the carrier. • Bolts to 25 N-m (18 lbs. ft.). 21. Two upper bolts (6). Leave finger tight. 7.
Page 219: Drive Axle Assembly
DRIVE AXLE ASSEMBLY 2. Small seal-retaining clamp (11) on axle shaft with OUTER DEFLECTOR RING side cutter, and discard. 3. Separate joint seal (13) from C/V joint race (18) at *--► Remove or Disconnect (Figures 34 through 38) large diameter, and slide seal away from joint along axle shaft.
Page 220 1. ASSEMBLY, TRI-POT HOUSING 2. RING, SHAFT RETAINING 3. SPIDER, TRI-POT JOINT 4. RING, NEEDLE RETAINER 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.
Page 221 SQUARE UP DEFLECTOR RING AND TIGHTEN 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 Figure 37—Installing Outer Deflector Ring...
Page 222 PUSH C/V JOINT ASSEMBLY ONTO AXLE SHAFT UNTIL RETAINING RING 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 Swage Ring Swage Ring Clamp Axle Assembly...
Page 223: Outer Jo In T Assembly
2. Balls (17). OUTER JO IN T ASSEMBLY A. Tap on the cage with a brass drift to tilt it «£► Disassemble (Figures 34, 42, and 43) enough to install the balls. B. Pack the inner joint (18) with chassis grease. 1.
Page 224: Inner Tr Ipo T Seal
INNER TR IPO T SEAL Remove or Disconnect (Figures 34, 40, and 45 through 48) SLIDE SPACER RING INTO GROOVE ON AXLE SHAFT Tools Required: J 8059 Snap Ring Pliers J 35910 Seal Clamp Tool 1. Retaining clamp protector from larger seal retaining clamp (9) (if so equipped).
Page 225 Important Inspect • Be sure that counterbore face of tripot spider Tripot balls (6) and needle rollers (7) for dam (3) faces end of shaft (12). age and wear. 6. Install shaft retaining ring (2) in groove of axle shaft with J 8059.
Page 226: Specifications
SPECIFICATIONS FASTENER TIG HTEN ING SPECIFICATIONS Fastener Lbs. Ft. Adjusting Sleeve Lock B olts................— Carrier Case Bolts....................Differential Ring Gear B olts................Left Hand Output Shaft Cover B olts..............Tube Attaching Bolts................... AVAILABLE SHIM SIZES Pinion Shim Kits..........................
Page 227: Special Tools
SPECIAL TOOLS J 8614-01 J 21551 J 29763 J 33844 J 33782 J 33893 J 33785 J 29369-2 J 33788 J 29307 J 33790 J 33791 J 33792 J 8001 5® J 25025-1 J 23423-A J 36652 9. Bearing Cup Installer 10.
Page 228 NOTES...
Page 229 SECTION 4C2 8 1/4 AND 9 1/4-INCH RING GEAR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 230 GENERAL DESCRIPTION The front axle used on K model vehicles has a center transmit the driving force. This prevents tire scuffing disconnect feature that, under most conditions, allows when going around corners and prevents premature shifting into and out of four-wheel drive when the vehi wear on internal axle parts.
Page 231 23. Adjuster plug (61) with side bearing cup (33) and AXLE HOUSING O-ring seal (62) (K3 models). Use J 36615 (figure Inspect 24. Nut (46). Use J 8614-01 to hold the pinion flange (figure 11). • Axle housing bore for nicks or burrs that would 25.
Page 233 SHIMS, THRUST WASHERS, AND ADJUSTER SLEEVES Inspect 1. Right Output Shaft • Shims and thrust washers for cracks and chips. 2. Deflector Damaged shims should be replaced with an equal 3. Seal ly sized service shim. 4. Output Shaft Bearing •...
Page 235 1. Right Output Shaft 2. Deflector 3. Sea! 4. Output Shaft Bearing 5. Axle Tube 6. Bolt 7. Thrust Washer 8. Retaining Ring 9. Connector 10. Differential Actuator 11. * Washer 12. ‘ Retaining Ring 13. Engagement Switch 14. Shifter Fork Spring 15.
Page 236 A djuster 63. Bolt 64. Lock Figure 10-Turning the Adjuster Plug (K3 Models)
Page 237 Seal 39. Bearing Cup Figure 13— Removing the Pinion Figure 16— Removing the Inner Bearing Cap...
Page 238: Assembly Of The Axle
F5285 Figure 18— Removing the Pin (K1, 2 Models) Figure 19— Replacing the Carrier Bushings ASSEMBLY OF THE AXLE F. Rotate the tool several times to make sure the Important bearing cup is not cocked in the bore. Apply axle lubricant to all bearings, seal lips, gears, •...
Page 239: Pinion Installation
J 36598-3 (K15-25) J 36598-3 (K15-25) J 36598-4 (K35) J 36598-4 (K35) 40. Bearing Cup 39. Bearinq Cup F5868 F5867 Figure 20— Installing the Outer Pinion Bearing Cup Figure 21— Installing the Inner Pinion Bearing Cup 9. Push the dial indicator downward until the needle 1.
Page 240 J 36601-4 (K15-25) J 36601-3 (K35) A. Button Located In Bore B. Bearing Swung Out of Bore C. Nut D. W asher E. Pilot F. Flats 39. Bearing (Inner Pinion) J 21777-35 (K15-25) J 29763 41. Bearing (Outer Pinion) J 21777-8 (K35) F5869...
Page 241: Differential Case Assembly
J 35512 (K15-25) J 36614 (K35) F5870 Figure 23— Installing the Pinion Bearing DIFFERENTIAL CASE ASSEMBLY Install or Connect (Figures 1 through 4, and Tools Required: J 22761 Side Bearing Installer (K1, 2 Models) J 29710 Side Bearing Installer (K3 Models) Figure 26—...
Page 242 J 36613 Bearing Installer (K3 Models) J 8092 Driver Handle J 36599 Sleeve Adjusting Wrench J 36615 Adjuster Plug Wrench (K3 Models) J 36603 Side Bearing Cup Installer 1. Bearings (30) to the sleeves (32) and/or adjuster plug (61) (K3 models). •U s e J 8092 and J 36612 (K1, 2 models) or J 36613 (K3 models) (figure 27).
Page 243: Adjusting Backlash
4. Follow the steps for adjusting backlash. ADJUSTING BACKLASH Tools Required: • Gear backlash should be between 0.08-0.25 J 8001 Dial Indicator Set mm (0.003-0.010 inch) with a preferred specifi cation of 0.13-0.18 mm (0.005-0.007 inch). 1. Refer to figures 1 through 4. 2.
Page 244: Test
TEST -► «- Install or Connect (Figures 1 through 4, 19, 1. Wipe oil out of carrier and carefully clean each and 34) tooth of the ring gear. 2. Apply gear marking compound sparingly to all ring gear teeth using a medium stiff brush. When prop Tools Required: erly used, the area of pinion tooth contact will be J 36600 Output Shaft Seal Installer (K1, 2)
Page 245 CONDITION: CONDITION: • BACKLASH CORRECT. . BACKLASH CORRECT. • PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT. IS TOO FAR AWAY FROM RING GEAR. HEEL HEEL HEEL HEEL DRIVE SIDE COAST SIDE DRIVE SIDE COAST SIDE (CONVEX) (CONCAVE) (CONVEX) (CONCAVE) CORRECTION: CORRECTION: INCREASE THE PINION SHIM THICKNESS.
Page 246 4. Subtract dimension “ A” from dimension “ B.” 5. The correct shim size will be one size smaller than the figure obtained in step 5. Examples: • If the figure obtained in step 5 was 3.53 mm, use a 3.30-mm shim. •...
Page 247 C. Measure w ith Axle Shaft Forced Outboard 1. Shaft 5. Tube 9. Carrier Connector 23. O utput Shaft 29. Carrier Case F5877...
Page 248 MEASURING DIMENSION “B” MEASURING DIMENSION “A” (K15-25 SHOWN) F5878 Figure 37— Measuring to Calculate Shim 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 h im (20), as selected previously, to the output shaft (23).
Page 249 • Damper spring fits into shift fork indentation. flange while moving the shift fork with the drift. • Make sure clip is seated in groove of shift shaft. The shift mechanism should work smoothly, •A p p ly a bead of sealer (GM P/N 1052942) or without binding.
Page 250 1. ASSEMBLY, TRI-POT HOUSING 2. RING, SHAFT RETAINING 3. SPIDER, TRI-POT JOINT 4. RING, NEEDLE RETAINER 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.
Page 251 SHEET STEEL (3mm MIN THICKNESS) WITH 28mm DRILLED HOLE PIPE COUPLING: 3" (K10/20) M24X2.0 4" (K30) SQUARE UP DEFLECTOR RING AND TIGHTEN PUSH JOINT ASSEMBLY NUT UNTIL RING BOTTOMS AGAINST SHOULDER ONTO AXLE SHAFT UNTIL RETAINING OF OUTER RACE RING IS SEATED IN GROOVE ON AXLE SHAFT 18.
Page 252 E. Mount the proper size swage clamp tool in the A. Slide the seal (13) onto the axle shaft (12) and position the neck of the seal in the seal groove vise and proceed as follows: on the axle shaft. a.
Page 253 3. Tilt the cage (17) in opposite direction to remove PIVOT CAGE AND INNER RACE AT 90° TO CENTER opposing ball (15). LINE OF OUTER RACE WITH CAGE WINDOWS • Repeat this process until all six balls (15) are ALIGNED WITH LANDS OF OUTER RACE. removed.
Page 254 2. Small seal-retaining clamp (11) from the axle shaft SLIDE SPACER RING (12) with a side cutter, and discard. INTO GROOVE ON • Separate seal (10) from the tripot housing (1) at the large diameter and slide the seal away from the joint along the axle shaft (12).
Page 255 Important • The seal (13) must not be dimpled, stretched or out of shape in any way. If the seal is not shaped correctly, slide the swage ring (9) off the seal and onto the housing (1). Carefully insert a thin, flat, blunt tool (no sharp edges) between the seal opening and the housing to release the air.
Page 256 SPECIFICATIONS FASTENER TIG H TEN IN G SPECIFICATIONS Fastener Lbs. Ft. Lbs. In. Actuator........................— Axle Tube Bolts..................... — Carrier Case Bolts....................— Drain and Fill P lu g s....................— Front Axle S w itch....................— Ring Gear Bolts..................... —...
Page 257 SPECIAL TOOLS J 29307 J 36616 J 36612 J 22761 J 36613 J 29710 J 22888 J 8092 J 36609 J 8107-2 J 36597 J 29369-1 J3612-B J 29369-2 J 36606 J 33842 J 8614-01 J 34011 1. Slide Hammer 2.
Page 258 J 34037 J 35512 & J 36614 J 34672 J 36366 J 36600 J 22833 J 36615 J 36598 J 34047-3 J 8001 J-36599 J 36601 J 8059 J 29763 J 35910 J 36603 19. Pinion Bearing Installer (K15-25 Models) 30.
Page 259 SECTION 4C3 ALL WHEEL DRIVE FRONT AXLE 7 1/4-INCH RING GEAR NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 260: General Description
GENERAL DESCRIPTION The ring gear bolts to the differential case with left The front axle on the all wheel drive model uses a full-time four-wheel drive system, with no disengage hand thread bolts. ment feature. The differential case is supported in the axle housing The axle uses a conventional ring and pinion to trans...
Page 261 F7475...
Page 262 • Insert a screwdriver into the slots provided and pry to separate the case (figure 5). 10. Differential case (35). 11. Bolts (18) and lock tabs (19) from the side bearing adjuster sleeves (32) (figure 6). 12. Bearing cups (33) and sleeves (32) from the case. •...
Page 263 Figure 5— Separating the Carrier Case Halves 30. Bearing 32. Sleeve 29. Carrier Case 18. Bolt 19. Lock Tab 32. Sleeve F1782 F1780 Figure 8— Removing the Sleeve Bearing Figure 6— Removing the Lock Tabs Inspect • Housing for cracks. Replace the housing if any cracks are found.
Page 264: Thrust Washers, Shims, And Adjuster S Leeves
Figure 12— Removing the Inner Pinion Bearing Cup F7549 Figure 10— Removing the Pinion Flange • Low m ileage bearings may have very sm all scratches and pits on the rollers and the bearing cups from the initial preload. Do not replace a bearing for this reason.
Page 265 Figure 14— Replacing the Case Bushings ASSEMBLY OF THE AXLE Important Lubricate all the seal lips, bearings, gears, and bearing surfaces with axle lubricant prior to assem bly. DIFFERENTIAL CASE ASSEMBLY Install or Connect (Figures 1, 2 and 15) Tool Required: J 33790 Side Bearing Installer 1.
Page 266: Pinion Bearing Installation
PIN IO N BEARING J 33837-1 INSTALLATION J 33837-3 ■n- Install or Connect (Figures 1, 2, 16 and 17) Tool Required: J 33837 Pinion Bearing Remover and Installer 1. Bearing (41) into the case using J 33837-1, J 33837-3, and J 33837-4 (figure 16). J 33837-4 2.
Page 267 B. Button Moved Out o f Bearing Bore F5791...
Page 268: Differential Case Installation
C. No further tightening should be attempted until bearing preload has been checked. Measure • Pinion bearing preload. Use an inch pound torque wrench (figure 21). The correct preload is 1.7-2.8 N-m (15-25 lbs. in.). 1. Rotate the pinion with the torque wrench and observe the reading.
Page 269 1. Tighten the right sleeve (32) to 140 N-m (100 lbs. ft.) using J 33792 (figure 23). 2. Tighten the left sleeve (32) to 140 N.m (100 lbs. ft.) using J 33792 (figure 23). 3. Mark the location of the adjusting sleeves in rela tion to the carrier halves (figure 25), so the notches in the adjusting sleeves can be counted when turned.
Page 270: Gear Tooth Contact Pattern C H Eck
TEST GEAR TOOTH CONTACT 1. Wipe oil out of the carrier and carefully clean each PATTERN CHECK tooth of the ring gear. 2. Apply gear marking compound sparingly to all ring Before final assembly of the differential, a gear tooth gear teeth using a medium stiff brush.
Page 271 CONDITION: CONDITION: • BACKLASH CORRECT. • BACKLASH CORRECT. • PINION DEPTH INCORRECT-PINION GEAR • PINION DEPTH CORRECT. IS TOO FAR AWAY FROM RING GEAR. HEEL HEEL HEEL HEEL DRIVE SIDE COAST SIDE DRIVE SIDE COAST SIDE (CONVEX) (CONCAVE) (CONVEX) (CONCAVE) CORRECTION: CORRECTION: INCREASE THE PINION SHIM THICKNESS.
Page 272: Abs Sensor Ring
Tools Required: J 33844 Bearing Installer J 33893 Axle Seal Installer J 33791 Case Bushing Installer 1. Apply a bead of sealer (GM P/N 1052357) or equivalent to one carrier case surface. Follow the sealer m anufacturer’s instructions to apply the sealer.
Page 273 1. ASSEMBLY, TRI-POT HOUSING 2. RING, SHAFT RETAINING 3. SPIDER, TRI-POT JOINT 4. RING, NEEDLE RETAINER 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.
Page 274 TAP DEFLECTOR RING OFF OUTER RING AND DISCARD 3. Deflector ring. • Position and square up the sensor ring (19) at the press diameter of the outer race (18). 21. Deflector Ring • Using a 76-mm (3-inch) pipe coupling (K1-K2) A.
Page 275 5. Pinch swage ring (9) by hand slightly to distort into oval shape and slide onto large diameter of seal. 6. Push C joint onto axle shaft until retaining ring (14) is seated in groove (figure 35). 7. Slide large diameter of seal with large swage ring in place over outside of C/V joint race (20) and locate seal lip in housing groove.
Page 276 MAKE SURE SWAGE RING AND SWAGE RING CLAMP ARE IN PROPER ALIGNMENT F7488 Figure 37— Installing Swage Ring PIVOT CAGE AND INNER RACE AT 90° TO CENTER LINE OF OUTER RACE WITH CAGE WINDOWS ALIGNED WITH LANDS OF OUTER RACE. LIFT OUT CAGE AND INNER RACE.
Page 277: Inner Tripo T Seal
3. Tilt cage (19) in opposite direction to remove opposing bail (17) (figure 38). 4. Repeat this process until all six balls are removed. 5. Position cage (19) and inner race (18) 90 degrees to centerline of outer race (20) and align cage win dows with lands of outer race (figure 39).
Page 278 4. Seal (10) from tripot housing by separating (1) at Important large diameter and sliding seal away from joint • Seal (10) must not be dimpled, stretched or out along axle shaft. of shape in any way. If seal is not shaped cor 5.
Page 279: Specifications
SPECIFICATIONS FASTENER TIG H TEN IN G SPECIFICATIONS Fastener Lbs. Ft. Adjusting Sleeve Lock B olts................— Carrier Case Bolts....................Differential Ring Gear B olts................Left Hand Output Shaft Cover B olts..............Tube Attaching Bolts................... AVAILABLE SHIM SIZES Pinion Shim Kits......................
Page 280: Special Tools
SPECIAL TOOLS J 8614-01 J 21551 J 33844 J 29763 J 33782 J 33893 ( S ? C = 3 J 33785 J 29369-2 J 33788 J 29307 J 33790 17 . J 33791 J 33792 J 8001 J 22912-01 3®...
Page 281 SECTION 5 BRAKES CONTENTS SUBJECT PAGE Master C y lin d er..................................5A-1 Vacuum B ooster................................5D1-1 Hydraulic B o o ster................................5D2-1 SECTION 5A MASTER CYLINDER NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
Page 282: General Description
GENERAL DESCRIPTION Bendix master cylinders have the information stamped Master cylinders have identifying information stamped into the front surface of the body. The first digit indicates into the unit. Delco chassis master cylinders (composite or cast the plant where it was built. The second digit digit shows iron) have identification information on the front surface the year it was built.
Page 283 1. Cover 2. Diaphragm 3. Reservoir 4. Grommet 5. Quick Take-Up Valve 6. Spring 7. Spring Retainer 8. Primary Seal 9. Secondary Piston 10. Secondary Seal 11. Snap Ring 12. Primary Piston Figure 3— Removing the Reservoir Assem bly Body F0770 Figure 2—...
Page 284: Cast Iron Master C Ylin D
Bail Cover Diaphragm Body Spring Spring Retainer Primary Seal Secondary Piston Secondary Seals Primary Piston Assem bly Snap Ring F0774 Figure 6— Cast Iron Master Cylinder Components 5. Snap ring (11). • The primary piston must be compressed when installing the snap ring. 6.
Page 285: Bendix Master C Ylin D
CAUTION: If air pressure is used to remove 2. Primary seal (27) and spring retainer on secondary the secondary piston, place the open end of piston (28). the cylinder bore approxim ately 25 mm (1 3. Secondary seals (29) on secondary piston (28). inch) from a padded workbench or other sur...
Page 286: Fastener Tightening Specifications
41. Cover 42. Diaphragm — 42 43. Filter 44. Reservoir 45. Compensating Valve Seal 46. Valve Poppet 47. Spring ^ 4 4 48. Secondary Spring 49. Secondary Piston ___ 55 50. Piston Return Spring 51. Primary Piston 52. Snap Ring 53.
Page 287 SECTION 5D1 VACUUM BOOSTER NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 288 1. Boot 2. Silencer 3. Vacuum check Valve 4. Grommet 5. Front Housing Seal 6. Power Piston Bearing 7. Rear Housing 8. Front Housing 9. Return Spring 10. Piston Rod (Gaged) 11. Reaction Retainer 12. Filter 13. Diaphragm Retainer 14. Diaghragm 15.
Page 289 1. Boot 2. Silencer 3. Vacuum Check Valve 4. Grom met 7. Front Housing Seal 8. Primary Piston Bearing 9. Rear Housing 10. Front Housing 11. Return Spring 12. Piston Rod (Gaged) 13. Reaction Retainer 14. Power Head Silencer 15. Diaphragm Retainer 16.
Page 290 8. P rim ary P is to n B e a rin g 12. Piston Rod (Gaged) 13. Reaction Retainer 14. Power Head Silencer 15. Diaphragm Retainer 16. Primary Diaphragm F5823 17. Primary Support Plate Figure 6— Booster Inner Components 18.
Page 291 • Use crocus cloth to polish away minor corrosion from the housings or diaphragm support. IJjjp Clean • All parts in clean denatured alcohol. • Do not immerse the power piston assembly in alco hol. Wipe clean with an alcohol dampened cloth. •...
Page 292 13. RETAINER, DIAPHRAGM 16. DIAPHRAGM, POWER PISTON 17. PLATE, PRIMARY SUPPORT 19. DIVIDER, HOUSING 20. DIAPHRAGM, SECONDARY 41. PISTON, POWER V2783 Figure 11— Installing the Primary Diaphragm 7. Reaction piston (23) and reaction disc (22) in reac tion body (25). 8.
Page 293 D. Apply force in a clockwise direction to lock the front and rear housings. E. Back off the fixture screw. F. Stake housing at two tabs 180 degrees apart (figure 13). Notice: Do not stake a tab that has previous ly been staked.
Page 294 NOTES...
Page 295: Unit Repair
SECTION 5D2 HYDRAULIC BOOSTER NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 296 16. Cover 17. Bracket 18. Nut 6. O-Ring 19. Boot 7. Spring 20. Pedal Rod 21. Pin 8. Housing 22. Piston Assembly 9. Bolt 23. Seal 10. Seal \ o 27 24. Retainer 1. Retainer 11. Accumulator Valve 2. Accum ulator 12.
Page 297 F0764 Figure 4— Removing the Accumulator Valve Figure 6— Installing the Tube Seat 8. HOUSING 22. PISTON ASSEMBLY F9318 Figure 5— Removing the Tube Seat Figure 7— Installing the Piston Assembly Tools Required: J 26889 Accumulator Piston Compressor J 24551-A Seal Protector J 25083 Seal Protector 1.
Page 298: Unit Repair
12. Output pushrod assembly (figure 8). • Retainer (24), piston return spring (25), baffle (27), and output pushrod (28) using J 24551-A or J 25083. 13. Retainer (26). 14. Plug and spring assembly (figure 3). A. O-ring seal (6) on plug (5). B.
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 SECTION 6 ENGINE CONTENTS SUBJECT PAGE General Engine M echanical............................6A-1 2.2L L4 Engine (VIN 4 ) ..............................6A1-1 4.3L V6 Engine (VIN Z ) ..............................6A3-1 4.3L V6 Engine (VIN W )..............................6A4-1 V8 E ng in es..................................6A5-1 6.5L Diesel E n gin e................................6A7-1 Model 220 TBI U n it.................................
Page 302 CONTENTS (cont’d) SUBJECT PAGE Piston Selection (2.2L E ng ines)..........................6A- 7 Piston Selection (All Except 2.2L Engines)......................6A- 7 A ssem bly..................................6A- 7 Camshaft Bearings................................. 6A- 9 Cam shaft Bearing Replacement (2.2L Engines)....................6A- 9 Cam shaft Bearing Replacement (All Except 2.2L Engines)................6A- 9 Hydraulic Lifters................................6A-10 Valve Lifter Leakdown Rate Test (Flat Type Lifters O nly)................
Page 303 4. Apply RTV to one of the clean surfaces. Use a 4. Assemble parts in the normal manner and torque bead size as specified in the procedure. Run the immediately to specifications. bead to the inside of any bolt holes. Do not allow the sealer in any blind threaded holes, as it may Important prevent the bolt from seating properly or cause...
Page 304 3. If the cylinders are found to exceed the specified cylinder, and measure across the gage contact points with an outside micrometer, with the out-of-round or taper, honing or boring will be nec essary. Any cylinders that were found to have less gage at the same zero setting when removed than 0.13 mm (0.005 inch) wear or taper may not from the cylinder (figure 3).
Page 305 HONING PISTON AND CO NNECTING ROD ASSEM BLIES 1. When honing the cylinders, follow the hone manu facturer’s recommendations for use, cleaning, and DISASSEMBLY lubrication during honing. Use only clean, sharp stones of the proper grade for the amount of mate rial to be removed.
Page 306 4086-8 Press Ram B5072 Figure 6— Removing the Piston Pin 2. Connecting rod bearing inserts. If the inserts are to be reused, place them in a rack so they may be reinstalled in their original connecting rod and cap. 3. Piston pin (figure 6). •...
Page 307: Piston Selection (2.2L E Ng Ines)
PISTON SELECTION 4. Mark the piston to identify the cylinder for which it was fitted. (2.2L ENGINES) ASSEMBLY Refer to the proper section. Assembling the Piston and Connecting Rod PISTON SELECTION (ALL EXCEPT 2.2L ENGINES) Assemble (Figure 11) 1. Check the used piston to cylinder bore clearance. Tool Required: J 24086-B Piston Pin Remover and Installer Set Measure (Figures 9 and 10)
Page 308 Installing the Piston Rings C. Adjust the piston pin installer (J 24086-9) to the correct length, using the letter-number scale on the installer adjuster (figure 11). This is neces Measure (Figures 4 and 12) € sary to ensure the piston pin is pressed into the piston to the correct depth.
Page 309: Camshaft Bearings
Measure (Figure 14) € Ring clearance. Use a feeler gage as shown in figure 14. Compare with “ Specifications” in the proper section. Figure 14— Measuring Ring Clearance CAMSHAFT BEARINGS 1. Rear camshaft plug or cap. CAMSHAFT BEARING 2. Inner camshaft bearings. Use J 6098-01 REPLACEMENT (2.2L ENGINES) (figure 15).
Page 310: Hydraulic Lifters
3. Outer camshaft bearing. Use J 6098-01 (figure 16). A. Checking oil hole alignm ent w ith brass rod. • Assemble the bearing tool and driver handle. Make rod as shown using rod about " • Drive the outer camshaft bearings out of the 762 mm (30") long.
Page 311: Disassembly
4. Operate the lifter through full travel of the plunger by pumping the weight arm to fill the lifter with test fluid and force out air. Important • Lifter must be completely submerged at all times. • Continue pumping for several strokes after defi nite resistance is felt.
Page 312 B. Locate the indicator so movement 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 bore.
Page 313: Repair
REAMING VALVE GUIDES REPAIR The valve guides used in engines covered by this VALVE GRINDING manual are simply holes bored into the cylinder head Pitted valves must be refaced to the proper angle. except on the 5.7L H.D. and 7.4L engines. The 5.7L Valve stems that show excessive wear, or valves that H.D.
Page 314: Measuring Main Bearing Clearance
ASSEMBLY 7.4L engines: — J 7049-1: 0.08 mm (0.003 inch) oversize. — J 7049-2: 0.38 mm (0.015 inch) oversize. Assemble — J 7049-3: 0.76 mm (0.030 inch) oversize. — These reamers also available in Reamer Set Valves and components. Refer to the proper sec J 7049.
Page 315: Measuring Connecting Rod Bearing Clearance
4. Normally main bearing journals wear evenly and A standard or undersize bearing may produce the are not out-of-round. However, if a bearing is being proper clearance. Refer to the proper section for fitted to an out-of-round journal, make sure to fit to bearing availability.
Page 316: Thread Repair
t j | Measure (Figure 29) • Gaging plastic at its widest point, using the scale on the gaging plastic envelope (figure 29). • If the clearance exceeds specifications, select a new, correct size, connecting rod bearing and remeasure the clearance. •...
Page 317 SPECIAL TOOLS J 8087 J 8089 J 24086-B J 8101 J 6098-01 J 8001 J 9666 J 5790-B 1. CYLINDER BORE GAGE 2. PISTON PIN REPLACER SET 3. CAMSHAFT BEARING REPLACER 4. HYDRAULIC LIFTER LEAKDOWN TESTER 5. WIRE BRUSH 6. VALVE GUIDE CLEANING TOOL 7.
Page 318 NOTES...
Page 319 SECTION 6A2 2.2L L4 RPO LN2, VIN 4 NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 320: General Description
Intake M anifold..............................6A2-23 Exhaust Manifold.............................. 6A2-23 Cylinder Head..............................6A2-23 Valve Lifters...............................6A2-27 Oil Pump Overhaul............................6A2-28 Thread Repair..............................6A2-30 Assembly of Engine.............................. 6A2-31 Prior to Assembly............................. 6A2-31 Crankshaft Installation............................6A2-31 Crankshaft Rear Oil Seal Installation......................6A2-31 Camshaft Installation............................6A2-32 Flywheel Installation............................6A2-32 Piston and Connecting Rod Installation......................6A2-32 Oil Pump Drive Installation..........................6A2-34 Oil Pump Installation............................
Page 321: Valve Train
Pins are chromium steel and have a floating fit in the ENGINE LUBRICATION pistons. They are retained in the connecting rods by a Figure 5 press fit. Full pressure lubrication, through a full-flow oil Connecting rods are made of forged steel. Full filter, is furnished by a gear type oil pump.
Page 322 SR207LN2-EDS...
Page 323 1 RINGS, PISTON 35 WASHER, CLUTCH PRESSURE BOLT, CRANKCASE FRONT PLATE PISTON AND PIN COVER ROD, CONNECTING PLATE. CLUTCH PRESSURE 70 COVER, CRANKCASE FRONT 4 BOLT, CONNECTING ROD DISC, CLUTCH SEAL, CRANKCASE FRONT 5 BEARING, CONNECTING ROD 38 SEALANT COVER OIL PLUG, CYLINDER BLOCK OIL BOLT, OIL PUMP DRIVE 72 CHAIN, TIMING...
Page 325 1 PIPE, CRANKCASE VENT VALVE 44 STUD, OUTLET 2 RETAINER, CRANKCASE VENT 45 NUT, OUTLET VALVE 46 NUT, EXHAUST MANIFOLD 5 VALVE, CRANKCASE VENT 47 SENSOR, OXYGEN 6 GROMMET, CRANKCASE VENT 48 BRACKET, REAR ENGINE LIFT VALVE 49 STUD, EXHAUST MANIFOLD 10 BOLT 50 STUD, CYLINDER HEAD 17 TUBE, CRANKCASE VENT...
Page 326 OVERHEAD OILING AND RETURN MAIN OIL GALLERY N30005-6A2-J— EDS...
Page 327: Oil Fill Tube Removal
INTAKE MANIFOLD REMOVAL Figure 7, 57 and 58 ^ > 3 |+-»| Remove or Disconnect 1. MAP sensor and 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.
Page 328: Crankshaft Pulley Removal
UPPER INTAKE MANIFOLD ASSEMBLY BOLT ACCELERATOR CABLE BRACKET MAP SENSOR BOLT MAP SENSOR SEAL N30011 — 6A2— J— EDS Figure 7 - Accelerator Cable Bracket and MAP Sensor feEl Clean • Coolant pump gasket surfaces. FRONT CRANKSHAFT PULLEY REMOVAL ^ ENGINE Figure 11 Remove or Disconnect 1.
Page 329: Crankcase Front Cover Oil Seal Removal
f lP ' FRONT ENGINE 1 BRACKET ASSEMBLY, ACCESSORY STUD - 10 N-m (89 LBS. IN.) 2 OUTLET, COOLANT BOLTS - 50 N-m (37 LBS. FT.) 3 ADAPTER, COOLANT OUTLET BOLTS - 50 N-m (37 LBS. FT.) 4 THREMOSTAT GASKET, COOLANT OUTLET ADAPTER NUT - 10 N-m (89 LBS.
Page 330: Timing Chain, Tensioner And Camshaft Sprocket Removal
1 BOLT 2 SPROCKET, CAMSHAFT 3 BOLT 4 TENSIONER 5 BOLTS Important 6 SPOCKET, CRANKSHAFT • Take care not to damage the seal seat. TIMING CHAIN, TENSIONER AND CAMSHAFT SPROCKET REMOVAL Figures 13 and 56 Remove or Disconnect 1. Timing chain tensioner bolts. 2.
Page 331: Cylinder Head Removal
FRONT ENGINE 1 PIPE ASM., CRANKCASE VENT 2 RETAINER, CRANKCASE VENT 3 VALVE. CRANKCASE VENT 4 GROMMET, CRANKCASE VENT 1 BOLT 5 COVER ASM., VALVE ROCKER ARM SR201LN2-EDS 2 ROCKER COVER 3 GASKET Figure 14 - Crankcase Vent Valve and Tube 4 ROCKER STUD 5 FLANGE, MUST BE FREE OF OIL UPON CYLINDER HEAD REMOVAL...
Page 332: Oil Pump Drive Removal
1 BRACKET 2 BOLT 3 OIL PUMP DRIVE ASSEMBLY 4 O-RING OIL PUMP DRIVE REMOVAL SHAFT 6 RETAINER; HEAT AND W ATER SOAK Figure 17 PRIOR TO INSTALLATION Remove or Disconnect 7 BOLT 8 OIL PUMP 1. Oil pump drive to block bolt. 9 CYLINDER BLOCK MC0101-6A2—...
Page 333: Camshaft Removal
1 J 24270 2 CLOTH N30015-6A2— J-EDS Figure 19 - Removing the Cylinder Ridge Important Important • Use care not to damage the camshaft bearings • Mark the relationship of the pressure plate with the cam when withdrawing the camshaft. assembly to the flywheel to assure proper 2.
Page 334 - Install the self-threading screw. - Pry out plug. Oil gallery screw plugs. C lea n • Sealing material from mating surfaces. • Boil cylinder block in caustic solution. - Flush with clean water or steam. • Oil passages. • All blind holes. •...
Page 335: Crankshaft
If cracks, severe gouges or burned spots are found, the crankshaft must be replaced. PRESS Measure • Crankshaft journals. With a micrometer, measure taper and run-out. If the readings are within 1 J 24086-8BA specifications, note results for later selection of 2 J 24086-10 bearing inserts.
Page 336 1 G AG ING POINT MC0500-6A2-L-EDS Figure 24 - Piston to Cylinder Bore Gaging Points 2. Piston pin for: a. Scoring. b. Galling caused by improper installation. c. Fit in connecting rod and piston. 3. Piston for: a. Scoring of the skirt. b.
Page 337 INSERT FEELER GAGE AT TOP OF RING GROOVE TO MEASURE RING SIDE CLEARANCE. The piston must be mounted on the connecting rod in such a manner that the piston mark indicating COMPRESSION front of engine lines up with the side of the RING connecting rod that faces the front of the engine.
Page 338: Main And Rod Bearings
V Important • In order to provide an effective compression seal, the ring gaps must be staggered upon installation, refer to Figure 49. MAIN AND ROD BEARINGS MAIN AND ROD BEARING INSPECTION Figure 29 Main bearings are of the precision insert type and do not utilize shims for adjustment.
Page 339 • If clearance obtained meets specification, the bearing size used for measurement is correct. • If clearance obtained does not meet the specification, choose a service bearing that will correct the clearance and meet the specification. If the proper bearings are unavailable, the crankshaft must be replaced.
Page 340: Camshaft
Measure • Crankshaft end play, refer to Figure 31. • Connecting rod side clearance, refer to Figure 52. CAMSHAFT CAMSHAFT INSPECTION Figure 32 Tool Required: J 8520 Cam Lobe Lift Indicator Inspect Sprocket. Key way and threads. Bearing surfaces and lobes for: - Wear.
Page 341: Intake Manifold
INTAKE MANIFOLD CHECKING OIL HOLE ALIGNMENT W ITH BRASS ROD. MAKE AS SHOWN USING 3/32" ROD Clean ABOUT 762MM (30") LONG. Mating surfaces on intake manifold and cylinder head. EGR passage of excessive carbon deposits. Inspect Manifold for cracks, broken flanges and gasket surface damage.
Page 342 4. Valves. NOTICE: Avoid breaking the valve guide. If the valve stem has mushroomed, remove burrs by chamfering the valve stem with an oil stone or file. Do not remove the valve from the guide using a hammer and drift punch. 5.
Page 343 I Measure • Valve guide clearance. - With a hole gage, measure the valve guide I.D. and measure the valve stem with a micrometer and compare the clearance. - INTAKE CLEARANCE • 0.028 - 0.066 mm (0.0011 - 0.0026 in.) - EXHAUST CLEARANCE •...
Page 344 • Valve face for grooving. If the groove is so deep that re-facing would result in a knife edge margin, the valve must be replaced. • The valve face may be reground to specifications if it is otherwise in good condition. If the valve face cannot be ground within the limits given, it must be replaced.
Page 345: Valve Lifters
exercised in the handling of parts. Valve lifters must be kept in order so they may be reinstalled in their original position. VALVE LIFTER DIAGNOSIS 1. Momentarily noisy when vehicle is started: This condition is normal. Oil drains from the lifters which are holding the valves open when the engine is not running.
Page 346: Oil Pump Overhaul
• Valve spring damper clicking on rotator. To check valve spring and guide clearance, remove the rocker covers: a. Occasionally this noise can be eliminated by rotating the valve spring and valve. Crank engine until noisy valve is off its seat.
Page 347 Valve. If the valve is stuck, soak the pump housing in carburetor cleaning solvent. Inspect • For foreign material, if found, determine the source. ^ Clean • All parts of sludge, oil and varnish. • Varnish may be removed by soaking in carburetor or cleaning solvent.
Page 348: Thread Repair
INSTALL INSERT TAP HOLE TO INSTALL INSERT DRILL HOLE TO INTO NEWLY PROPER SIZE ON MANDREL PROPER SIZE THREADED HOLE M40066— 6A7— W - E D S Figure 46 - Repairing Threaded Holes Assemble THREAD REPAIR 1. Lubricate all internal parts with engine oil during Figure 46 assembly.
Page 349: Assembly Of Engine
VIEW A 1 CYLINDER BLOCK 2 CRANKSHAFT REAR SEAL 3 CRANKSHAFT 4 BEARINGS 5 BEARING CAPS 6 BOLT 7 INSTALL SEAL (2) PERPENDICULAR AND FLUSH TO THIS SURFACE MC0023— 6A2-L-EDS Figure 47 - Crankshaft Assembly ASSEMBLY OF ENGINE Tighten PRIOR TO ASSEMBLY The importance of cleanliness during assembly •...
Page 350: Camshaft Installation
Tighten • Attaching screws to 3-7 N*m (27-62 lbs. in.). 5. Tighten “ T ” handle of tool to push seal into bore. Continue until tool collar is flush against block. 6. Loosen “ T ” handle completely. Remove attaching screws and tool. •...
Page 351 2. Turn crankshaft to bottom dead center. 3. Connecting rod thread protector, refer to Figure 18. Important • In order to provide an effective compression seal, the ring gaps must be staggered, refer to Figure 49. 4. J 8037 to piston, refer to Figure 50. 5.
Page 352: Oil Pump Drive Installation
Measure • Rod bearing clearance, refer to “ Main and Rod Bearings” in this section for measurement procedure. • If the readings are within limits, select a suitable set of inserts. If the readings are unsatisfactory and available inserts will not correct the clearance, the crankshaft must be replaced.
Page 353: Valve Lifter Installation
V Important • Install lifter(s) to bore being careful to align flat sides (top) of lifter(s) with flat sides of anti-rotation bracket(s). When properly installed, flat sides of each lifter are aligned parallel to the anti-rotation bracket, the roller at the bottom of each lifter is parallel to the camshaft.
Page 354: Valve Rocker Arm Cover Installation
1 LONG BOLTS 2 SHORT BOLTS 3 STUD 4 NUMBERS ON GASKET INDICATE TORQUE SEQUENCE CYLINDER HEAD BOLT TORQUE PROCEDURE 1 TIGHTEN BOLTS IN SEQUENCE (ITEM 4) TO: LONG BOLTS: 63 N-m (46 LBS. FT.) SHORT BOLTS: 58 N-m (43 LBS. FT.) 2 TIGHTEN ALL BOLTS AN ADDITIONAL ANGLE OF 90°...
Page 355: Crankcase Front Cover Oil Seal Installation
CRANKSHAFT PULLEY HUB INSTALLATION Figure 11 Tools Required: J 29113 Crankshaft Pulley Hub Installer |-n-| Install or Connect 1. Coat front cover seal contact area with engine oil. 2. Apply RTV sealer 1052917 equivalent to keyway in crankshaft. 3. Place crankshaft pulley hub in position over key on crankshaft.
Page 356: Coolant Inlet Installation
STUD GASKET INTAKE MANIFOLD C L I P N30009— 6A2— J— EDS Intake Manifold Figure 57 - Lower Tighten COOLANT INLET INSTALLATION Figure 10 • Nuts to 10 N*m (89 lbs. in.) Install or Connect EXHAUST MANIFOLD INSTALLATION 1. New gasket and coolant inlet. Figure 8 NOTICE: Refer to “...
Page 357 A UPPER INTAKE MANIFOLD ASSEMBLY TIGHTENING SEQUENCE 1 BOLT 2 STUD 3 UPPER INTAKE MANIFOLD ASSEMBLY 4 GASKET 5 LOWER INTAKE MANIFOLD 6 EGR VALVE INJECTOR N30010-6A2-J-EDS Figure 58 - Upper Intake Manifold • Nuts in sequence to 33 N*m (24 lbs. ft.), refer to Figure 57.
Page 358: Oil Fill Tube Installation
OIL FILTER, CONNECTOR AND OIL FILL TUBE INSTALLATION BY-PASS VALVE INSTALLATION Figure 59 Figure 6 -M- Install or Connect Install or Connect -►+ 1. Seal. 2. Fill tube. 1. Oil filter by-pass valve. a. Insert valve in cylinder block. NOTICE: Refer to “...
Page 359: Fastener Tightening Specifications
S P E C IF IC A T IO N S FASTENER TIGHTENING SPECIFICATIONS Accelerator Cable Mounting Bracket..................25 N-m (18 lbs. ft.) Accessory Bracket Asm. to Block.................... 50 N-m (37 lbs. ft.) Camshaft Sprocket........................105 N*m (77 lbs. ft.) Camshaft Thrust Plate.......................
Page 360 Lobes, Camshaft......................Lubricant, 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 b a ll............Dri-Slide Moly lubricant, GM P/N 1052948...
Page 361: Engine Specifications
ENGINE SPECIFICATIONS DESCRIPTION METRIC (ENGLISH) GENERAL DATA: Type 4 cyl in line Displacement 2.2 Liter 134 cu. in. Bore 89 mm (3.50) Stroke 88 mm (3.46) Compression 8.85:1 Firing Order 1-3-4-2 CYLINDER BORE: Diameter 88.991-89.009 (3.5036-3.5043) Out of Round (Max.) 0.013 (0.0005) Taper (Max.)
Page 362 ENGINE SPECIFICATIONS DESCRIPTION METRIC (ENGLISH) VALVE SYSTEM: Lifter Hydraulic Rocker Arm Ratio 45° Face Angle (All) Seat Angle (All) 46° (0.002) Seat Runout 0.05 (.0012) Face Runout (Max. All) Seat Width Intake 1.25-1.50 (0.049-0.059) Exhaust 1.60-1.90 (0.063-0.075) (0.031 in.) minimum Valve Margin 0.08 mm minimum Stem to Guide...
Page 363: Special Tools
SPECIAL TOOLS J 5590 CRANKCASE G EAR INSTALLER VALVE SPRING COMPRESSOR J 5892-C 3 J 8037 PISTON RING COMPRESSOR 4 J 8062 VALVE SPRING COMPRESSOR CYLINDER BORE G A G E 5 J 8087 J 8101 VALVE GUIDE CLEANER CAMSHAFT LOBE LIFT INDICATOR 7 J 8520 VALVE SPRING TESTER J 9666...
Page 364 SPECIAL TOOLS J 3 4 68 6 REAR MAIN BEARING OIL SEAL INSTALLER J 3 5 46 8 SEAL CENTERING TOOL J 3 5 95 3 SUPPORT FOOT J 36 29 5 ENGINE/TRANSAXLE FRAME HANDLER J 3 6 6 6 0 TORQUE ANGLE METER J 3 8 84 7 VALVE GUIDE REAMER FOR 0 .0 7 5 mm (O.S.
Page 365 SECTION 6A3 4.3L V6 RPO LB4, VIN Z NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 366 CONTENTS (cont’d) SUBJECT PAGE Timing Chain and S p ro ckets..........................6A3-22 Crankshaft Sprocket R eplacem ent........................6A3-22 Front C o v e r.................................6A3-22 Coolant P u m p ................................6A3-23 Oil Pan and Rocker Arm C o v e rs ......................... 6A3-23 Oil P u m p ..................................
Page 367: General Description
GENERAL DESCRIPTION BALANCE SHAFT ENGINE CONSTRUCTION The 4.3L engine, RPO LB4 (VIN Z), is a liquid-cooled S/T Vehicles and C/K Vehicles with light duty 90-degree V6 type with overhead valves, cast iron emissions block, and cylinder heads. 4.3L (VIN Z) engines used in The cast-iron balance shaft is mounted in the crank...
Page 368 V1200...
Page 369 1. Oil Pump Shaft Extension 135. Flywheel Bolt 108. Connecting Rod Nut 2. Oil Pump Body 136. Lower Main Bearing Insert 109. Plug 5. Pump Cover 137. Crankshaft Front Oil Seal 110. Knock Sensor 6. Pressure Regulator Valve 111. Plug 138.
Page 371 163. Bolt 20. Valve Stem Key 700. Rocker Arm 21. Inlet Valve Spring Cap 164. Coolant Outlet Cover Bolt 22. Valve Stem Oil Shield 165. Coolant Outlet Gasket 701. Rocker Arm Cover 23. Valve Stem Oil Seal (O-Ring) 166. Thermostat 702.
Page 373 145. KEY, WOODRUFF 31. BOLT, OIL PUMP 148. CAMSHAFT 56. PUMP, OIL 149. GASKET, COOLANT PUMP 57. SCREEN, OIL PUMP 150. BOLT/STUD, COOLANT PUMP 58. SHAFT, OIL PUMP DRIVE 151. PUMP, COOLANT 59. PIN 152. SPROCKET, CRANKSHAFT 60. SPRING, OIL PRESSURE RELIEF 153.
Page 374 F9375 Figure 7— Engine Lubrication Diagram (Engines Without Balance Shaft)
Page 375 Front View Rear View Show ing Path Of Oil To Tim ing Chain. S how ing Main Gallery, Oil F ilte r And C rankshaft Oil Feed. V0575...
Page 376 Figure 9— Engine Lubrication Diagram (Engines With Balance Shaft)
Page 377 A. REGULATOR VALVE (SHOWN IN OPEN POSITION) B. SUCTION C. OIL PRESSURE SWITCH D. VALVE LIFTER GALLERY E. MAIN OIL GALLERY F. BYPASS VALVE FRONT VIEW FRONT VIEW SHOWING PATH OF OIL TO TIMING CHAIN. REAR VIEW SHOWING MAIN GALLERY, OIL FILTER AND CRANKSHAFT OIL FEED. V0504...
Page 378: Disassembly Of The Engine
DISASSEMBLY OF THE ENGINE 3. Coolant drain plug and or knock sensor from the TOOLS AND SHOP EQUIPMENT block. A clean well-lit work area should be available. Other • Allow the coolant to drain from the block into a necessary equipment includes: a suitable parts cleaning proper container.
Page 379: Cylinder Head Removal
Figure 11— Rocker Arm Cover and Components Store all reusable components in an exact order so TORSIONAL DAMPER REMOVAL they can be reassembled in the same position from which they were removed. NOTICE: The inertial weight section o f the torsional damper is assem bled to the hub Remove or Disconnect (Figure 12) with a rubber sleeve.
Page 380: Oil Pump Removal
5. Camshaft. OIL PUMP REMOVAL A. Install three 5/16-18-inch bolts 100-125 mm (4-5 inches) long into the camshaft’s threaded Remove or Disconnect holes. Use these bolts to handle the camshaft (figure 16). 1. Oil pump to main bearing cap bolt. B.
Page 381 • 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 numbered 2-4-6. 3. Check the connecting rod and cap for identification marks.
Page 382: Flywheel Removal
87. RETAINER, CAMSHAFT 88. SCREW, CAMSHAFT RETAINER 148. CAMSHAFT 152. SPROCKET, CRANKSHAFT 153. BOLT, CAMSHAFT SPROCKET 154. SPROCKET, CAMSHAFT 155. CHAIN, TIMING V3273 Figure 15— Camshaft and Components • Use the long guide rod of J 5239 to push the connecting rod and piston out of the bore through the top of the engine.
Page 383: Crankshaft Rear Oil Seal Retainer Removal
J 24270 A. Cloth — F9385 Figure 18— Removing the Cylinder Ridge +-► Remove or Disconnect • Crankshaft rear oil seal. Insert a screwdriver into the notches provided in the seal retainer and pry Piston the seal out (figure 20). CRANKSHAFT REAR OIL SEAL RETAINER REMOVAL +-►...
Page 384: Main Bearing Removal (Without Removing C Rankshaft)
3. Crankshaft from the cylinder block with extreme care, taking care to avoid damage to crankshaft journals and thrust flange surfaces. 4. Upper main bearing inserts. MAIN BEARING REMOVAL (W ITH O U T REMOVING CRANKSHAFT) Important Check the main bearing caps for location markings. M ark the caps if necessary.
Page 385: Piston And Connecting Rod Assembly
64. PLUG, OIL PRESSURE CROSSOVER HOLE 65. PLUG, OIL PRESSURE CROSSOVER HOLE 111. PLUG, OIL GALLERY HOLE OIL GALLERY HOLE 113. PLUG, 115. PLUG, ENGINE BLOCK COOLANT DRAIN HOLE 147. PLUG, OIL GALLERY HOLE OIL GALLERY HOLE 157. PLUG, V2887 Figure 23—...
Page 386: Camshaft
A. Straight Edge B. Feeler Gage V0571 Figure 25— Checking Alignment of Manifold Flanges CRANKSHAFT SPROCKET REPLACEMENT Inspect (Figure 25) Remove or Disconnect (Figure 27) Manifolds for cracks, broken flanges, and gasket Tool Required: surface damage. J 5825-A Crankshaft Sprocket Puller Alignment of manifold flanges.
Page 387: Oil Pan And Rocker Arm Covers
1. Shaft Extension 2. Pump Body 3. Drive Gear and Shaft 4. Idler Gear 5. Pump Cover 6. Pressure Regulator Valve 7. Pressure Regulator Spring 8. Retaining Pin 9. Screws 10. Pickup Screen and Pipe B9445 Figure 28— Oil Pump Components »...
Page 388: Valve Train Components
• With the shaft extension (1) installed on the pump, 6. Retaining pin (8). turn the drive shaft by hand to check for smooth 7. Pressure regulator spring (7) 8. Pressure regulator valve (6). operation. JJJ* Clean NOTICE: Be careful of twisting, shearing, or collapsing the pipe when installing it to the •...
Page 389: Hydraulic Lifters
• Rocker arm areas that contact the valve stems and the socket areas that contact the ends of the push- rods. These areas should be free of wear or dam age. • Rocker arm nuts. • Pushrod ends for scoring, roughness, or bends. —...
Page 390: Assembly
B. Install a nut and flat washer. C. Turn the nut to remove the stud. • Rocker arm stud to 47 N-m (35 lbs. ft.). -► 4- Install or Connect (Figure 33) Pressed-ln Studs Tools Required: Remove or Disconnect (Figure 32) J 5715 Reamer (0.003-inch oversize) or J 6036 Reamer (0.013-inch oversize) Tool Required:...
Page 391: Thermostat And Coolanto Utlet
THERMOSTAT AND COOLANT O UTLET Remove or Disconnect 1. Bolts. 2. Coolant outlet. 3. Gasket. 4. Thermostat. Inspect Coolant outlet for cracks. "► + Install or Connect 1. Thermostat. 2. New gasket. Figure 35— Checking the Valve Seals 3. Coolant outlet. 5.
Page 392: Assembly Of The Engine
• Main bearing and connecting rod journals for taper and out-of-round. • Maximum journal taper is 0.001 inch. • Maximum out-of-round is 0.002 inch. • Crankshaft run-out. A. Mount the crankshaft in V-blocks or between centers. B. Use a dial indicator. C.
Page 393: Crankshaft Rear Oil Seal Retainer Installation
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 and seal retainer. |-»4-| Install or Connect (Figure 38) 1. New gasket (84) to the block. •...
Page 394: Balance Shaft Installation
2. Camshaft to the engine (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. Important •...
Page 395: Piston And Connecting Rod Installation
PISTON AND CONNECTING ROD INSTALLATION CONNECTING ROD BEARING SELECTION Connecting rod bearings are of the precision insert type and do not use shims for adjustment. DO NOT FILE RODS OR ROD CAPS. If clearances are exces sive, install a new bearing. Service bearings are avail able in standard size and 0.0014-mm undersize for use with new and used standard size crankshafts.
Page 396 its bore (figure 45). Guide the connecting rod to 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 rod and bearing cap should be marked, beginning at the front of the engine.
Page 397: Oil Pump Installation
OIL PUMP INSTALLATION OIL PAN INSTALLATION Install or Connect -►+ Install or Connect (Figure 48) 1. Oil pump to the engine. • Apply PST sealant (GM P/N 1052080 or equivalent) to the front cover to block joint and to the crank •...
Page 398: Cylinder Head Installation
3. Cylinder head bolts. Coat threads of the cylinder CYLINDER HEAD INSTALLATION head bolts with sealing com pound (GM P/N 1052080 or equivalent) and install finger-tight. Clean Tighten Gasket surfaces on the block and cylinder head. Cylinder head bolts in three steps, using the Install or Connect (Figure 49) sequence shown in figure 49.
Page 399 V2974...
Page 400: Valve A Djustm Ent
1. Rotate the engine until the mark on the torsional damper lines up with the “ 0” mark on the timing tab and the engine in the number one firing posi M(§) 0 (D <S)m tion. This may be determined by placing fingers on the number one valve as the mark on the damper comes near the “...
Page 401: Rocker Arm Cover Installation
ROCKER ARM COVER Tighten INSTALLATION A. Bolts on center exhaust tube to 36 N-m (26 lbs. ft.). B. Bolts on front and rear exhaust tubes to 28 N-m Install or Connect (Figure 53) (20 lbs. ft.). C. Bend the tab washers over the heads of all 1.
Page 402: Engine Accessory Installation
Left Side 60. Heat Shields 61. Washer 62. Tab Washer 63. Bolts or Studs V0570 Figure 54— Exhaust Manifolds and Components 3. Fill the cooling system with the proper quantity and ENGINE ACCESSORY grade of coolant. INSTALLATION 4. Crank the engine several times. Listen for any Install the engine accessories (distributor, oil filter, unusual noises or evidence that parts are binding.
Page 403 SPECIFICATIONS ENGINE SPECIFICATIONS (4.3L) All Specifications are in INCHES unless otherwise noted. GENERAL DATA: Type Displacement 4.3L (262 Cu. In.) LB4 (Z) RPO (VIN Code) Bore 4.00 Stroke 3.48 Compression Ratio 9.3:1 Firing Order 1-6-5-4-3-2 Oil Pressure (Minimum) 6 psi @ 1000 RPM; 18 psi @ 2000 RPM; 24 psi @ 4000 RPM CYLINDER BORE: Diameter 4.0007-4.0017...
Page 404 SPECIFICATIONS ENGINE SPECIFICATIONS (4.3L) (CONT.) All Specifications are in INCHES unless otherwise noted. DISPLACEMENT: 4.3L (LB4, VIN Z) CRANKSHAFT: 2.4484-2.4493 Diameter #2, #3 2.4481-2.4490 2.4479-2.4488 ■ Main Production 0.0002 (Maximum) Journal Taper Service Limit 0.001 (Maximum) Production Out Of 0.0002 (Maximum) Round Service Limit 0.001 (Maximum)
Page 405 SPECIFICATIONS (CONT.) FASTENER TIG H TEN IN G SPECIFICATIONS Item Ft. Lbs. In. Lbs. Camshaft Sprocket B o lts .................. — Camshaft Thrust Plate Screws................ — Connecting Rod Bolt Nuts (Torque Plus 70°)..........— — Coolant Outlet Bolts................... Coolant Pump B olts................
Page 406: Special Tools
SPECIAL TOOLS J 39046 J 5 8 0 2 -0 1 J 5715 J 8062 J 6036 J 6880 J 35468 J 5 8 2 5 - A J 8080 J 8037 J 5590 J 5239 J 35621 J 2 3 7 3 8 - A J 36660 9.
Page 407 SECTION 6A4 4.3L V6 RPO L35, VIN W NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Page 408 CONTENTS (cont’d) SUBJECT PAGE Upper and Lower Intake and Exhaust M anifolds................... 6A4-20 Cam shaft..................................6A4-21 Camshaft B earings..............................6A4-21 Timing Chain and S p ro ckets..........................6A4-21 Crankshaft Sprocket R eplacem ent........................6A4-21 Front C o v e r................................6A4-21 Coolant P u m p ................................
Page 409: General Description
GENERAL DESCRIPTION ENGINE CONSTRUCTION thrust side (right side) to reduce piston slap as the connecting rod travels from one side of the piston to the The 4.3L engine, RPO L35 (VIN W), is a liquid-cooled other side after a stroke. The pins are a press fit in the 90 degree V6 type with overhead valves, a balance connecting rod and a floating fit in the piston.
Page 411 31. BOLT, OIL PUMP 143. GASKET, FRONT COVER 56. PUMP, OIL 144. INSERT, UPPER MAIN BEARING 57. SCREEN, OIL PUMP 145. KEY, WOODRUFF 58. SHAFT, OIL PUMP DRIVE 148. CAMSHAFT 59. PIN 149. GASKET, COOLANT PUMP PRESSURE RELIEF 150. BOLT/STUD, PUMP SPRING, OIL COOLANT...
Page 412 3 70 6r3 92 4...
Page 413 20. KEY, VALVE STEM 179. MANIFOLD, EXHAUST 21. CAP, INLET VALVE SPRING 186. STUD, INTAKE MANIFOLD 22. SHIELD, VALVE STEM OIL 195. BOLT, UPPER INTAKE MANIFOLD 24. SEAL, INLET VALVE STEM 196. NUT, UPPER INTAKE MANIFOLD 26. SPRING, VALVE, WITH DAMPER 197.
Page 414 V0503 Figure 5— Engine Lubrication Diagram camshaft, balance shaft rear bearing, and crankshaft ENGINE LUBRICATION bearings. The valve lifter oil gallery supplies oil to the Lubrication schematics are shown in figures 5 and 6. valve lifters. Oil flows from the hydraulic lifters through The gear-type oil pump is driven from the distributor the hollow pushrods to the rocker arms.
Page 415 A. REGULATOR VALVE (SHOWN IN OPEN POSITION) B. SUCTION C. OIL PRESSURE SWITCH D. VALVE LIFTER GALLERY E. MAIN OIL GALLERY F. BYPASS VALVE FRONT VIEW FRONT VIEW SHOWING PATH OF OIL TO TIMING CHAIN. REAR VIEW SHOWING MAIN GALLERY, OIL FILTER AND CRANKSHAFT OIL FEED. V0504...
Page 416: Tools And Shop Equipment
DISASSEMBLY OF THE ENGINE TOOLS AND SHOP EQUIPMENT DRAINING THE ENGINE A clean, well-lit, work area should be available. Other Remove or Disconnect necessary equipment includes: a suitable parts cleaning tank, compressed air supply, trays to keep parts and 1. Oil pan plug and washer and allow the oil to drain fasteners organized, and an adequate set of hand tools.
Page 417: Egr Valve Removal
1. BOLT 2. COVER, ROCKER ARM VALVE 3706r4808 Figure 7— Rocker Arm Cover and Components EGR VALVE REMOVAL Important +-► Remove or Disconnect (Figure 8) • Do not disassemble the CPI unit. It is only serviced as an assembly. For information on the upper and 1.
Page 418 VIEW B 4. BOLT 5. 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 LIFT BRACKET 18. UPPER INTAKE MANIFOLD PLASTIC COVER 85. EGR VALVE 86.
Page 419: Cylinder Head Removal
19. BOLT 20. GUIDE ASSEMBLY 21. NUT 22. BALL 23. ARMS, ROCKER 24. PUSHROD 26. LIFTER, HYDRAULIC 3706r4876 Figure 9— Valve Train Components CYLINDER HEAD REMOVAL ► Remove or Disconnect 1. Spark plugs. 2. Cylinder head bolts. 3. Cylinder heads. 4.
Page 420: Oil Pump Removal
30. Pump Assembly 31. Bolt 32. Shaft Extension 33. Retainer V0510 Figure 12— Oil Pump and Components TIM IN G CHAIN AND CAMSHAFT SPROCKET REMOVAL 27. Gasket 82. Nut Remove or Disconnect (Figure 13) 28. Reinforcement 83. Bolt 29. Oil Pan 84.
Page 421: Balance Shaft Removal
34. NUT 35. STUD 36. KEY 37. GEAR, BALANCE SHAFT DRIVE 38. SPROCKET, CRANKSHAFT 39. BOLT 40. SPROCKET, CAMSHAFT 41. CHAIN, TIMING V2629 Figure 13— Camshaft and Components BALANCE SHAFT REMOVAL Remove or Disconnect (Figure 16) Tools Required: J 38834 Balance Shaft Bearing Service Kit J 5825-A J 26941 Bearing Remover 1.
Page 422 Figure 16— Removing Balance Shaft Assembly J 24270 A. Cloth F9385 Figure 17— Removing Cylinder Ridge 2. Mark the cylinder numbers on the tops of each piston. • Marking them from the front to the rear, with the engine in an upright position and viewed from (Typical) the front.
Page 423: Crankshaft Rear Oil Seal Removal
5. Connecting rod and piston. A. Attach J 5239 to the connecting rod bolts. B. Use the long guide rod J 5239 to push the con necting rod and piston out of the bore through the top of the engine. 6.
Page 424: Main Bearing Removal (Without Removing Crankshaft)
M AIN BEARING REMOVAL (W ITH O U T REMOVING CRANKSHAFT) Important Check the main bearing caps for location markings. Mark the caps if necessary. The caps must be returned to their original locations during assembly. Remove or Disconnect (Figure 21) Tool Required: J 8080 Main Bearing Shell Remover and Installer...
Page 425: Cylinder Bore
A. Feeler Gage B. Straight Edge V0578 Figure 23— Inspecting the Block C. If the gap is found to be greater than 0.05 mm (0.002 in.) within 152 mm (6 inches) at any sealing location, the block must be replaced. D.
Page 426: Piston And Connecting Rod Assembly
3. Camshaft and balance shaft cup plugs (89) to Inspect proper depth. • Coat plug outside diameter with sealant (GM • Ring fit. P/N 1052080 or equivalent). UPPER AND LOWER INTAKE 4. Oil filter adapter, gasket, and bolts. AND EXHAUST MANIFOLDS Tighten •...
Page 427: Camshaft
CAMSHAFT +«■ Install or Connect (Figure 26) Tool Required: Important J 5590 Crankshaft Gear Installer • Whenever the camshaft needs to be replaced, a 1. Key (if removed). new set of lifters must also be installed. 2. Crankshaft sprocket using J 5590. Inspect FRONT COVER Camshaft lobes and journals for scratches, pitting,...
Page 428: Oil Pan And Rocker Arm Covers
Inspect -►+ Install or Connect (Figure 27) • Gasket flanges for bending or damage. Tool Required: • Rubber grommets and parts on the rocker arm cov J 35468 Front Cover Aligner and Oil Seal Installer er for deterioration. 1. New seal so that the open end of the seal is toward the inside of the cover.
Page 429: Valve Train Components
4. Pump cover (65). • Match together the index marks on the two gears made during disassembly. • Mark where the idler gear (55) and drive gear and shaft (63) mesh together, so they can be reinstalled 7. Pump cover (65). with the same gear teeth indexed.
Page 430: Pushrods, Rocker Arms, Balls, And Nuts
PUSHRODS, ROCKER ARMS, BALLS, AND NUTS 67. Valve Keeper >3*1 Clean 68. Cap 69. Shield • All parts in clean solvent and dry them with com 70. O-Ring Seal pressed air. 71. Seal • Make sure the oil passages through the pushrods 72.
Page 431: Rocker Arm Stud Replacement
ROCKER ARM STUD REPLACEMENT Remove or Disconnect • Rocker arm stud by unscrewing. Install or Connect NOTICE: Refer to “Notice” on page 6A4-1. • Rocker arm stud. Tighten • Rocker arm stud to 47 N-m (35 lbs. ft.). CYLINDER HEAD ASSEMBLY + 4 - Install or Connect (Figures 30, 31, and 32) Tools Required:...
Page 432: Crankshaft And Bearings
t } | Measure (Figure 33) ■H- Install or Connect Main bearing and connecting rod journal diameters NOTICE: Do not install thermostat assembly (figure 33). Refer to ’’Specifications,” and compare without rubber O-ring. Omitting rubber O-ring dimensions. m ay result in poor engine warm-up and Main bearing and connecting rod journals for taper reduced heater performance.
Page 433: Flywheel
FLYWHEEL • If the flywheel is replaced, new balance weights of the same size must be installed in the same hole locations as the old flywheel. Inspect Clean • Flywheel for burning, scoring, warping, and wear. • Mating surfaces of the crankshaft and flywheel. Replace the flywheel if necessary.
Page 434: Crankshaft Rear Oil Seal Retainer Installation
C. if correct end play cannot be obtained, be cer CRANKSHAFT REAR OIL tain that the correct size rear main bearing has SEAL INSTALLATION been installed. Production engines may have rear main bearings that are 0.008 inch wider Install or Connect (Figure 36) across the thrust faces than standard.
Page 435: Balance Shaft Installation
34. NUT 35. STUD 36. KEY 37. GEAR, BALANCE SHAFT DRIVE 38. SPROCKET CRANKSHAFT 39. BOLT 40. SPROCKET, CAMSHAFT 41. CHAIN, TIMING V2629 Figure 37— Camshaft and Components B. Retaining ring on balance shaft front bearing must be seated on case. 3.
Page 436: Timing Chain And Sprocket Installation
V0526 Figure 39— Installing Balance Shaft and Components TIM IN G CHAIN AND SPROCKET INSTALLATION Install or Connect (Figure 41) . Camshaft sprocket and timing chain. Important • Line up the tim ing marks on the cam shaft sprocket and crankshaft sprocket (figure 41). •...
Page 437: Front Cover Installation
Figure 42— Installing Torsional Damper NOTICE: Refer to “Notice” on page 6A4-1. FRONT COVER INSTALLATION 5. Torsional damper bolt and washer. Install or Connect Tighten 1. Front cover gasket to the front cover. • Use gasket cement to hold the gasket in place. •...
Page 438 ENGINE UEFT ENGINE HtONT ENGINE RIGHT ^ A. Oil Ring Rail Gaps B. 2nd Compression Ring Gap G Notch In Piston 0. Oil Ring Spacer Gap (Tang In Hole Or Slot With Arc) E. Top Compression Ring Gap B7895 Figure 43— Piston Ring End Gap Locations J 8037 Figure 46—...
Page 439: Oil Pump Installation
NOTICE: Refer to “Notice” on page 6A4-1. 3. Connecting rod cap with bearing insert, tjjj Measure . Oil pump to main bearing cap bolt. • Connecting rod bearing clearance. Refer to Tighten SECTION • Oil pump to main bearing cap bolt to NOTICE: Refer to “Notice”...
Page 440: Cylinder Head Installation
4 l FRONT B7874 Figure 49— Cylinder Head Bolt Tightening Sequence Tighten Cylinder head bolts in three steps, using the sequence shown in figure 49. A. The first sequence to 34 N-m (24 lbs. ft.). B. The second sequence to 61 N-m (45 lbs. ft.). C.
Page 441: Lower Intake Manifold Installation
19. BOLT 20. GUIDE ASSEMBLY 21. NUT 22. BALL 23. ARMS, ROCKER 24. PUSHROD 26. LIFTER, HYDRAULIC 3706r4876 Figure 50— Valve Train Components Important No lash adjustment is needed. Tighten • Rocker arm nuts (21) to 27 N-m (20 lbs. ft.). LOWER INTAKE MANIFOLD INSTALLATION Install or Connect (Figure 51)
Page 442: Upper Intake Manifold Installation
UPPER INTAKE MANIFOLD INSTALLATION •► 4- Install or Connect (Figure 52) NOTICE: For steps 3 and 4, refer to “Notice " on page 6A4-1. 1. Upper intake manifold gasket. 2. Upper intake manifold. • Use care not to pinch the in je c to r wires between the upper and lower intake manifolds.
Page 443: Exhaust Manifold Installation
N O T IC E : R e f e r to “ N o t i c e ” o n p a g e 6 A 4 -1 . Tighten • Bolts to 20 N-m (15 lbs. ft.). 3.
Page 444: Engine Setup And Testing
3. Fill the cooling system with the proper coolant. ENGINE SETUP AND TESTING 4. Crank the engine several times. Listen for any After overhaul, the engine should be tested before unusual noises or evidence that any parts are bind installing it in the vehicle. If a suitable test stand is not ing.
Page 445: Engine Specifications
SPECIFICATIONS ENGINE SPECIFICATIONS (4.3L) Ail Specifications are in INCHES unless otherwise noted. GENERAL DATA: Type Displacement 4.3L (262 Cu. In.) RPO (VIN Code) L35 (W) Bore 4.00 Stroke 3.48 Compression Ratio 9.05:1 Firing Order 1-6-5-4-3-2 Oil Pressure (Minimum) 25-50 psi @ 1200 RPM; 42-60 psi @ 2400-5000 RPM CYLINDER BORE: Diameter 4.0007-4.0017...
Page 446 SPECIFICATIONS ENGINE SPECIFICATIONS (4.3L) (CONT.) All Specifications are in INCHES unless otherwise noted. DISPLACEMENT: 4.3L (L35, VIN W) CRANKSHAFT: 2.4488-2.4495 Diameter #2, #3 2.4485-2.4494 2.4480-2.4489 Main Production 0.0002 (Maximum) Journal Taper Service Limit 0.001 (Maximum) Production 0.0002 (Maximum) Out Of Round Service Limit 0.001 (Maximum)
Page 447 SPECIFICATIONS FASTENER TIG H TEN IN G SPECIFICATIONS Item Lbs. Ft. Lbs. In Balance Shaft Drive Gear Retaining S tu d ............Balance Shaft Driven Gear Bolt (Torque Plus a 35° Turn)......Balance Shaft Retainer B o lt................— Camshaft Sprocket B o lts ..................Camshaft Sprocket Nut..................
Page 448: Special Tools
SPECIAL TOOLS J 8001 J 39046 J 26841 J 8062 •I 24270 J 35458 _ 1 JB.'- l J X l i J - J 21882 J 5825*A «. Q l. J 8080 J 8037 J 5590 J 5239 J 35821 ■...
Page 449: 6A5 V8 Engines
SECTION 6A5 V8 ENGINES 5.0L (305 CID) RPO L03, VIN H 5.7L (350 CID) RPO L05, VIN K 7.4L (454 CID) RPO L19, VIN N NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
Page 450 CONTENTS (cont’d) SUBJECT PAGE Oil Pan and Rocker Arm C o v e rs ......................... 6A5-30 Oil P u m p ..................................6A5-30 Valve Train Com ponents............................6A5-32 Pushrods, Rocker Arms, Balls, and N u ts ..................... 6A5-32 Hydraulic Lifters..............................6A5-32 Cylinder Head................................6A5-32 Disassem bly................................
Page 451: Engine Identification
The crankshaft is supported by five precision insert The first type is the “ small block” engine, which is type bearings, with crankshaft thrust taken at the num available in 5.0L (305 CID) and 5.7L (350 CID) dis ber five (rear) bearing. placements.
Page 453 To Oil Cooler 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 (7.4L Engines)
Page 454 V1202...
Page 455: Automatic Transmission
10. Coolant Pump 149. Connecting Rod Bearing Cap 11. Coolant Pump Gasket 150. Connecting Rod Bearing 12. Coolant Pump Bolt 151. Piston Pin 13. Plug 152. Connecting Rod 71. Oil Pan 153. Piston 72. Bolt 154. Piston Rings 73. Nut 155.
Page 456 20 21x 4 0 - ^ ® 41 — ^ 2 5 1 ^ 2 51 2 5 ° ^ £ ^ 54 ^ $ *--2 5 2 ^ ---- 252 <S«-255 — 255 $ * -2 5 6 — 256 V1196...
Page 457 . Exhaust Manifold . Spark Plug . Washer 3. Exhaust Manifold Lock 205. Plug 4. Bolt/Stud 206. Spark Plug Wire Support . Heat Shield 207. Air Injection Pipe Extension 7. Outer Heat Stove 208. Dowel Pin . Inner Heat Stove 209.
Page 458 1 8 4 / / 183 177 3706r1204...
Page 459 10. Coolant Pump 184. Oil Pressure Regulator Valve Spring 11. Coolant Pump Gasket 185. Spring Retaining Pin 12. Coolant Pump Bolt 187. Pick-up Screen and Pipe 13. Coolant Pump Plug 190. Gasket 74. Oil Pan Gasket 191. Piston Rings 75. Oil Pan Bolt 192.
Page 461: Disassembly Of The Engine
1. EXHAUST MANIFOLD 260. PUSHROD GUIDE 4. BOLT/STUD 301. STUD 6. HEAT SHIELD ASSEMBLY 302. COOLANT OUTLET 21. INTAKE MANIFOLD 303. THERMOSTAT 22. INTAKE MANIFOLD GASKET 304. GASKET 23. INTAKE MANIFOLD SEAL 309. ROCKER COVER GASKET 30. ROCKER COVER BOLT 310.
Page 462: Exhaust Manifold Removal
2. Block drain plugs. "► 4- Install or Connect Tighten N O T IC E : F o r s t e p s 1 a n d 2 , r e f e r to “N o t ic e ” •...
Page 463 . Bolts and studs (4). 3. Tab washers (3) and washers ( 4. Heat shields ( 5. Exhaust manifold (1). Use care not to damage the AIR system injection tubes (if used). COOLANT PUMP REMOVAL Remove or Disconnect (Figures 14 and 15) 1.
Page 464: Oil Pump Removal
(5.0L and 5.7L Engines) Figure 16— Intake Manifold OIL PUMP REMOVAL TORSIONAL DAMPER REMOVAL Remove or Disconnect (Figures 28 and 30) 4- + Remove or Disconnect (Figure 27) . Bolt. Tool Required: . Oil pump, with drive shaft and connector. J 39046 Torsional Damper Puller and Installer FRONT COVER REMOVAL 1.
Page 465 A. Sealing Compound 21. Intake Manifold 22. Gasket ^ N \ 23. Seal F9330 Figure 17— Intake Manifold (7.4L Engines) make a note that the tim ing chain should be replaced during assembly (figure 32). 1. Bolts (100). . Camshaft sprocket (101) and timing chain ( together.
Page 466 30. BOLT 32. ROCKER ARM COVER F9326 Figure 19— Rocker Arm Cover (7.4L Engines) B. Using the manufacturer’s directions, install a bly. Mark the connecting rods with a scratch awl ridge reamer into the top of the cylinder (figure if necessary. 34).
Page 467: Flywheel Removal
The tool will also prevent the rod bearing half from falling out of the connecting rod during removal. 3. Connecting rod and piston from the block. A. Push on the guide rod (item A, figure 35) to push the piston and connecting rod out. B.
Page 468 Figure 23— Valve Train Components (7.4L Engines) CRANKSHAFT REMOVAL Remove or Disconnect (Figure 39) • Check the main bearing caps for location markings. Mark the caps if necessary. The caps m ust be © returned to their original locations with the orienta tion arrow pointing forward during assembly.
Page 469 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) Figure 27— Removing the Torsional Damper 5. Main bearing inserts (135 and 136). If the main 3. Crankshaft. Lift the crankshaft straight up. Use care bearings are to be reused, mark them to ensure to avoid damage to the crankshaft journals and they are installed in their original positions before...
Page 470 70. Oil Pump 76. Nut 77. Bolt 79. Oil Pan Baffle F9365 Figure 29— Oil Pan Baffle A. Sealing Compound 74. Gasket 75. Bolt 76. Oil Pan F9331 Figure 30— Oil Pan (7.4L Engines) 91. Front Cover 93. Bolt F9357...
Page 471 A. 16 mm /s-inch) M axim um ' 100. Bolt . Cam shaft Sprocket . T im ing Chain B8012 Figure 32—Timing Chain and Sprockets Figure 34— Removing the Cylinder Ridge...
Page 472: Automatic Transmission
A. WEIGHT 110A. FLYWHEEL (MANUAL TRANSMISSION) 110B. FLYWHEEL (AUTOMATIC TRANSMISSION) 111. BOLT, FLYWHEEL 168. PIN. FLYWHEEL DOWEL V2878 Figure 36— Flywheel (5.0L and 5.7L Engines) 80. SCREW, SEAL RETAINER 81. NUT, SEAL RETAINER 82. RETAINER, SEAL 83. STUD, SEAL RETAINER 84.
Page 473: Cleaning, Inspection, And Repair
130. Crankshaft 131. Rear Seal 132. Rear Main Bearing Cap 133. Main Bearing Cap 134. Bolt 135. Lower Main Bearing Insert 136. Upper Main Bearing Insert F9332 Figure 39— Crankshaft and Components (7.4L Engines) CLEANING, INSPECTION, AND REPAIR 3. Cylinder bores. A solvent tank large enough to hold the larger engine parts will be needed along with various bristle brushes 4.
Page 474: Cylinder Bores
must be flat (within 0.10 mm {0.004 inch}) to The area where the main bearing inserts con ensure proper head gasket sealing. tact the main bearing bore should be smooth. If a main bearing cap is damaged and requires MAIN BEARING CAP REPLACEMENT replacement, replace it as outlined later.
Page 475: Piston Selection
210. PLUG, ENGINE BLOCK COOLANT DRAIN 220. PLUG, OIL FEED HOLE 221. PLUG, OIL GALLERY HOLE 222. PLUG, OIL GALLERY HOLE 223. PLUG, OIL GALLERY HOLE 224. PLUG, OIL GALLERY HOLE 225. PLUG, OIL GALLERY HOLE 226. PLUG, OIL GALLERY HOLE 227.
Page 476: Camshaft
CAMSHAFT Important Flanges • Whenever the camshaft needs to be replaced, a new set of valve lifters must also be installed. the same side when installed in the cylinder bore. If a connecting rod is ever transposed Inspect from one block or cylinder to another, new con necting rod bearings should be fitted and the Camshaft lobes and journals for scratches, pitting, connecting rod should be numbered to corre...
Page 477: Camshaft Bearings
J 22102 3706r0273 Figure 47— Crankshaft Sprocket Replacement (5.0L Figure 48—Crankshaft Sprocket Replacement (7.4L and 5.7L Engines) Engines) CRANKSHAFT SPROCKET REPLACEMENT • Camshaft journal diameter. Use a micrometer (fig ure 46). The proper diameter is listed in “ Specifica Disassemble (Figures 47 and 48) ❖...
Page 478 “ lumpy” when turned, replace the coolant pump. If FRONT COVER the shaft end play exceeds 0.381 mm (0.015 inch), IJ|I replace the coolant pump. Clean * Coolant pump body at the drain (weep) hole. Slight staining around the weep hole is normal. Replace Old gasket from the gasket surfaces.
Page 479 9. Pickup screen and pipe (187). 179 180 • Do not remove the pickup screen and pipe unless replacem ent is required. The 7.4L engine uses a pickup pipe and screen that are welded to the oil pump assembly must be ground off for replacement.
Page 480: Hydraulic Lifters
• Turn the driveshaft by hand to check for smooth operation. N O T IC E : B e c a r e f u l o f tw is tin g , s h e a r in g , o r c o l la p s i n g t h e p ip e w h ile...
Page 481: Cleaning And Inspection
A. Compress the springs (256) with J 8062 (figure 55). B. Remove the valve keepers (251). C. Remove J 8062. . Caps (253), shields (255), springs with dampers (256), and rotators (254). 3. O-ring seals (252) (if used) and seals (257). 4.
Page 482 3. Coat lower end (press-fit area) of stud with hypoid axle lubricant. Drive the stud into place with a ham mer and J 6880. Stud is installed to proper depth when the tool bottoms on the cylinder head (figure 58). ASSEMBLY (5.0L AND 5.7L ENGINES) Assemble (Figures 53 and 59) Tools Required:...
Page 483 4. Valve springs with dampers (256). t { | Measure (Figures 60 and 61) 5. Caps (253). • Valve spring installed height of each valve spring . Valve keepers (251). as follows: A. Compress the valve spring using J 8062 (figure 1.
Page 484: Crankshaft And Bearings
Tighten • Bolts (24) or studs (20) to specifications. — 5.0L and 5.7L engines: 28 N-m (21 lbs. ft.). — 7.4L engines: 37 N-m (27 lbs. ft.). TORSIONAL DAMPER Inspect • Torsional damper weight for signs of shifting on the hub.
Page 485: Crankshaft Rear Oil Seal Retainer (5.0L And 5.7L Engines)
Figure 65— Checking Crankshaft Run-Out Figure 66— Seal Removal Notches (5.0 and 5.7L Engines) Measure (Figures 64 and 65) CRANKSHAFT REAR • Main bearing and connecting rod journal diameters OIL SEAL RETAINER (figure 64). Compare with “ Specifications.” Grind or replace the crankshaft if necessary.
Page 486: Undersize Main Journals (5.0L And 5.7L Engines)
Selective 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 0.0254-mm 0.001 -inch) undersize insert which will decrease the clearance 0.0127 mm (0.0005-inch) from using a full standard bearing.
Page 487: Crankshaft Rear Oil Seal Installation (7.4L Engines)
Inspect • Crankshaft for binding. Try turning the crankshaft to check for binding. If the crankshaft does 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 a faulty insert could cause a lack of clearance at the bearing.
Page 488: Camshaft, Timing Chain, And Sprocket Installation
80. SCREW, SEAL RETAINER 81. NUT, SEAL RETAINER 82. RETAINER, SEAL 83. STUD, SEAL RETAINER 84. GASKET, SEAL RETAINER 114. BLOCK, ENGINE V2976 Figure 70— Crankshaft Rear Oil Seal Retainer (5.0L and 5.7L Engines) Figure 71— Installing the Crankshaft Rear Oil Seal (5.0L and 5.7L Engines) B.
Page 489: Front Cover Installation
Figure 73—Timing Marks Figure 75— Installing the Torsional Damper N O T IC E : R e f e r to “ N o t i c e ” o n p a g e 6 A 5 -1 . 3.
Page 490: Piston And Connecting Rod Installation
Tighten • Bolt to specifications. ENGINE LEFT ENGMCHtONT ENOlNi MGHT — 5.0L and 5.7L engines: 95 N.m (70 lbs. ft.). — 7.4L engines: 115 N-m (85 lbs. ft.). PISTON AND CONNECTING ROD INSTALLATION CONNECTING ROD BEARING SELECTION Connecting rod bearings are the precision insert type and do not use shims for adjustment.
Page 491: Oil Pump Installation
Important • Each co n n e ctin g rod and bearing cap should be marked, beginning at the front of the engine. Cylinder 1, 3, 5 and 7 are the right bank and 2, 4, , and are the left bank (when viewed from the front of the engine).
Page 492: Oil Pan Installation
N O T IC E : R e f e r to “N o t i c e ” o n p a g e 6 A 5 -1 . . Oil pump to main bearing cap bolt. Tighten • Bolt to 90 N-m (65 lbs. ft.). OIL PAN INSTALLATION 5.0L AND 5.7L ENGINES Install or Connect (Figures 83 and 84)
Page 493: Valve Train Component Installation
• Place the gasket in position over the dowel pins with the bead up. 2. Cylinder head. Carefully guide the cylinder head into place over the dowel pins and head gaskets. 3. Cylinder head bolts. Coat the threads of the bolts with sealing compound (Loctite #592 or equivalent) and install finger tight.
Page 494: Valve Adjustm Ent
• Coat the mating surfaces of the rocker arms (42) and balls (41) with “ Moly Kote” or equivalent. 3. Pushrod guides (260), 7.4L engines only. 4. Rocker arms (42). 5. Balls (41). N O T IC E : R e f e r to “ N o t i c e ” o n p a g e 6 A 5 -1 . .
Page 495 40. Bolt 41. Ball 42. Rocker Arm 43. Pushrod 44. Hydraulic Lifter 46. Cylinder Head 260. Pushrod Guide F9325 Figure 89— Valve Train Components (7.4L Engines) firing position. If the valves move as the mark 4. Back out the adjusting nut until lash is felt at the comes up to the timing tab, the engine is in the pushrod then turn in the adjusting nut until all lash is removed.
Page 496: Intake Manifold Installation
Figure 92— Timing Marks Engines) INTAKE M ANIFOLD N O T IC E : R e f e r to “ N o t i c e ” o n p a g e 6 A 5 -1 . INSTALLATION 4.
Page 497: Coolant Pump Installation
Figure 94— Intake Manifold (5.0L and 5.7L Engines) Tighten • Bolts/studs to specifications: — 5.0L and 5.7L engines: • 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.
Page 498: Engine Accessory Installation
Figure 96— Intake Manifold (7.4L Engines) ENGINE ACCESSORY INSTALLATION Install the engine accessories (TBI unit, distributor, oil filter, generator, etc.) as directed in the proper Service Manual Section. Connect all vacuum hoses and electri cal equipment the same way as removed. ENGINE SETUP AND TESTING •...
Page 499 5. Run the engine speed at about 1000 until the Important engine is at operating temperature. 6. Listen for improperly adjusted valves or sticking lift • If a new camshaft or hydraulic lifters were ers, and other unusual noises. installed, add Engine Oil Supplement (GM P/N 7.
Page 500 1. Exhaust Manifold 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 103— Coolant Pump (7.4L Engines) Figure 102— Coolant Pump (5.0L and 5.7L Engines)
Page 501: Specifications
SPECIFICATIONS ENGINE SPECIFICATIONS (5.0L/5.7L) All Specifications are in INCHES unless otherwise noted. GENERAL DATA: Type Displacement 5.0L (305 CID) 5.7L (350 CID) RPO (VIN Code) L03 (H) L05 (K) Bore 3.736 4.00 Stroke 3.480 Compression Ratio 9.1:1 Firing Order 1-8-4-3-6-5-7-2 Oil Pressure (Minimum) 6 PSI @ 1000 RPM;...
Page 502 SPECIFICATIONS ENGINE SPECIFICATIONS (5.0L/5.7L) (Cont.) ______ All specifications are in INCHES unless otherwise noted.______ DISPLACEMENT: 5.0L (305 Cu. In.) 5.7L (350 Cu. In.) CRANKSHAFT: 2.4484-2.4493 Diameter #2, #3, #4 2.4481-2.4490 2.4479-2.4488 Main Production 0.0002 (Maximum) Journal Taper Service Limit 0.001 (Maximum) Production 0.0002 (Maximum) Out Of...
Page 503 SPECIFICATIONS ENGINE SPECIFICATIONS (7.4L) All Specifications are in INCHES unless otherwise noted. GENERAL DATA: Type Displacement 7.4L (454 CID) Bore 4.25 Stroke 4.00 Compression Ratio 7.9:1 Firing Order 1-8-4-3-6-5-7-2 Oil Pressure (Minimum)* 10 psi @ 600 RPM Minimum; 25 psi @ 2000 RPM CYLINDER BORE: Diameter 4.2500-4.2507...
Page 504 SPECIFICATIONS ENGINE SPECIFICATIONS (7 .4 L) (CONT.) All Specifications are in INCHES unless otherwise noted. DISPLACEMENT: 7.4L CRANKSHAFT: 2,7482-2.7489 Diameter #1, #2, #3, #4, #5 0.0004 (Maximum) Production Taper Main 0.001 (Maximum) Service Limit Journal 0.0004 (Maximum) Production Out Of Round Service Limit 0.001 (Maximum)
Page 505 SPECIFICATIONS (CONT.) FASTENER TIG H TEN IN G SPECIFICATIONS (5.0L AND 5-7L ENGINES) Item Lbs. Ft. Lbs. Ii — Camshaft Sprocket B o lts..................— Connecting Rod Bolt N uts.................. — Coolant Outlet Bolts..................... — Coolant Pump B olts..................... —...
Page 506 SPECIAL TOOLS y»< J 39046 J 23738-A J 8062 J 9290 01 J 21882 J 3049-A J 35468 J 5802-01 J 22102 J 5715 J 6036 J 8037 J 6880 J 5239 J 5825-A J 5590 1. TORSIONAL DAMPER REMOVER AND INSTALLER 2.
Page 507: 6A7 6.5L Diesel
SECTION 6A7 6.5L DIESEL RPO L49, VIN P RPO L56, VIN S RPO L65, VIN F RPO L57, VIN Y N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a lw a y s r e in s t a ll th e m a t th e s a m e lo c a t io n f r o m w h ic h t h e y w e r e r e m o v e d .
Page 508 CONTENTS (cont’d) SUBJECT PAGE Cylinder B o re s ................................6A7-23 Cylinder Bore Reconditioning G uidelines..................... 6A7-23 B o rin g ..................................6A7-24 Rough H o n in g ................................ 6A7-24 Finish H o n in g ................................. 6A7-24 Piston and Connecting Rod A ssem blies......................6A7-26 D isassem bly................................
Page 509 CONTENTS (cont’d) SUBJECT PAGE Coolant Crossover Installation..........................6A 7-49 Dipstick Tube Installation............................6A7-50 Exhaust Manifold Installation..........................6A7-50 Glow Plug Installation.............................. 6A7-50 Injection Nozzle Installation........................... 6A7-51 Injection Line Installation............................6A7-51 Intake Manifold Installation............................ 6A7-52 Oil Pump Drive Installation............................ 6A7-52 Engine Accessory Installation..........................6A7-53 Rear Crankshaft Oil Seal Installation........................6A7-53 Flywheel Installation..............................
Page 511 62. Clamp 1. Oil Pump Drive 110. Coolant Crossover and 63. Oil Fill Tube 2. Bolt Thermostat Housing 64. Nut 3. Oil Pump Drive Clamp 111. Connecting Rod Nut 65. Oil Filler Cap 4. Oil Pump Drive Gasket 112. Connecting Rod Bearing 5.
Page 512 V2131...
Page 513 150. Crankcase Depression 196. Valve Stem Key 239. Fuel Drain Back Hose. 197. Exhaust Valve Rotator Regulator Valve (CDR) 240. Clamp 198. Exhaust Valve Seal 241. Fuel Injection Pump 151. Clamp 199. Valve Spring Driven Gear 152. Hose (CDR) 153. Grommet (CDR) 200.
Page 514 ■ v . * ^ 7 7 7 ,“ / 7 , ^ j A f t . 2 - a « a s 3706r4751...
Page 515 90. Camshaft Bolt 51. Bolt 1. Oil Pump Drive 91. Camshaft Thrust Bearing 52. Coolant Plate Gasket 2. Bolt 92. Camshaft Sprocket Key 3. Oil Pump Drive Clamp 53. Thermostat By-Pass Hose 93. Camshaft Sprocket Spacer 54. Coolant Pump and Plate 4.
Page 516 "S-lM « » 180 167180 1 8 2 170 169 » ^ , 1 78 ^ - 1 7 9 21 2 ^ ^ 2 0 7 r ? i > 3706r4752...
Page 517 150. Crankcase Depression 196. Valve Stem Key 239. Fuel Drain Back Hose Regulator Valve (CDR) 197. Exhaust Valve Rotator 240. Clamp 151. Clamp 198. Exhaust Valve Seal 241. Fuel Injection Pump 152. Hose (CDR) 199. Valve Spring Driven Gear 153. Grommet (CDR) 200.
Page 518 A. FORWARD 13. OIL FILTER BYPASS VALVE B. TO OIL COOLER 16. OIL FILTER C. FROM OIL COOLER 192. ROCKER ARM D. FROM OIL PUMP 211. PUSHROD E. TO TURBOCHARGER (IF EQUIPPED) 213. VALVE LIFTERS F. FROM TURBOCHARGER (IF EQUIPPED) 400.
Page 519 Figure 10— Flywheel Removal Figure 11— Oil Pump Drive CLEANING Install or Connect N O T IC E : F o r s t e p s 1 a n d 2 , r e f e r to “N o t i c e ’ N O T IC E : C le a n th e e n g in e o n l y w h e n...
Page 520 Figure 12— Intake Manifold 4. Injection lines at the pump. «— ► Remove or Disconnect (Figure 13) • Cap the lines and pump fittings immediately. • Tag the lines for installation. 1. Injection line clips at the brackets. 5. Injection line brackets. 2.
Page 521 201. Exhaust Manifold 204. Bolts V2133 Figure 15— Exhaust Manifold Left Side A. HIGH PRESSURE INLET B. FUEL RETURN PORT C. NOZZLE NUT V3891 Figure 14— Injection Nozzles 2. Fuel return hose. N O T IC E : W h e n r e m o v in g a n in je c t io n n o z z le , u s e J 2 9 8 7 3 .
Page 522 40. PAN, OIL 263. TUBE, DIPSTICK 264. BRACKET, DIPSTICK 265. WASHER 266. 267. O-RING F9546 Figure 17— Exhaust Manifold Right Figure 18— Dipstick Tube Assembly 5. Coolant crossover (110). Important 6. Gaskets (103). 7. Hose (53). The pushrods must be installed in the original direction at assembly.
Page 523 53. HOSE, THERMOSTAT BY-PASS 62. CLAMP, HOSE ,106 103. GASKET 104. GASKET, THERMOSTAT HOUSING 106. BOLT/STUD 107. OUTLET, COOLANT 108. THERMOSTAT 109. BOLT, COOLANT OUTLET 110. CROSSOVER, COOLANT 53. HOSE 62. CLAMP, HOSE 103. GASKET 104. GASKET, THERMOSTAT HOUSING 106. BOLT / STUD 107.
Page 524 269 72 , PUMP, COOLANT 46. COVER, FRONT CRANKCASE . TABLE, OIL FILL 48. POINTER, TIMING . NUT 49. SCREW, TIMMING POINTER Figure 23— Removing the Torsional Damper GROMMET 50. PLATE, COOLANT PUMP , BOLT/STUD 52. GASKET, COOLANT PLATE 3. Injection pump gear (241). BOLT 54.
Page 525 46. COVER, FRONT 225. NUT 242. GASKET, INJECTION PUMP 244. PUMP, INJECTION 3706r4645 Figure 24— Electronic Injection Pump (Except L57, VIN Y) A. TIMING MARKS 88. GEAR, CAMSHAFT 241. GEAR, INJECTION PUMP 225. NUT 242. GASKET, INJECTION PUMP 228. BRACKET, THROTTLE SPRING 244.
Page 526 A. ALIGN MARKS AS SHOWN 84. SPROCKET, CRANKSHAFT 85. CHAIN, TIMING 86. BOLT, CAMSHAFT 87. WASHER, CAMSHAFT 88. GEAR, CAMSHAFT 89. SPROCKET, CAMSHAFT 91. PLATE, THRUST 92. KEY, CAMSHAFT SPROCKET 93. SPACER, CAMSHAFT SPROCKET B8068 Figure 26— Camshaft and Components O IL PUMP REMOVAL PISTON AND CO NNECTING ROD REMOVAL...
Page 527 C. Perform the cutting operation with a ridge ream REAR CRANKSHAFT SEAL er (figure 28). Do not remove excessive mate REMOVAL rial. Excessive removal of m aterial may require cylinder reboring to the next over size. Remove or Disconnect (Figure 30) D.
Page 528: Automatic Transmission
19. FLYWHEEL CRANKSHAFT 73. BOLT 83. CRANKSHAFT 75. CAP, CRANKSHAFT BEARING 76. BEARING, CRANKSHAFT 77. BEARING, CRANKSHAFT THRUST B8070 Figure 31— Crankshaft and Components CLEANING, INSPECTION, AND REPAIR 4. Oil filter bypass valve. Pry out with screwdriver. You will need a solvent tank, large enough to hold the larger engine parts, along with various bristle brushes A.
Page 529 3. Main bearing bores and main bearing caps. Tighten • All main bearing bores should be round and • Bolt to 25 N-m (18 lbs. ft.). uniform in ID at all bearing supports. • The area where the main bearing inserts con CYLINDER BORES tact the main bearing bore must be free of burrs and scratches.
Page 530 BORING • The boring operation is done with a single point tool that leaves tool marks similar to those found on a phonograph record. The speed and feed of the boring tool should be controlled to minimize the depth of these tool marks. •...
Page 531 MEASUREMENT LOCATION FOR A1, B1, AND C1 96 mm (3.8 INCHES) CENTERLINE 155 mm (6.1 INCHES) MEASUREMENTS MEASURE THE CYLINDER BORES AT POINTS SHOWN ABOVE AND RECORD MEASUREMENTS FOR CALCULATIONS DEPTH FROM TOP 90 DEGREES TO IN LINE WITH OF BLOCK CRANKSHAFT CRANKSHAFT 20 mm (0.79 IN)
Page 532 CLEANING AND INSPECTION XJjji Clean • Piston. • Remove all carbon deposits. A. 1 5 °K E Y S T 0 N E C O M P R E S S IO N RING Important B. REC TA NG ULAR C O M P R E S S IO N RING •...
Page 533 Diameter Measure (Figures 37, 38, and 39) 1. Piston pin diameter (figure 37). Check against “Specifications.” PISTON SELECTION 2. Piston pin bushing ID. Use an inside micrometer To determine the piston to cylinder bore clearance (figures 38 and 39). perform the following measurements: 3.
Page 534 A. RING MUST EXTEND BEYOND NOTCH B. INSERT ONE END OF RING IN RING GROOVE C. RING SPLIT MUST BE TOWARD BOTTOM OF A. Piston Crown Indent PISTON B. C onnecting Rod Bearing Tangs B9401 Figure 40— Aligning the Piston and Connecting Figure 43—...
Page 535 B4979 Figure 45— Measuring the Ring End Gap Figure 47— Measuring Ring Clearance INTAKE AND EXHAUST MANIFOLDS Clean • Old pieces of gasket from the gasket surfaces. • Soot deposits from the intake manifold. L® Inspect • Manifolds for cracks, broken flanges, and gasket surface damage.
Page 536 Be sure to fit the correct cam bearing into the bore. ALL BEARING LOCATIONS ARE VIEWED FROM THE FRONT OF THE BLOCK, WITH THE BLOCK IN AN UPRIGHT POSITION. The cam bearing bores vary in size. The cam bearings are num bered 1 through 5, with the numbers located on the back of the bearing.
Page 537 3. Inner camshaft bearings using J 33049 (figure 49). Disassemble ❖ A. Assemble the tool with the pilot engaged in the front bearing and the pilot flange against the Front crankshaft seal. Pry the seal out with a large front face of the block. screwdriver.
Page 538 Inspect • Sealing flanges for bending or damage. • Rubber grommets and parts on the rocker arm cov er for deterioration. • Oil pan for rock damage or cracks. • Oil pan baffle for loose fit. • Drain plug threads for stripping. O IL PUMP Disassemble ❖...
Page 539 A. SEAL, EXHAUST VALVE STEM 207. VALVE, INTAKE 208. VALVE, EXHAUST 210. SHIM 406. VALVE KEEPER 407. CAP 408. SHIELD 409. SEAL, VALVE 410. VALVE SPRING WITH DAMPER 411. ROTATOR V3876 Figure 52—Valves and Components B. Install the retainers with a drift of at least 13-mm (1/2-inch) diameter.
Page 540 ACCEPTABLE CRACK LENGTH NOT OVER 5 mm (3 /ie") UNACCEPTABLE A. NOTCH (LOCATION MAY VARY.) 272. PRECHAMBER CRACK LENGTH B8413 OVER 5 mm p h e ") Figure 54-—Prechamber 5. Prechambers (272) (if required) (figure 54). • Drive out with a small nylon or brass drift insert ed through the injection nozzle hole.
Page 541 Valve Guides and Valve Seats | j | Measure (Figures 57 and 58) N O T IC E : V a lv e s e a t s 6 .5 L e n g in e s a r e Valve spring installed height of each valve spring, i n d u c t i o n - h a r d e n e d .
Page 542 Measure IN JEC TIO N NOZZLE TESTS Tool Required: • G low plug resistance. C onnect an ohm m eter J 29075-B Nozzle Tester between the electrical connector blade and the J 29079-125 Adapter Kit glow plug body. Replace any glow plug with a J 29079-1 Line Assembly resistance greater than 2 ohms.
Page 543 2. Depress the tester lever slowly. Note at what pres SPRAY PATTERN sure the needle of the pressure gage stopped. The This nozzle features a longer nozzle overlap, greater maximum observed pressure is the opening pres pintle to body clearance, and an internal wave washer sure.
Page 544 corresponding main bearing bulk head. The total diame B. Main bearing and connecting rod journals for taper ter size range of the main bearing bores 1 through 5 is and out-of-round (figure 59). If the journals are 79.826 mm to 79.850 mm. This range is divided into tapered or out-of-round more than 0.025 mm (0.001-inch), replace the crankshaft.
Page 545 Inspect 2. Uniformly heat the flywheel gear to temperature which will expand the gear to permit installation. Temperature must not exceed 200° C (400° F). • Flywheel for burning, scoring, warping, and wear. 3. As soon as the gear has been heated, install on Replace the flywheel if necessary.
Page 546 A. ALIGN MARKS AS SHOWN 84. SPROCKET, CRANKSHAFT 85. CHAIN, TIMING 86. BOLT, CAMSHAFT 87. WASHER, CAMSHAFT 88. GEAR, CAMSHAFT 89. SPROCKET, CAMSHAFT PLATE, THRUST KEY, CAMSHAFT SPROCKET SPACER, CAMSHAFT SPROCKET B8068 Figure 62—Camshaft and Components Measure • Main bearing clearance. Refer to SECTION 6A. 4.
Page 547 Tighten Inspect • Bolts to specifications, in the follow ing Crankshaft for binding. Try turning the crankshaft to check for binding. If the crankshaft does not turn sequence: freely, loosen the main bearing cap bolts, one pair A. Inner bolts: 150 N-m (110 lbs. ft.). at a time, until the tight bearing is located.
Page 548 Measure TORSIONAL DAMPER INSTALLATION • Timing chain free play as follows: Install or Connect (Figure 66) 1. Mount a dial indicator to the front of the block. 2. Position the dial indicator so that the plunger contacts the timing chain between the two •...
Page 549 46. COVER, FRONT 225. NUT 242. GASKET, INJECTION PUMP 244. PUMP, INJECTION 3706r4645 Figure 67— Front Cover Installation will be stamped “O.S.” on the cast pad adjacent to 1. Hydraulic lifters to the engine. the lifter bore and on the top rail of the cylinder A.
Page 550 3. Clamps (210). Tighten • Clamp bolts to 26 N-m (18 lbs. ft.). Important • After all clamps are installed, turn the crank shaft by hand 720 degrees (two full turns), to insure free movement of the lifters in the guide plates.
Page 551 A. Use short pieces of 10 mm (3/s-inch) hose to protect the crankshaft journal. B8045 Figure 70— Installing the Piston and Connecting Figure 71— Installing the Connecting Rod and Piston N O T IC E : R e f e r to “N o t i c e ” o n p a g e 6 A 7 -1 . 4.
Page 552 Figure 74— Injection Pump 1. Oil pan rear seal to the oil pan (40). pump and camshaft gears as shown. The slot in 2. Oil pan (40) to the engine. the injection pump gear should be in the vertical 6 o’clock position (figure 75).
Page 553 Figure 76— Oil Pan and Oil Pump 2. Cylinder head. Make sure the gasket surfaces are clean. Guide the head carefully into place over the dowel pins. N O T IC E : R e f e r to “ N o t i c e ” o n p a g e 6 A 7 -1 . 3.
Page 554 B8027 Figure 78— Aligning the Timing Mark •A pp ly a 5-mm (3/16-inch) bead of RTV sealant This measurement can be estimated by aligning (GM P/N 12345739) to the rocker arm covers, the torsional damper mark with the first lower inboard of the bolt holes.
Page 555 IN JEC TIO N PUMP INSTALLATION -►+ Install or Connect (Figure 74) N O T IC E : F o r s t e p s 6 a n d 7, r e f e r to “ N o t i c e ” o n p a g e 6 A 7-1 .
Page 556 53. HOSE, THERMOSTAT BY-PASS 62. CLAMP, HOSE ,106 103. GASKET 104. GASKET, THERMOSTAT HOUSING 106. BOLT/STUD 107. OUTLET, COOLANT 108. THERMOSTAT 109. BOLT, COOLANT OUTLET 110. CROSSOVER, COOLANT 53. HOSE 62. CLAMP, HOSE 103. GASKET 104. GASKET, THERMOSTAT HOUSING 106. BOLT / STUD 107.
Page 557 IN JEC TIO N NOZZLE INSTALLATION ■>4- Install or Connect (Figure 84) Tool Required: J 29873 Nozzle Socket N O T IC E : W h e n in s t a llin g a n in je c t io n n o z z le u s e J 2 9 8 7 3 .
Page 558 3. Injection lines to the nozzles. Uncap the lines before assembly. Do not bend the injection lines. Tighten • Injection line fittings at both ends of the lines to 25 N-m (19 lbs. ft.). 4. Injection line clips to the brackets. INTAKE M ANIFOLD INSTALLATION «-+...
Page 559 2. Oil pump drive to the engine. Index the drive or ENGINE ACCESSORY pump with the camshaft gear and oil pump drive INSTALLATION shaft. Make sure the drive or pump seats fully. Install the engine accessories as directed in the prop "...
Page 560 FLYWHEEL INSTALLATION -► Install or Connect (Figure 90) 1. Flywheel (19). N O T IC E : R e f e r to “ N o t i c e ” o n p a g e 6 A 7 -1 . 2.
Page 561 SPECIFICATIONS FASTENER TIG H TEN IN G SPECIFICATIONS Item Lbs. Ft. Lbs. In. Bell Housing Bolts....................Block Drain Plugs....................Camshaft Gear B o lt..................... Camshaft Thrust Plate..................Connecting Rod Cap Nuts................... Coolant Crossover/Thermostat Housing B olts..........Crankshaft Pulley Bolts..................Cylinder Head Bolts—...
Page 562 ENGINE SPECIFICATIONS All Specifications are in millimeters (mm) unless otherwise noted. GENERAL DATA: 6.5L Displacement L49, L56, L57, and L65 90-degree V8 Diesel Type Bore Stroke Compression Ratio 21.3:1 Firing Order 1-8-7-2-6-5-4-3 Oil Pressure 10 psi at idle (hot); 40-45 psi at 2000 RPM CYLINDER BORE:1 Diameter Refer to “...
Page 563 ENGINE SPECIFICATIONS (CONT.) All Specifications are in millimeters (mm) unless otherwise noted. DISPLACEMENT 6.5L CAMSHAFT: Intake 7.133 Exhaust 7.133 #1, #2, #3, #4 54.970-55.025 50.970-51.025 Journal Clearance #1, #2, #3, #4 0.025-0.118 Journal Clearance #5 0.020-0.113 Camshaft End Play 0.051-0.305 VALVE SYSTEM: Lifter Hydraulic Roller...
Page 564 CRANKSHAFT M AIN BEARING SELECTION AND SPECIFICATIONS 6.5L ENGINES CRANKSHAFT MAIN JOURNAL CYLINDER & CASE MAIN BEARING BORE DIAMETERS DIAMETERS 79.842 79.834 #1 TO #4 79.850 79.834 79.842 79.826 STAMP 1 STAMP 3 STAMP 2 74.912 1-.026 U.S. IN CASE 1-.013 U.S.
Page 565 SPECIAL TOOLS < S > tt Iff I f J 39046 J 8037 J 33049 29664 J 8062 J 29873 J 22102 SgfiB J 6098-10 J 24270 J 29075-B J 39063 J 39084 J 39507 . RING COMPRESSOR J 33042 2.
Page 566 NOTES...
Page 567 SECTION 6C1 MODEL 220 TBI UNIT N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a lw a y s r e in s t a ll th e m a t th e s a m e lo c a t io n f r o m w h ic h t h e y w e r e r e m o v e d .
Page 568 GENERAL DESCRIPTION Identification The fuel control system has an electric fuel pump, located in the fuel tank with the gage sending unit, that The throttle body identification number is stamped pumps fuel to the TBI unit through the fuel supply line, vertically on the throttle body next to the vacuum ports then through an in-line fuel filter.
Page 569 1. R E G U L A T O R A SSY , F U E L P R E S S U R E 2. C O V E R A S S Y , F U E L M E T E R 3.
Page 570 THROTTLE BODY DISASSEMBLY CAUTION: DO NOT remove the four screws IDLE AIR CONTROL (IA C ) VALVE securing the pressure regulator to the fuel meter cover. The fuel pressure regulator N O T IC E : T h e I A C v a lv e is a n e le c t r ic a l c o m includes a large spring under heavy com...
Page 571 1. Lower (small) O-ring from nozzle of injectors and meter body assembly. Discard gaskets. discard. 2. Fuel meter cover gasket and discard. Important 3. Upper (large) O-ring from top of fuel injector cavity and discard. • Note locations of nuts for proper reassembly later.
Page 572 N O T IC E : U p p e r a n d l o w e r O - r in g s m u s t b e Important i n s t a l le d b e f o r e in je c t o r s o r im p r o p e r s e a tin g o f la r g e O -r in g c o u ld c a u s e f u e l to le a k .
Page 573 " Tighten N O T IC E : R e f e r to N o t i c e ” o n p a g e 6 C 1 -1 . 2. Two ISC actuator assembly attaching screws, coat Thread-mounted IAC valve assembly to 18 N-m (13 ed with Loctite 262 (P/N 10522624), or equivalent.
Page 574 NOTES...
Page 575 SECTION 6D ENGINE ELECTRICAL CONTENTS SUBJECT PAGE SD Starter Motors............................6D2A-1 28-MT Starter Motors............................6D2B-1 CS-144 Generators............................6D3A-1 Distributors...............................6D4A-1 SECTION 6D2A SD STARTER MOTORS NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
Page 576 CONTENTS (cont’d) SUBJECT PAGE Drive E n d ...................................6D2A-12 Frame and Field A ssem b ly..........................6D2A-13 Pinion Clearance C h e c k ............................6D2A-13 S p ecifications................................6D2A-14 Starter..................................6D2A-14 Solenoid S w itches..............................6D2A-14 Fastener Tightening Specifications........................6D2A-14 Lubrication.................................
Page 577 DIAGNOSIS 2. Low free speed and high current draw indicates: STARTER MOTOR TESTS • Too much friction. Tight, dirty or worn bear Before disassembling the starter motor for repair, the ings, bent armature shaft or loose pole shoes following test should be made. allowing the armature to drag.
Page 578 DISASSEMBLY OF THE SD-300 STARTER MOTOR If the motor does not perform to specifications, it may 4. Brake washer (34) from the commutator end of the need to be disassembled for further testing of the com armature shaft. ponents. Normally, the starter motor should be disas 5.
Page 579 3. Solenoid 57. Field Frame 31. Drive Housing 58. Through Bolts 41. End Frame 51. Field Coil Connection F9322 Figure 4— Light Duty Starter Motor 1. Shift Lever Finger 9. Armature 31. Drive Housing 39. Drive Collar F4215 Figure 5— Disengaging the Drive Collar from the Ring Shift Lever Fingers BRUSHES...
Page 580 Brush Grounded Brush Holder 23. “ S ” Terminal Insulated Brush H older 24. Motor Terminal Pivot Pin 25. “ BAT” Terminal Brush Holder Spring 66. Contact Disk Assembly Brush Holder Support 67. Cover F4220 F4219 Figure 8— Replacing Brushes on the SD-300 Figure 9—...
Page 581 2. Armature (9) with the drive assembly (32), shift Models with Solenoid Shield: lever (1), plunger (2), and return spring (5) from the 1. Solenoid shield nuts (20) from the solenoid clamp drive end frame (figure 11). screws (54). 3. Return spring from the plunger. 2.
Page 582 1. Shift Lever Assembly 2. Plunger 9. Armature 32. Drive Assembly V1292 Figure 11— Armature, Drive, and Shift Lever Assembly INSPECTION • Shorts between the commutator bars are some CLEANING , IN SPECTIO N , AND times produced by brush dust or copper dust. ELECTRICAL TESTS 5.
Page 583 F1970 Figure 13—Testing the Armature for Grounds Figure 15— Checking the Field Coils for Opens (SD-300) 8. Brush holders for dirt or damage. • Make sure that the brushes are not binding in the holders. 9. Brush springs for distortion or discoloring. If the springs are weak, bent, or discolored, replace them.
Page 584 Grounds (SD-260) 13. Field coils for shorts. • Shorts are indicated by poor motor performance after everything else has been checked out. On the SD-210 and SD-260 starter motors, the coils cannot be replaced separately because of the integral frame construction. The frame and field assembly must be replaced.
Page 585 • Coil resistance can be determined by divid C. Note the ampere reading. A high reading indi cates a shorted or grounded winding, and a low ing the voltage by the current (amperes) list reading indicates excessive resistance. ed in “ Specifications” at the end of this section.
Page 586 6. Stop collar to the retainer ring (figure 19). C. Align the scribe marks or end frames and field frame. • Place the thrust collar onto the shaft with the D. Slide the field frame over the armature. The sm all flange tow ard the re ta in er ring and brush retaining tool socket will slide out as the squeeze the collars together.
Page 587 9. Spring (5) onto the plunger (2). PIN IO N CLEARANCE CHECK 10. Plug (15). The pinion clearance should be checked after reas 11. Solenoid (3) and clamp (53) onto the drive end sembly of the motor. It cannot be adjusted. Improper frame, aligning the “...
Page 588 3. Momentarily flash a jumper lead from the solenoid 5. Measure the distance between pinion and pinion motor terminal to the solenoid frame. This will shift stop collar (figure 23). the pinion into cranking position and it will remain • Clearance should be 0.25 mm to 4.06 mm so until the battery is disconnected (figure 22).
Page 589 SECTION 6D2B 28-MT STARTER MOTORS N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a l w a y s r e in s ta ll th e m a t th e s a m e lo c a t io n fr o m w h ic h t h e y w e r e r e m o v e d .
Page 590 Figure 1—28-MT Starter Motor GENERAL DESCRIPTION STARTER MOTOR The starter has an overrunning roller-type clutch and an enclosed shift lever. The solenoid is sealed to pre The Delco Remy 28-MT is a gear reduction starter. vent entry of foreign material. An internal gear at the gear-reduction end of the driveshaft is driven by the armature shaft gear at a IDENTIFICATION...
Page 591 46. CARBON PILE 47. BATTERY 48. AMMETER V3861 Figure 2— No-Load Test Connections 4. Compare the ammeter and RPM readings to those N O T I C E : N e v e r o p e r a t e t h e s t a r t e r m o t o r listed under “...
Page 592 6. Low no-load speed and low current draw indicates 7. High free speed and high current draw indicates a higher internal resistance due to poor connec shorted fields. If shorted fields are suspected, tio n s, d efective leads, d irty com m utator, and replace the field coil assem bly and check for causes listed under step 5.
Page 593 1. BOLT, THROUGH 2. SCREW, BRUSH PLATE 3. FRAME, COMMUTATOR END 4. SEAL, O-RING (C.E. END) 5. BRUSH (GROUNDED) 24. PLATE (IF USED) 6. SCREW, GROUNDED BRUSH 7. ASSEMBLY, BRUSH HOLDER 25. BOLT, DRIVE HOUSING (SHORT ON SOME MODELS) 8. BRUSH (INSULATED) 26.
Page 594 A. FRAME, FIELD AND BRUSH HOLDER GROUP B. GEAR REDUCTION AND DRIVE GROUP 1. BOLT, THROUGH 2. SCREW, BRUSH PLATE 3. FRAME, COMMUTATOR END 16. PIN, DOWEL 4. SEAL, O-RING (C.E. END) 17. SEAL, O-RING (FIELD FRAME) 12. BEARING, C.E. ARMATURE 13.
Page 595 C. DRIVE SHAFT AND CLUTCH GROUP 20. LEVER, SHIFT 21. PLUG, DRIVE HOUSING 24. PLATE (IF USED) 25. BOLT, DRIVE HOUSING (SHORTER ON SOME MODELS) 26. BOLT, DRIVE HOUSING (LONG) 30. WASHER, THICK 27. BRACKET, ARMATURE SUPPORT 37. BUSHING, D.E. HOUSING 28.
Page 596 CLEANING, INSPECTION, AND REPAIR 9. Armature assembly (13) for the following: CLEANING • Gear teeth that are broken, or that show evi dence of step wear or root interference. N O T IC E : D o n o t c le a n o r im m e r s e th e s t a r t e r •...
Page 597 REPAIR PROCEDURES ARMATURE BEARING REPLACEMENT If necessary, replace the bearings (12 and 14) or armature (13) as follows (figure 3). Remove or Disconnect (Figures 3 and 11) N O T IC E : B a ll b e a r in g s t h a t a r e r e m o v e d fr o m t h e a r m a t u r e m u s t b e r e p l a c e d...
Page 598 TOP VIEW SIDE VIEW 32 MM (1.26 IN.) ■55 MM (APPROX.)- DIA. CIRCLE rr~r> cnn LOCALLY FABRICATED TOOL WIDE END OF DRIVE SHAFT MATERIALS NEEDED- ACCESS • PIECE OF FLAT METAL STOCK ABOUT 5 MM (OR 3/16 IN.) HOLE THICK, AND 55 MM (OR 2 1/4 IN.) SQUARE OR ROUND. CENTER SUPPORT •...
Page 599 C. Push the spring fully onto the post and release GEAR REDUCTION AND DRIVE the free end to engage the notch in the brush GROUP socket. Important (Figure 6) N O T I C E : B r u s h l e a d s m a y b e d a m a g e d b y e x c e s s iv e h a n d lin g .
Page 600 5. BRUSH, GROUNDED 6. SCREW, GROUNDED BRUSH 7. ASSEMBLY, BRUSH HOLDER 8. BRUSH, INSULATED 11. BRUSH, GROUNDED 56. SOCKET, BRUSH 57. POST, SPRING 58. TAB, TERMINAL 59. INSULATION V3873 Figure 14— Springs and Brushes on the Brush Holder B. Insert the brush screws (6) through the terminal tabs on the brush holder and thread into the brush lead terminals.
Page 601 ++• 6. Commutator end frame (3). Install or Connect (Figures 4, 5, and 15) A. Align the marks on the commutator end frame and frame and field assembly (15) made prior N O T IC E : F o r s t e p s 1, 7, 8, a n d 9, r e f e r to to disassembly (figure 5).
Page 602 SPECIFICATIONS STARTER MOTORS No Load Test @ 1 0 Volts (Includes Solenoid Current) Starter Solenoid AMPS Maximum Minimum Maximum Part No. Part No. Series Minimum 10456454 28-MT 3000 5600 1113295 10456454 1113296 28-MT 3000 5600 SOLENOID SW ITCHES Pull-In Winding Hold-ln Winding Switch Part No.
Page 603 SECTION 6D3A CS-144 GENERATORS N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a lw a y s r e in s t a ll th e m a t th e s a m e lo c a t io n f r o m w h ic h t h e y w e r e r e m o v e d .
Page 604 Figure 1— CS-144 Generator Both the “ L” and “ I” terminals serve to turn on the regulator and allow field current to flow when the switch is closed. The “ I” terminal may be connected either directly to the switch, or through a resistor. The “ I” circuit may be used with or without anything connected to the “...
Page 605 250. Voltmeter 251. Ammeter 256. Battery 257. Carbon Pile A. Connect Resistor to “ L” Terminal F7081 Figure 3— Connections for Generator Output Test DISASSEMBLY DRIVE END FRAME N O T IC E : T h e r o t o r m a y b e d is t o r t e d i f th e v is e is o v e r tig h te n e d .
Page 606 1. Nut 107. Drive End Bearing 221. Rotor 14. Washer 226. Regulator 116. Inside Collar 117. Outside Collar 227. Rectifier Bridge 28. Through Bolt 30. Screw 128. Retainer 228. Capacitor 31. Grounded Screw 131. Brush Holder 229. Pulley 35. Insulated Screw 216.
Page 607 106. Slip Ring 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 Collar F7082...
Page 608 Figure 7— Slip Ring End Frame with Stator Removed INSPECTION AND REPAIR CLEANING AND INSPECTIO N 5. Drive end bearing for roughness, looseness, or wear. If the condition of the bearing is doubtful, replace it. 6. Windings for burned insulation. Replace the rotor or stator if either looks burned.
Page 609 ELECTRICAL TESTS Except as stated, make the following tests with an ohmmeter on the low range scale. ROTOR FIELD WINDING CHECKS The rotor may be checked electrically with a self-pow ered test lamp or an ohmmeter (figure 10). Open Winding To check for opens, connect the test lamp or ohmme...
Page 610 Figure 12— Rectifier Bridge Check A. Ohmmeter Connections Checking For Grounds F6292 Figure 11— Checking the Stator ASSEMBLY 5. “ BAT” terminal nut (1) with the flat side down to the SLIP RING END FRAME insulated heat sink (figure 8). •...
Page 611 Figure 13— Stator in the Slip Ring End Frame A. Retract the brushes in the holder. B. Retain the retracted brushes with a retaining pin. C. Make sure the pin extends through the end frame when the brush holder is in place. After the rotor and drive end frame are installed, the pin will be pulled out, allowing the brushes to contact the slip rings.
Page 612 SPECIFICATIONS GENERATOR SPECIFICATIONS Series Rotor Field-Ohms Field Current @ 1 2 Ampere Part No. (Type 100) 27°C (80°F) Volts 27°C (80‘F) AMPS Rating 1102635 2.1-2.4 5.0-5.7 CS-144 10479884 CS-144 2.1-2.4 5.0-5.7 FASTENER TIG H TEN IN G SPECIFICATIONS Ft. Lbs. Pulley N u t....................
Page 613 SECTION 6D4A DISTRIBUTORS N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a lw a y s r e in s t a l l th e m a t th e s a m e lo c a t io n f r o m w h ic h th e y w e r e r e m o v e d .
Page 614 Figure 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 V2792...
Page 615 50 11 10. Rotor 11. Pickup Coil 14. Module 23. Cap 25. Screw 26. Shaft Assembly 27. Pin 29. Gear 30. Housing 31. Washer 33. Tang Washer 33 31 29 49. Retainer 50. Shield F4261 Figure 3— V8 Engine Distributor Components DISASSEMBLY 7.
Page 616 10. Pickup coil (11). 11. Two screws (25) holding the module to the hous ing. 12. Module (14). INSPECTION AND ELECTRICAL TESTS The reading should be infinite. If not, replace Inspect the coil. B. Connect an ohmmeter to both pickup coil leads 1.
Page 617 ASSEMBLY A. Place the retainer over the center bushing with DISTRIBUTOR the teeth pointing upward. B. Place a 15-mm (5/8-inch) socket head onto the Install or Connect (Figures 2, 3, 4, and 7) edge of the retainer. Keep the socket centered on the retainer so the teeth are not damaged.
Page 618 SPECIAL TOOLS...
Page 619: Automatic Transmission
TR A N SM ISSIO N SECTION 7 TRANSMISSION CONTENTS SUBJECT PAGE HYDRA-MATIC 4L60-E Automatic Transmission Unit Repair.................7A14B-1 HYDRA-MATIC 4L80-E Automatic Transmission Unit Repair.................7A17B-1 New Venture Gear 3500 (5LM60) Manual Transm ission..................7B1-1 New Venture Gear 4500 Manual Transm ission...................... 7B2-1 Borg-Warner T5 Manual Transm ission........................
Page 620 NOTES...
Page 621: Automatic Transmission
SECTION 7A-14B HYDRA-MATIC 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR RPO M30 NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number is not available, a fastener of equal size and strength (or stronger) may be used.
Page 622: General Service Information
TRANSMISSION DISASSEMBLY 2-4 Servo Assembly Figures 2 and 3 General Service Information Tool Required: Figure 1 J 29714 Servo Cover Compressor Tool Required: | Remove or Disconnect J 8763-02 Holding Fixture and Base 1. Install J 29714. NOTICE: It is not recom m ended to use air 2.
Page 623: Servo Pin Length
Servo Pin Length Figures 3,4 and 5 Tools Required: J 33037 Band Apply Pin Tool J 22269-01 Piston Compressor As a diagnostic aid, the servo pin length should now be checked. If the pin length is too short or too long, be certain to inspect the 2-4 band and reverse input drum for damage or wear when disassembled.
Page 624 Remove or Disconnect Figures 4 and 5 1. 4th apply piston (25). Servo return spring (12). Servo pin retainer ring (24), washer (23) and apply pin spring (22). 2nd apply piston pin (13). 5. Install J 22269-01. 6. Retainer ring (14). 7.
Page 625: Speed Sensor And Case Extension
Speed Sensor and Case Extension Figures 6 and Tool Required: J 38417 Speed Sensor Remover and Installer 1. Speed sensor retaining bolt (35). Speed sensor assembly (36) and O-ring seal (37) with J 38417. 3. Case extension bolts (32), case extension (31) and extension seal ring (30).
Page 626 Pan And Filter Assembly Figure 8 Clean • Exposed ends of bottom pan screws and spray with penetrating oil. Remove or Disconnect Screws (76), oil pan (75) and gasket (73). 2. Oil filter (72) and filter seal (71). • Filter seal may be stuck in the pump. | p | Inspect •...
Page 627 6 9 - 63 SPRING ASSEMBLY, MANUAL DETENT 88 LEVER, INSIDE DETENT 89 LINK, MANUAL VALVE 340 VALVE, MANUAL Figure 11 Manual Valve Link 63 SPRING ASSEMBLY, MANUAL DETENT 64 BOLT, MANUAL DETENT SPRING 66 SOLENOID ASSEMBLY, WIRING HARNESS AND 69 SWITCH ASSEMBLY, TRANSMISSION PRESSURE RH0109-4L60-E BOLT, PRESSURE SWITCH ASSEMBLY...
Page 628 2 3RD ACCUMULATOR 38 PLUG, TR A N SM ISSIO N CASE (ACCUM. BLEED) REVERSE INPUT 40 RETAINER AND BALL ASSEMBLY, 3RD ACCUM . 4 3-4 CLUTCH EXHAUST 91 NO. 10 CHECKBALL 5 OVERRUN CLUTCH FEED 92 SCREEN,TCC 6 OVERRUN CLUTCH CONTROL 8 1-2 UPSHIFT RH0113-4L60-E RH0112-4L60-E...
Page 629 Transmission End Play Check Figures 15 and 16 Tools Required: J 24773-A Oil Pump Remover J 25022-A End Play Adaptor (245 mm) J 34725 End Play Adaptor (298 mm) J 25025-7A Post Dial indicator As a diagnostic aid, transmission end play should be checked prior to removing the internal parts.
Page 630: Band, Reverse Input Clutch
2-4 Band, Reverse Input Clutch, Input Clutch And Input Gear Set Figures 18 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.
Page 631: Reaction Gear S
3. J 29837 and output shaft (687). Reaction Gear Set | V | Important Figure 21 • The manufacturer assembles the output Remove or Disconnect shaft and reaction internal gear w ith 1. Input internal gear (664) and reaction carrier adhesive for ease of assembly.
Page 632 Lo And Reverse Clutch Parts Figures 2 2 ,23 and 25 Tools Required: J 34627 Snap Ring Remover/Installer J 23327 Clutch Spring Compressor [ZT| Remove or Disconnect 1. Bolts (715) and parking lock bracket (710). |~f~| Important • Due to interference, the parking pawl may have to be removed before removing or installing the low and reverse piston.
Page 633: Inner Manual Linkage
8 9 --------- 3 A APPLY AIR PRESSURE HERE TO REMOVE LO A ND REVERSE PISTON FROM THE CASE 693 RING, LO A N D REVERSE CLUTCH RETAINER 694 SPRING ASSEMBLY, LO AN D REVERSE CLUTCH 78 PLUG, STEEL CUP 695 PISTON, LO AND REVERSE CLUTCH 79 SHAFT, PARKING BRAKE PAWL RH0122-4L60-E...
Page 634: Component Repair And Transmission Reassembly
Figure 25 Manual Shaft Seal Figure 26 Case Vent Assem bly | y | Inspect Case F ig u re 2 4 Figures 2 6 ,2 7 and 28 • Actuator rod (85) for damage. [ y | Inspect • Inside detent lever (88) for damage or cracks.
Page 635: Ball A Ssem Bly
• Case interior for: Third Accumulator Retainer and Ball Assembly Damaged ring grooves or casting flash. Figure 29 Clutch plate lugs worn or damaged. [ f f i Inspect Bushing (33) scored, worn, or damaged (see Bushing Replacement). • Ball for: Presence.
Page 636: Lo And Reverse Clutch Piston
p 7 | Install or Connect F ig u re 3 2 1. Piston seals (696) onto the piston (695). • Lubricate w ith Transjel™ J 36850 or equivalent. 2. Piston (695) into the case. • Index the piston with the notch in the bottom of the case.
Page 637: Carrier A Ssem Bly
Parking Pawl Figure 33 [ y | Inspect • Parking pawl (81) for cracks, burrs, or damage. • Parking pawl return spring (80) for distortion or damage. • Parking pawl pivot shaft (79) for damage and freeness of fit with the parking pawl. [++I Install or Connect Figure 33 1.
Page 638: Reaction Internal Gear And Support
• R etain w ith T ransjel™ J 36850 or equivalent. 2. Reaction internal gear and support (684 and 685) onto the bearing as shown. 3. Reaction carrier to support thrust bearing assembly (683) onto the support (685). • Outer bearing race goes toward the support. 4.
Page 639 INSTALL THE APPROPRIATE SELECTIVE SPACER PLATE TO THE FINAL ASSEMBLY AFTER DIM ENSION "D" IS OBTAINED. IDENTIFICATION SIDE UP. 682A SUPPORT ASM ., LO A N D REVERSE CLUTCH W A V ED 682A PLATE, LO AND REVERSE CLUTCH (WAVED) 682B PLATE, SPACER LO A N D REVERSE CLUTCH (SELECTIVE) 682C PLATE ASSEMBLY, LO A N D REVERSE CLUTCH (FIBER) 682D PLATE, LO A ND REVERSE CLUTCH (STEEL)
Page 640 LO AND REVERSE CLUTCH SPACER PLATE SELECTION CHART USE THIS SELECTIVE PLATE IF GAGE DIMENSION "D" IS IDENTIFICATION PLATE THICKNESS FROM 28.065m m 1.684mm 1.829m m 27.545m m NONE (.072") (.066") (1.102") (1.081") 1.314m m 1.168m m 28.586m m 28.066m m (.052") (.046") (1.122")
Page 641: Lo And Reverse Clutch Support Assembly
• Support assembly for: Lo and Reverse Clutch Support Assembly Cracks or damaged lugs. Figures 42,43 and 44 |++| Install or Connect □ Remove or Disconnect Figures 42,43 and 44 Figure 42 1. Roller clutch assembly (678) into the cam and 1.
Page 642: Reaction S Haft
Reaction Sun Gear and Shell Figure 45 [jy| Inspect • Reaction sun gear (673) for: Nicked, scored, or worn bushing (See Bushing Replacement). Damaged spline or teeth. Loose or w eak retaining ring (do not remove this ring, except to replace it.). •...
Page 643: Input Internal Gear And Output Shaft
Input internal gear (664) for: Install or Connect Cracks. Figure 47 Damaged spline or gear teeth. 1. Place new rotor over output shaft. Input carrier to reaction shaft thrust bearing 2. Place J 36352-4 in groove on output shaft. (663) for wear or damage. 3.
Page 644 Input Carrier and Sun Gear Figure 50 Tool Required: J 34627 Snap Ring Pliers | y | Inspect • Input carrier assembly (662) for: Pinion gear damage. Excessive pinion washer wear - end play should be 0.20 to 0.61 mm (0.008 to 0.024 inch).
Page 645: Input Clutch Assembly
3. The 3-4 clutch plates (654). 4. Five 3-4 clutch boost spring assemblies (600). 5. The 3-4 clutch apply plate (653). 6. The 3-4 clutch ring retainer plate (652). 7. Forward clutch backing plate retainer ring (651) and backing plate (650). 8.
Page 646: Check Valve Retainer And Ball Assembly - Replacement Procedures
• Check valve retainer and ball assembly (617) Overrun clutch spring assembly (634). for: Overrun clutch piston (632). Damage. • Inner and outer lip seals (631). The ball must move freely in the retainer. 5. Forward clutch piston assembly (630). The retainer must be tight in the turbine •...
Page 647 615 616 617 600 623 627 628 633 632 635 636 645A 645B 637 638 639 642 643 649A 649B ILL. ILL. DESCRIPTION DESCRIPTION SPRING ASM., 3-4 CLUTCH BOOST (5) PLATE, FORWARD CLUTCH (APPLY) BEARING ASSEMBLY, STATOR SHAFT/ SELECTIVE PLATE, FORWARD CLUTCH (WAVED) WASHER 649A PLATE ASSEMBLY, FORWARD CLUTCH (STEEL) WASHER, THRUST (SELECTIVE)
Page 648 [ y | Inspect Figures 54 and 56 • Turbine shaft O-ring seal (618) for: Damage. Nicks or cuts. • Input housing check valve ball (620): The ball must move freely. Leak check the ball with solvent. | T ] Important •...
Page 649 1. Inner and outer 3-4 clutch lip seals (624) on the 3-4 clutch piston. • Seal lips must face away from 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.
Page 650 J 29883 621 HOUSING AND SHAFT ASSEMBLY, INPUT 621 HOUSING AND SHAFT ASSEMBLY, INPUT 622 SEAL, O-RING INPUT TO FORWARD HSG. 623 PISTON, 3RD AND 4TH CLUTCH 625 RING, 3RD AND 4TH CLUTCH (APPLY) 623 PISTON, 3RD AND 4TH CLUTCH 626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH 625 RING, 3RD AND 4TH CLUTCH (APPLY) 628 HOUSING, FORWARD CLUTCH...
Page 651 Assemble • Overrun clutch plates (645) for: Figures 61 and 62 C o m p o sitio n p la te d am ag ed ta n g s, 1. Overrun clutch spring assembly (634) onto the delamination, or excessive wear. overrun clutch piston.
Page 652: Forward Clutch Sprag Assembly
• Forward sprag outer race (644) for: Spline damage. Surface finish damage. Plugged lubrication holes. 637 638 639 637 BEARING ASSEMBLY, INPUT SUN GEAR 638 SNAP RING, OVERRUN CL. HUB RETAINING 639 HUB, OVERRUN CLUTCH 641 RETAINER AND RACE ASSEMBLY, SPRAG 642 FORWARD SPRAG ASSEMBLY 643 RETAINER RINGS, SPRAG ASSEMBLY RH0160-4L60-E...
Page 653 |-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) for: C o m p o sitio n p la te d am ag ed ta n g s, delamination, or wear.
Page 654 The 3-4 clutch apply plate (653) for: Flatness. Bent tangs. Surface finish damage. 649B H^t-I Assemble Figures 69 through Forward clutch apply plate (646) into the input clutch housing. • Index as shown. 649A Waved steel forward clutch plate (648) into the input clutch housing.
Page 655: Clutch Air Check
FORWARD CLUTCH 3-4 CLUTCH BACKING PLATE SELECTION INFORMATION CHART ALL MODELS QUANTITY REQUIRED PLATE TYPE THICKNESS ALL MODELS BACKING PLATE TRAVEL = STEPPED 5.60mm PLATE THICKNESS IDENTIFICATION APPLY PLATE (.220") 6.97mm - 7.07mm (.274" - .278") t FLAT STEEL 1.78mm CLUTCH PLATES 6.38mm - 6.48mm (.070")
Page 656 3-4 BACKING PLATE SELECTION BACKING PLATE "BACKING MODEL TRAVEL PLATE Use Backing Plate Which Gives Correct Travel DIM. I.D. 5.88mm - 5.68mm (.231 "-.224") 2.10mm - ,90mm 4.99mm - 4.76mm (.083" - .035") (.196" - .187") 4.10mm - 3.90mm (.161"- .154") HOUSING AND SHAFT ASSEMBLY, INPUT PLATE ASSEMBLY, 3RD AND 4TH CLUTCH PLATE, 3RD AND 4TH CLUTCH...
Page 657 SPRING A S M ., 3-4 CLUTCH BOOST (5) RETAINER AND RACE ASSEMBLY, SPRAG RING, OIL SEAL (SOLID) FORWARD SPRAG ASSEMBLY RETAINER AND CHECKBALL ASSEMBLY RETAINER RINGS, SPRAG ASSEMBLY HO USING A ND SHAFT ASSEMBLY, INPUT RACE, FORWARD CLUTCH (OUTER) SEAL, O-RING INPUT TO FORWARD HSG.
Page 658 J 23327-1 J 25018-A UNDER J 23327-1 605 HOUSING A N D DRUM ASSEMBLY, RH0174-4L60-E REVERSE INPUT CLUTCH 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: Reverse Input Clutch Backing Plate Selection
7. Backing plate (613). |h^h| Assemble • Chamfered side up Figures 78, 79,81,82 and 83 8. Retaining ring (614). 1. Inner and outer seals (608) on the piston. • Lips must face away from the hub as Reverse Input Clutch Backing Plate Selection shown.
Page 660: Reverse Input And Input Clutches
612A 612B CORRECTLY HOUSING AND DRUM ASSEMBLY, REVERSE INPUT CLUTCH PISTON ASM., REVERSE INPUT CLUTCH SPRING ASM., REVERSE INPUT CLUTCH 615 BEARING ASSEMBLY, STATOR SHAFT / RING, REVERSE INPUT CLUTCH SPRING RETAINER SELECTIVE WASHER PLATE, REVERSE INPUT CLUTCH (BELLEVILLE) 616 WASHER, THRUST (SELECTIVE) 612A PLATE ASM., REVERSE INPUT CLUTCH (FIBER) 621 HOUSING AND SHAFT ASSEMBLY, INPUT 612B PLATE, REVERSE INPUT CLUTCH (STEEL)
Page 661: Oil Pump Body
f ^ | Assemble Figure 87 • Reverse input and input clutch assembly into the transmission case. A. Index the 3-4 clutch plates with the input internal gear. B. M ake sure all clutch plates are fully engaged. C. When properly assembled, the reverse input clutch housing will be located just below the case oil pump face.
Page 662 Pump cover (215) and pump body (200) for: From the pump pocket: Worn or damaged bushings (see Bushing • Pump guide rings (210) Replacement Procedure). • Pump vanes (213) Foreign material or debris. • Pump rotor (212) Porosity. • Pump guide (211) Scored or irregular mating faces.
Page 663 DESCRIPTION 200 BODY, PUMP 201 RING, OIL SEAL (SLIDE TO WEAR PLATE) 202 SEAL, O-RING (SLIDE SEAL BACK-UP) 203 SLIDE, PUMP 204 SPRING, PIVOT PIN 205 PIN, PIVOT SLIDE 206 SPRING, PUMP SLIDE (OUTER) 207 SPRING, PUMP SLIDE (INNER) 208 SUPPORT, PUMP SLIDE SEAL 209 SEAL, PUMP SLIDE 210 RING, PUMP VANE 211 GUIDE, ROTOR...
Page 664 8. Vanes (213). |^jH| Measure 9. Vane guide ring (210). Figure 90 10. Pump slide spring (206 and 207). • Oil pump rotor (212) thickness. 11. Oil seal assembly (2), retainer (94). • Oil pump slide (203) thickness. • Use J 25016. f ? l Important •...
Page 665 8. Reverse boost valve (219) into the reverse boost valve sleeve. • Small end of the valve first • R etain w ith T ransjel™ J 36850 or equivalent. 9. Reverse boost valve sleeve (220) into the pressure regulator bore. 10.
Page 666 f f ] Important • Rotate the transmission to a horizontal position. If the transmission is assembled properly the turbine shaft should turn by hand. If not identify and correct the misassembly now. Transmission End Play Check Figures 99 through 103 and 106,107 and 108 Tools Required: J 24773-A End Play Checking Fixture J 25022 End Play Checking Fixture Adaptor...
Page 667 TRANSMISSION END PLAY WASHER SELECTION CHART WASHER THICKNESS I.D. 1.87 - 1.97 mm (.074" - .078") 2.04 - 2.14 mm (.080" - .084") 2.21 - 2.31 mm (.087" - .091") 2.38 - 2.48 mm (.094" - .098”) 2.55 - 2.65 mm (.100"...
Page 668 | ^ | Assemble [ y | Inspect Figure 103 Figures 105, 106 and 107 • O-ring seal (618) into the groove in the end of • The 1-2 accumulator cover and pin assembly the turbine shaft. (57) for: Porosity or damage. | V | Important Scored piston wall.
Page 669 1993 1-2 ACCUMULATOR 3-4 ACCUMULATOR MODELS SPRING COLOR SPRING COLOR ORANGE, LT. GREEN, CHD, CJD, KCD VIOLET WHITE OR PLAIN CAD, CBD, KAD, ORANGE, LT. GREEN, DK. GREEN MJD, MND WHITE OR PLAIN ORANGE, LT. GREEN, CCD, CFD, KBD WHITE OR PLAIN SHD, TLD DK.
Page 670 6. Spacer plate and gaskets onto the case. 12. Bore plug retainer (395), bore plug (381) and 3-2 control valve train (391 - 393). | V j Important 13. 3-2 downshift bore plug retainer (395), bore plug (381) and valve train (389 - 390). •...
Page 671 3. Wiring harness (66), manual spring assembly (63), pressure switch assembly (69) and all remaining valve body bolts. NOTICE: Torque valve body bolts in a spiral pattern starting from the center. If bolts are torqued at random, valve bores may be distorted and inhibit valve operation.
Page 673 VALVE, M A N U A L VALVE ASSEMBLY, CONTROL BODY SEAL, FORWARD ACCUMULATOR OIL PISTON, FORWARD ACCUMULATOR PIN, FORWARD ACCUMULATOR SPRING, FORWARD ACCUMULATOR VALVE, FORWARD ABUSE SPRING, FORWARD ABUSE VALVE PLUG, BORE PIN, COILED SPRING VALVE, LOW OVERRUN SPRING, LOW OVERRUN VALVE COVER, FORWARD ACCUMULATOR BOLT, FORWARD ACCUMULATOR COVER SPRING, 1-2 SHIFT VALVE...
Page 674 63 SPRING ASSEMBLY, M A N U A L DETENT 88 LEVER, INSIDE DETENT 89 LINK, M A N U A L VALVE RH0110-4L60-E 340 VALVE, M A N U A L Figure 112 Manual Valve Link 2 3RD ACCUM ULATOR REVERSE INPUT 4 3-4 CLUTCH EXHAUST 5 OVERRUN CLUTCH FEED...
Page 675 Figure 115 Case, Pan and Filter Assembly Figure 114 Outside Electrical Connector 2-4 Servo Assembly Install or Connect Figures 116 through 120 Figure 115 Tools Required: 1. Filter seal (71) onto the oil filter. J 33037 Band Apply Pin Tool •...
Page 676 • I Inspect ||j|| Measure • Pistons for: F ig u re 117 Porosity or damage. 1. Measure piston (17) dimension *A. Ring groove damage. 2. Measure housing (20) dimension **B. 3. Check model application. 2ND APPLY PISTON AND HOUSING APPLICATION HOUSING PISTON MODEL...
Page 677 | ^ | Assemble Figures 118 through 120 1. Cushion spring (16) into the 2nd apply piston (17). 2. Cushion spring retainer (15) on the cushion spring. 3. Install J 22269-01. A. Compress the retainer past the snap ring groove in the 2nd apply piston. B.
Page 678: Speed Sensor And Case Extension
Seal ring (37) on the case extension. Case extension (31) and bolts (32). • Position extension so the speed sensor bore is on the gear selector lever side of the case. Tighten • Torque to 35 N*m (26 lb. ft.). Remove case extension oil seal (34).
Page 679: Torque Converter Assembly
Figure 123 Case Extension and Seal Figure 125 Case Extension Oil Seal Assem bly Torque Converter Assembly Figure 126 Tool Required: J 35138 Torque C o n v erter End Play Checking Tool [j? ] Inspect The torque converter assembly must be replaced for any of the following conditions: •...
Page 680 The Torque C onverter s h o u ld n o t be replaced If: • The fluid has an odor, discoloration or no evidence of metal or clutch plate material. A. Drain out as much fluid as possible. B. Replace the oil filter and pan gasket. C.
Page 681 HYDRA-MATIC 4L60-E C A S E R E V E R S E INPUT C L U T C H O V E R R U N F O R W A R D F O R W A R D INPUT L O A N D L O R O L L E R...
Page 683 ILL. ILL. DESCRIPTION DESCRIPTION 1 TORQUE CONVERTER ASSEMBLY 48 PLATE, VALVE BODY SPACER 2 BOLT, PUM P TO CASE 49 SCREEN, SHIFT SOLENOIDS 3 O-RING, PUM P TO CASE BOLT 50 SCREEN, PRESSURE CONTROL SOLENOID 4 PUM P ASSEMBLY, OIL 51 SCREEN, 3-2 CONTROL SOLENOID 5 SEAL, OIL (PUM P TO CASE) 52 GASKET, SPACER PLATE TO VALVE BODY...
Page 684 622 623 626 627 628 632 631 645A 645B 638 639 649A 649B 654A 654B 671 672 682C 682D 682B 682A...
Page 685 ILL. ILL. DESCRIPTION DESCRIPTION SPRING A S M ., 3-4 CLUTCH BOOST (5) 654A PLATE ASSEMBLY, 3RD A N D 4TH CLUTCH (FIBER) WASHER, THRUST (PUM P TO DRUM) 654B PLATE, 3RD AND 4TH CLUTCH (STEEL) BAND ASSEMBLY, 2-4 PLATE, 3RD AND 4TH CLUTCH BACKING (SEL) BUSHING, REVERSE INPUT CL.
Page 687 VALVE, M A N U A L VALVE ASSEMBLY, CONTROL BODY SEAL, FORWARD ACCUMULATOR OIL PISTON, FORWARD ACCUMULATOR PIN, FORWARD ACCUMULATOR SPRING, FORWARD ACCUMULATOR VALVE, FORWARD ABUSE SPRING, FORWARD ABUSE VALVE PLUG, BORE PIN, COILED SPRING VALVE, LOW OVERRUN SPRING, LOW OVERRUN VALVE COVER, FORWARD ACCUMULATOR BOLT, FORWARD ACCUMULATOR COVER SPRING, 1-2 SHIFT VALVE...
Page 688 V A L V E S L O C A T E D IN T H E V A L V E B O D Y LO OVERRUN FORWARD ABUSE ACTUATOR FEED LIMIT ACCUM VALVE 1-2 SHIFT VALVE REV ABUSE 3-2 DOWNSHIFT 3-4 SHIFT VALVE 2-3 SHUTTLE VALVE...
Page 689 SPRINGS LOCATED IN THE PUMP SPRINGS LOCATED IN THE VALVE BODY PRESSURE CONV CL REGULATOR VALVE SHIFT...
Page 690 ILL. DESCRIPTION BODY, PUMP RING, OIL SEAL (SLIDE TO WEAR PLATE) SEAL, O-RING (SLIDE SEAL BACK-UP) 203 SLIDE, PUMP 204 SPRING, PIVOT PIN PIN, PIVOT SLIDE 206 SPRING, PUM P SLIDE (OUTER) SPRING, PUM P SLIDE (INNER) 208 SUPPORT, PUM P SLIDE SEAL 209 SEAL, PUM P SLIDE RING, PUMP VANE GUIDE, ROTOR...
Page 691 OUTER) 3 O-RING, PUMP TO CASE BOLT SEAL, O-RING (TURBINE SHAFT/ SELECTIVE 5 SEAL, OIL (PUMP TO CASE) WASHER) RING, OIL SEAL (2ND APPLY PISTON - OUTER) RING, OIL SEAL (SOLID) 19 RING, OIL SEAL (2ND APPLY PISTON - INNER) SEAL, O-RING INPUT TO FORWARD HSG.
Page 692 BUSHING, INPUT SUN GEAR (FRONT) B U S H IN G , CASE BUSHING, INPUT SUN GEAR (REAR) B U S H IN G , CASE EX TE N SIO N BEARING ASSEMBLY THRUST (INPUT CARRIER TO B U S H IN G , STATOR SHA FT (FRONT) REACTION SHAFT) B U S H IN G , STATOR SHAFT (REAR) BUSHING, REACTION CARRIER SHAFT (FRONT)
Page 693 TORQUE SPECIFICATIONS LOCATION QTY. SIZE TORQUE LOCATION QTY. SIZE TORQUE ACCUMULATOR 11 N-m PARK BRAKE 31 N -m COVER TO CASE (8 LB.-FT.) 1 .0 x 3 5 .0 BRACKET TO CASE (23 LB.-FT.) 1.25 X 20.0 ACCUMULATOR 11 N-m PUMP COVER TO 24 N-m COVER TO CASE...
Page 694 RH0213-4L60-E...
Page 695 J 8092 * * * * * J 34196-4 34196-5 J 23907 J 7004-1 J 8092 RH0214-4L60-E...
Page 696 J 8092 J 34196-4 J 8092 RH0215-4L60-E...
Page 697 SPECIAL TOOLS...
Page 698 SPECIAL TOOLS...
Page 699: Automatic Transmission
SECTION 7A-17B HYDRA-MATIC 4L80-E AUTOMATIC TRANSMISSION UNIT REPAIR RPO MT1 NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for the application. If the correct part number is not available, a fastener of equal size and strength (or stronger) may be used.
Page 700 TRANSMISSION DISASSEMBLY p 7 | Install or Connect 1. Holding fixture J 8763-02 and J 38655 onto NOTICE: It is not recommended to use air powered transmission. tools to disassemble or assemble transmissions/ transaxles. Improper bolt torques can contribute to NOTICE: Overtightening of tool could cause case transmission repair conditions and this information,...
Page 701 Figure 3 Removing Pan and Filter Assembly CONTROL VALVE ASSEMBLY 5. Three wiring clips (33), fluid level indicator stop (43), one bolt (36) using 10 mm socket, lube Figure 4 pipe (39), lube pipe retainer (37) and clamp (38). Remove or Disconnect 6.
Page 702 FRONT AND REAR SERVO Figures 5 and 6 Remove or Disconnect 1. Front servo piston assembly (55 through 60). 2. Six rear servo bolts (61) using 10 mm socket, cover (62) and gasket (63). 3. Rear servo/accumulator assembly (64 through 74).
Page 703 BAND APPLY PIN 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. Position J 38737 over the bore with the hex nut facing the parking pawl linkage.
Page 704 CUP, ORIFICE W/SEAIVPLUG-REAR LUBE (4WD) SEAL ASSEMBLY, REAR LUBE RING, SNAP SEAL RETAINER SEAL, EXTENSION TO CASE EXTENSION ASSEMBLY, CASE HELIX SEAL ASSEMBLY, CASE EXTENSION BOLT, HEX HD - M 10 X 1.5 X 30.0 SEAL, O-RING O UTPUT SHAFT RH0109-4L80-E Figure 10 Removing Case Extension Assembly PARKING LOCK PAWL AND ACTUATOR...
Page 705 PLUG, PARKING PAWL SHAFT HOLE SHAFT, M ANUAL SHAFT, PARKING LOCK PAWL PIN, M ANUAL SHAFT RETAINING PAWL, PARKING LOCK ACTUATOR ASSEMBLY, PARKING LOCK RETAINER, PARKING PAWL SHAFT LEVER AND PIN ASSEMBLY, INSIDE DETENT SPRING, PARKING PAWL RETURN NUT, HEX HEAD STUD, PARKING PAWL RETURN SPRING BRACKET, PARKING LOCK SEAL ASSEMBLY, M A N U A L SHIFT SHAFT...
Page 706 FRONT END PLAY CHECK 5. Remove tools. Figures 13 and 14 [ T | Important Tool Required: • During reassembly Front End Play Check must J 8001 Dial Indicator Set be repeated to verify accuracy of selective washer. | 9 | Important •...
Page 707 CASE ASSEMBLY, COMPLETE SHAFT & BUSHING ASSEMBLY, O UTPUT RHo i i Figure 15 Checking Rear Unit End Play IDENTIFICATION NOTCH THICKNESS R H 0 1 1 6 -4 L 8 0 -E (INCH) AND/OR NUMERAL Figure 17 Removing Pump Assem bly .074 - .078 NONE .082 - .086...
Page 708 OVERDRIVE UNIT AND FOURTH CLUTCH ASSEMBLY Figures and 20 Remove or Disconnect 1. Overdrive 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.
Page 709 FORWARD CLUTCH ASSEMBLY DIRECT CLUTCH ASSEMBLY Figure 22 Figure 21 Tool Required: Tool Required: J 38358-A Forw ard C lutch A ssem bly J 38733 Direct Clutch Assembly Remover Remover and Installer Remove or Disconnect Remove or Disconnect 1. Direct clutch housing assembly (623). 1.
Page 710 | Remove or Disconnect 1. Center support bolt (25), using 3/8"-12 pt. TORX® head socket. NOTICE: Discard bolt, 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.
Page 711 Figure 26 Removing Rear Band and Selective Thrust Washer INSPECT, CLEAN AND REPAIR SUBASSEMBLIES The assembly of some components will require use of an assembly 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.
Page 712 PARKING LOCK PAWL AND ACTUATOR TRANSMISSION CASE ASSEMBLY F ig u re 2 8 Figure [ y | Inspect |[ y | Inspect 1. Case (7) for: 1. Parking pawl (703) for: • Cracks. • Cracks. • Porosity. • Burrs. •...
Page 713 CASE ASSEMBLY, COMPLETE EXTENSION ASSEMBLY, CASE CONNECTOR, INVERTED FLARED TUBE HELIX SEAL ASSEMBLY, CASE EXTENSION PIPE, VENT BOLT, HEX HD - M10 X 1.5 X 30.0 SCREW, NAMEPLATE SCREEN, PWM SOLENOID NAMEPLATE BUSHING, CASE EXTENSION CUP, ORIFICE W/SEAL/PLUG-REAR LUBE (4WD) BUSHING, TRANSMISSION CASE SEAL ASSEMBLY, REAR LUBE PLUG, DIRECT OIL GAL - .25 DIA.
Page 714 Rear internal gear (666) for: • Stripped splines. • Damaged teeth. • Wear. Output shaft (671) for: • Stripped splines. • Damaged teeth. • Cracks. • Damaged bushing. Output carrier assembly (661) for: • Wear. • Damaged lugs. • Pinion gear damage. •...
Page 715 PLUG, ORIFICE CENTER SUPPORT RING, SNAP INTERMEDIATE CLUTCH SPRING AND RETAINER ASM., INTERMEDIATE CLUTCH PISTON, INTERMEDIATE CLUTCH SEAL, INTERMEDIATE CLUTCH (INNER) SEAL, INTERMEDIATE CLUTCH (OUTER) RING, OIL SEAL SUPPORT AND RACE ASSEMBLY, CENTER WASHER, THRUST SUPPORT/REACTION DRUM SPACER, SUPPORT TO CASE ROLLER CLUTCH ASSEMBLY RING, REACTION DRUM SPACER RACE, THRUST BEARING TO CENTER SUPPORT...
Page 716 Figure 31 Measuring Pinion End Play REACTION DRUM AND CARRIER ASSEMBLY CENTER SUPPORT ASSEMBLY Figures 33 through 36 Figures 30 and 32 Tools Required: |I? | Inspect J 6116-01 Rear Gear Assembly Holding 1. Reaction drum and carrier assembly (651) for: Fixture •...
Page 717 | jy | Inspect Figures 33 and 34 1. Intermediate clutch piston (636) for: • Cracks. • Damage. 2. Springs (635) for: • Collapsed coils. • Distortion. 3. Cup plug (530), orifice is open approximately 0.51 mm (0.020 inch). |h|h| Assemble Figures 33,35 and 36 1.
Page 718 GEAR UNIT ASSEMBLY Figures 37 through 40 |5 1 Assemble 1. Main shaft (662) into rear internal gear (666). 2. Snap ring (670) onto main shaft (662). 3. Inner race (648), lip up, thrust bearing (647) and outer race (669), lip down, onto rear internal gear hub (666), retain with TRANSJEL™...
Page 719 633 RING, SNAP CENTER SUPPORT/CASE 640 SUPPORT AND RACE ASSEMBLY, CENTER WASHER, THRUST SUPPORT/REACTION DRUM SPACER, SUPPORT TO CASE ROLLER CLUTCH ASSEMBLY RING, REACTION DRUM SPACER RACE, THRUST BEARING TO CENTER SUPPORT 649 SHAFT ASSEMBLY, SUN GEAR 651 DRUM AND CARRIER ASSEMBLY, REACTION RH0137 660 RING, OUTPUT SPEED SENSOR Figure 39 Installing Spacer Ring and Roller Clutch...
Page 720 16. Needle thrust bearing assembly (647), on long Important lipped race (648). • If spiral snap ring (627) is removed, a new snap 17. With center support assembly (640) on bench, ring (627) must be usea. attach race (646) onto rear hub with TRANSJEL™ J 36850 or equivalent.
Page 721 | y | Inspect Figure 42 1. Sprag assembly (624) for: • Damaged sprags or cage. • Distorted springs. 2. Intermediate clutch outer race (625) for: • Smoothness of inside diameter. • Spline damage. 3. Clutch housing (623) for: • Cracks. •...
Page 722 3. Intermediate clutch retainer (626). 4. Place snap ring (627) over direct clutch hub, in stall 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).
Page 723 HYDRA-MATIC 4L80-E CLUTCH PLATE APPLICATION CHART DIRECT CLUTCH NO. OF NO. OF NO. OF PISTON DISHED COMPOSITION TRAVEL FLAT STEEL M O D ELS PLATES PLATES PLATES CHECK 2.03MM 2.32MM 1.37MM THICKNESS (.0915”) (.054") (.080") 3.07-4.27MM (0.121-0.186") ALL MODELS RH0143-4L80-E Figure 47 Direct Clutch Plate Chart DIRECT CLUTCH FLUID PASSAGE REVERSE CLUTCH FLUID PASSAGE...
Page 724 INSPECT CHECKBALL HOUSING ASSEMBLY, FORWARD CLUTCH SOME SPRING AND RETAINER ASSEMBLY MODELS RH0146-4L80-E RING, SNAP Figure 50 Removing Forward Clutch Piston Release Springs | g | Clean • All components. | P | Inspect F ig u re 5 1 1.
Page 725 4. Piston (606) for: [51 Assemble • Cracks. Fig u re 5. Seals (603, 604 and 605) for: 1. Dished clutch plate (609). Inside dish down. • Cuts. 2. Steel plates (610) .0775" thickness and plate • Tears. assemblies (611). Starting with steel plate first. •...
Page 726 HOUSING ASSEMBLY, FORWARD CLUTCH SPRING AND RETAINER ASSEMBLY RH0146-4L80-E RING, SNAP Figure 53 Installing Forward Clutch Piston Release Springs HYDRA-MATIC 4L80-E CLUTCH PLATE APPLICATION CHART FORWARD CLUTCH NO. OF NO. OF NO. OF NO. OF PISTON FLAT S T EE L DISH ED CO M PO S IT IO N W AV ED S T EE L...
Page 727 FOURTH CLUTCH ASSEMBLY 10. Install snap ring (533). 11. Remove tools. Figures 56 through 59 12. Turn assembly over and install 4 of each clutch Tools Required: plates (525 and 526) alternating steel and fiber J 38731 Fourth Clutch Seal Protectors and plates.
Page 728 J 38731-3 J 38731-2 J 38731-1 L V\V\ PISTON, 4TH CLUTCH HOUSING, 4TH CLUTCH RH0152-4L80-E Figure 57 Assembling Fourth Clutch Assembly 4TH CLUTCH TRAVEL CHECK Inspect F ig u re 5 8 1. Place 4th clutch assembly (529) with the spring and retainer assembly (532) facing up.
Page 729 502 SHAFT, TURBINE 504 HOUSING ASSEMBLY, OVERRUN CLUTCH 514 CARRIER ASSEMBLY, OVERDRIVE 522 RING, SNAP (TURBINE SHAFT/CARRIER) _____________________________________________________ RH0154-4L80-E Figure 59 Overdrive Unit Assembly OVERRUN CLUTCH ASSEMBLY PISTON ASSEMBLY, OVERRUN CLUTCH SPRING AND RETAINER ASSEMBLY F ig u re s 6 0 th ro u g h 6 3 RING, SNAP RETAINER Tools Required: PLATE, OVERRUN CLUTCH...
Page 730 3. Piston (505) for: • Cracks. • Cut seal. 4. Housing (504) for: • Wear. • Open lube holes. • Damaged thrust faces. FE| Assemble Figures 61 and 63 1. Piston seal protector J 38729 into housing (504). A GAGE, FEELER 2.
Page 731 OVERDRIVE CARRIER ASSEMBLY Figure 64 l^p l Measure 1. Set dial indicator on pinion (518) to zero. Manually raise pinion. 2. End play is 0.229 to 0.610 mm (0.009 to 0.024 inch). |<$»| Disassemble Figures 65 and 66 1. Snap ring (521) and retainer pinion pin (520). NOTE: Mark top of pinion gears and location on carrier of pins to be reinstalled in original locations.
Page 732 [ y | Inspect Figure 67 1. Seals (501 and 503). 2. Checkball (534) on end of shaft (502). 3. Splines on shaft (502). Disassemble • Turbine shaft seals (501 and 503). Assemble Figures 68 and 69 1. Place seal installer J 38736 onto shaft. 2.
Page 733 RING, OIL SEAL (TURBINE SHAFT/STATOR HSG.) SHAFT, TURBINE RING, OIL SEAL (TURBINE SHAFT/FORWARD HSG.) HOUSING ASSEMBLY, OVERRUN CLUTCH PISTON ASSEMBLY, OVERRUN CLUTCH SPRING AND RETAINER ASSEMBLY RING, SNAP RETAINER PLATE, OVERRUN CLUTCH PLATE ASSEMBLY, OVERRUN CLUTCH PLATE, OVERRUN CLUTCH BACKING RING, SNAP ROLLER CLUTCH ASSEMBLY, OVERDRIVE ©...
Page 734 PUMP ASSEMBLY Pump Cover Figure 70 F ig u re 70 Tools Required: [ y | Inspect J 23129 Seal Remover 1. Pump gear face for: J 6125-IB Slide Hammer • Wear. • Scoring. Disassemble 2. Stator shaft splines for: 1.
Page 735 5 SEAL, OIL PUMP TO CASE BOLT, M 8 X 1.25 X 40 (5) RING, SNAP HELIX SEAL ASSEMBLY, PUMP BODY VALVE, TCC BUSHING, PUMP BODY SPRING, TCC VALVE BODY, OIL PUMP PLUG, TCC VALVE BORE GEAR, PUMP DRIVEN RING, RETAINER (REV. BOOST VALVE BUSHING) GEAR, PUMP DRIVE BUSHING, REVERSE BOOST VALVE COVER, PUMP...
Page 736 Pressure regulator valve (231) into bore. Bore plug (232) and valve straight pin (211). Springs (230 and 238) and retainer (229) in pressure regulator bore. Regulator boost valve (228) into boost valve bushing (227), stem out against spring (230). Snap ring (226). Converter limit valve (214), spring (213), plug (212) and pin (211).
Page 737 -A-l Assemble 1. New seal (57) onto piston (58). J 25025-1 2. Front servo piston spring (60) and retainer (59). 3. Ring (56), piston pin (55) and piston (57). REAR SERVO ACCUMULATOR Figure 76 Disassemble Retaining clip (64) from rear band apply pin (73) and inspect.
Page 738 c “: —.. ~ 7 tr c _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _ a _ _ _ _ _ _ _ _ _ _ n y u i c / v r r u n i o c i v u AAaaeni ui y BOLT, REAR SERVO COVER COVER, REAR SERVO GASKET, REAR SERVO COVER...
Page 739 CONTROL VALVE ASSEMBLY/ACCUMULATOR Assemble HOUSING • Accumulator housing assembly components Figures through 80 exactly as shown. Notice the positions of the NOTICE: valve and pistons. The use of a honing stone, fine sandpaper or crocus cloth is not recommended for servicing CONTROL VALVE ASSEMBLY stuck valves.
Page 740 H I! If _____ 45 \ BODY ASSEMBLY, CONTROL VALVE GASKET, VALVE BODY TO SPACER PLATE PLATE, VALVE BODY SPACER GASKET, ACCUMULATOR HSG. TO SPACER PLATE GASKET, SPACER PLATE TO CASE 51 HOUSING, ACCUMULATOR 53 BOLT, ACCUM. HOUSING TO VALVE BODY RH0171-4L80-E Figure 77 Control Valve Assem bly/Accum ulator Housing...
Page 741 PLUG, SHIFT SOLENOID FEED FILTER BODY, CONTROL VALVE FILTER, SHIFT SOLENOID FEED SCREEN FILTER, PRESSURE CONTROL SOL FEED SLEEVE, LO/REVERSE CHECKBALL PIN, COILED SPRING VALVE, MANUAL PLUG, CHECKBALL PRESSURE CONTROL SOLENOID BALL, .375 DIA. CLAMP, PRESSURE CONTROL SOL. RETAINING BUSHING, 3RD/REVERSE CHECKBALL CLIP, PWM SOLENOID RETAINING SEAL, O-RING SOLENOID ASSEMBLY, PWM...
Page 742 Assemble • Control valve assembly components exactly as shown. Notice the position of the valve lands GUIDE and bushing passages. Control Valve Assembly and Accumulator Housing F ig u re s a n d 8 0 Tool Required: Guide Pin J 25025-5 Assemble 1.
Page 743 3. Insert the T-handle forcing screw and hand tighten. NOTE: This will allow the spline of J 39195 to grip the spline of the stator for proper measurement. 4. Position J 8001 Dial Indicator as shown. check end play, push down on J 39195 handles to bottom stator.
Page 744 10. Roll pin (709). TRANSMISSION REASSEMBLY 11. Parking lock bracket (713) with two bolts (714). PARKING LOCK PAWL AND ACTUATOR Tighten ASSEMBLY • Bolts (714) to 24 N«m (18 lb. ft.) Install or Connect Figure 84 REAR BAND AND SELECTIVE THRUST NOTICE: Do not apply excessive force, prying, or WASHER...
Page 745 2. J 38868 to main shaft (662). 3. With transmission in a vertical position, 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.
Page 746 Install or Connect Figure 88 1. Locate J 23093 into the center support (640) direct 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.
Page 747 6. Align clutch plates (631 and 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.
Page 748 Figure 93 Installing Direct Clutch Assem bly BAND ASSEMBLY, FRONT RING, SNAP (INTERMEDIATE CLUTCH RETAINER) PLATE, INTERMEDIATE CLUTCH BACKING PLATE ASSEMBLY, INTERMEDIATE CLUTCH PLATE, INTERMEDIATE CLUTCH RH0181-4L80-E Figure 92 Installing Intermediate Clutch Plates and Front Band...
Page 749 FOURTH CLUTCH PLATES |hhh| Install or Connect Figures 97 and 98 1. Fourth clutch plates (525 and 526) starting with steel first into 4th clutch housing around overdrive carrier assembly. NOTE: Install steel plates with the narrow tang (“V” notch) at the 1 o’clock position in the housing. 2.
Page 750 J 37789 Figure 98 Installing Fourth Clutch Snap Ring PUMP ASSEMBLY Figures 99 and 100 Install or Connect 1. Gasket (6) on transmission case (7) using guide pins J 25025-1 at 12 o ’clock and 5 o’clock position. 2. Oil pump assembly (4) in transmission case (7) using J 37789, bolt holes closest together are towards channel face.
Page 751 3. Index J 8001 against end of turbine shaft. • Set dial to “0”. 4. Pull out turbine shaft (502) while holding output carrier up. • Increase lifting force to approximately 20 lbs. • Proper end play is 0.102 to 0.559 mm (0.004 to 0.022 inch).
Page 752 BAND APPLY PIN CHECK Figures 105,106 and 107 Tools Required: J 21370-10 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.
Page 753 PIN LENGTH I.D. 3.468"-3.474" 3.440"-3.446" 3.412"-3.418" ROTATE TO SIDE C 3.384"-3.390" 3.356"-3.362" ROTATE TO SIDE B 3.328"-3.334" 3.300"-3.306" RH0108-4L80-E Figure 107 Servo Pin Selection REAR SERVO ACCUMULATOR Figure 108 Install or Connect 1. Rear accumulator spring (74) in case bore. 2.
Page 754 6. Three wiring clips (33), fluid indicator stop (43) CONTROL VALVE ASSEMBLY and lube pipe clamp (38). INSTALLING CONTROL VALVE ASSEMBLY AND 7. Twenty-one bolts (35). Using 10 mm socket. ACCUMULATOR ASSEMBLY 8. Six bolts (76) using 8 mm socket into transmission fluid pressure switch assembly (40).
Page 755 PAN AND FILTER ASSEMBLY Figure 112 Install or Connect 1. 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&...
Page 756 33 CLAMP, ELECTRICAL CABLE 38 CLAMP, LUBE 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 SOLENOID ASSEMBLY, PWM RH0192-4L80-E...
Page 757 CUP, ORIFICE W/SEAL/PLUG-REAR LUBE (4WD) SEAL ASSEMBLY, REAR LUBE RING, SNAP SEAL RETAINER SEAL, EXTENSION TO CASE EXTENSION ASSEMBLY, CASE HELIX SEAL ASSEMBLY, CASE EXTENSION BOLT, HEX HD - M 1 0 X 1 .5 X 3 0 .0 675 SEAL, O-RING OUTPUT SHAFT RH0109-4L80-E Figure 113 Installing Case Extension Assem bly SPEED SENSOR ASSEMBLIES...
Page 758 RH0194-4L80-E...
Page 759 TORQUE CONVERTER ASSEMBLY BODY ASSEMBLY, CONTROL VALVE SEAL, O-RING (TURBINE SHAFT/TURBINE HUB) GASKET, VALVE BODY TO SPACER PLATE BOLT AND SEAL ASSEMBLY, PUMP TO CASE PLATE, VALVE BODY SPACER PUMP ASSEMBLY, COMPLETE GASKET, ACCUMULATOR HSG. TO SPACER PLATE SEAL, OIL PUMP TO CASE GASKET, SPACER PLATE TO CASE GASKET, PUMP COVER TO CASE SPRING, 4TH CLUTCH ACCUM.
Page 760 SEAL, OIL PUMP TO CASE BOLT, M8 X 1.25 X 40 (5) HELIX SEAL ASSEMBLY, PUMP BODY RING, SNAP VALVE, TCC BUSHING, PUMP BODY SPRING, TCC VALVE BODY, OIL PUMP GEAR, PUMP DRIVEN PLUG, TCC VALVE BORE RING, RETAINER (REV. BOOST VALVE BUSHING) GEAR, PUMP DRIVE BUSHING, REVERSE BOOST VALVE COVER, PUMP...
Page 761 PLUG, SHIFT SOLENOID FEED FILTER BODY, CONTROL VALVE FILTER, SHIFT SOLENOID FEED SCREEN FILTER, PRESSURE CONTROL SOL FEED SLEEVE, LO/REVERSE CHECKBALL PIN, COILED SPRING VALVE, MANUAL PLUG, CHECKBALL PRESSURE CONTROL SOLENOID BALL, .375 DIA. CLAMP, PRESSURE CONTROL SOL. RETAINING BUSHING, 3RD/REVERSE CHECKBALL CLIP, PWM SOLENOID RETAINING SEAL, O-RING VALVE, 3-4 SHIFT...
Page 762 SEAL, (1.615) SQUARE CUT SPRING, 4TH CLUTCH ACCUM. PISTON SPRING, 3RD CLUTCH ACCUM. PISTON PISTON, 3RD CLUTCH ACCUMULATOR HOUSING, ACCUMULATOR SEAL, (.859) SQUARE CUT BOLT, ACCUM. HOUSING TO VALVE BODY PISTON, 4TH CLUTCH ACCUMULATOR PIN, 4TH CLUTCH ACCUMULATOR PISTON RING, SNAP RH0196-4L80-E...
Page 763 RING, OIL SEAL (TURBINE SHAFT/STATOR HSG.) SHAFT, TURBINE RING, OIL SEAL (TURBINE SHAFT/FORWARD HSG.) HOUSING ASSEMBLY, OVERRUN CLUTCH PISTON ASSEMBLY, OVERRUN CLUTCH SPRING AND RETAINER ASSEMBLY RING, SNAP RETAINER PLATE, OVERRUN CLUTCH PLATE ASSEMBLY, OVERRUN CLUTCH PLATE, OVERRUN CLUTCH BACKING RING, SNAP ROLLER CLUTCH ASSEMBLY, OVERDRIVE BEARING ASSEMBLY, THRUST CARRIER/ OVERRUN...
Page 765 PLUG, ORIFICE CENTER SUPPORT SPACER, SUPPORT TO CASE BALL, CHECK ROLLER CLUTCH ASSEMBLY BEARING ASM., THRUST CARRIER/FORWARD CLUTCH RING, REACTION DRUM SPACER HOUSING ASSEMBLY, FORWARD CLUTCH RACE, THRUST BEARING TO CENTER SUPPORT SEAL, CLUTCH (CENTER) BEARING, NEEDLE THRUST SEAL, CLUTCH (OUTER) RACE, THRUST BEARING SEAL, CLUTCH (INNER) SHAFT ASSEMBLY, SUN GEAR...
Page 766 SHAFT, MANUAL PLUG, PARKING PAWL SHAFT HOLE PIN, MANUAL SHAFT RETAINING SHAFT, PARKING LOCK PAWL PAWL, PARKING LOCK ACTUATOR ASSEMBLY, PARKING LOCK LEVER AND PIN ASSEMBLY, INSIDE DETENT RETAINER, PARKING PAWL SHAFT NUT, HEX HEAD SPRING, PARKING PAWL RETURN BRACKET, PARKING LOCK STUD, PARKING PAWL RETURN SPRING BOLT, HEX HEAD - M6 X 1.25 X 20.0 SEAL ASSEMBLY, MANUAL SHIFT SHAFT...
Page 767 BUSHING, CASE EXTENSION BEARING ASM., THRUST CARRIER/FORWARD CLUTCH BUSHING, TRANSMISSION CASE ROLLER CLUTCH ASSEMBLY BUSHING, PUMP BODY BEARING, NEEDLE THRUST BUSHING, STATOR SHAFT (FRONT) BEARING, NEEDLE THRUST RR INTERNAL GEAR BUSHING, STATOR SHAFT (REAR) BUSHING, SUN GEAR SHAFT ROLLER CLUTCH ASSEMBLY, OVERDRIVE BUSHING, OUTPUT SHAFT BEARING ASSEMBLY, THRUST CARRIER/ OVERRUN CLUTCH BUSHING...
Page 768 SOME MODELS SEAL, O-RING (TURBINE SHAFT/TURBINE HUB) SEAL, OIL PUMP TO CASE SEAL ASSEMBLY, REAR LUBE SEAL, EXTENSION TO CASE HELIX 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...
Page 769 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS FASTENER APPLICATION ASSEMBLY TORQUE RECHECK TORQUE LB.-FT. LB.-IN. LB.-FT LB.-IN. SOLENOID TO VALVE BODY SCREW .......... — 5 MIN. — 44 MIN. CONTROL VALVE ASSEMBLY TO CASE SCREW ..... 9 MIN. 71 MIN. — — OIL TEST HOLE P L U G ..............8 MIN.
Page 770 SPECIAL TOOLS...
Page 771 SPECIAL TOOLS (CONT.)
Page 773 SECTION 7B1 NEW VENTURE GEAR 3500 (5LM60) MANUAL TRANSMISSION N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a lw a y s r e in s t a l l th e m a t th e s a m e lo c a t io n f r o m w h ic h t h e y w e r e r e m o v e d .
Page 774 DISASSEMBLY J 8763-21 Balance Bracket for C-Clamp TRANSM ISSIO N DISASSEMBLY J 36824 Transmission Adapters J 36509 Detent Sprint Plug Remover Disassemble (Figures 1 through 15) J 23907 Slide Hammer J 36825 4WD Output Shaft Oil Seal Remover Tool Required: J 3289-20 Base Holding Fixture (4WD models only) J 8763-02 Holding Fixture C-Clamp...
Page 777 1 SHAFT, INPUT 29 RING, SNAP (SELECTIVE) 2 RING, SYNCHRONIZER 30 BEARING ASSEMBLY, 5TH SPEED GEAR NEEDLE 3 BEARING, PILOT 31 GEAR ASSEMBLY. 5TH SPEED 4 SHAFT ASSEMBLY, MAIN <2WD) 5 SHAFT ASSEMBLY, MAIN (4WD) 32 SNAP RING 33 BEARING ASSEMBLY, OUTPUT SHAFT 6 RING, SNAP (SELECTIVE) 7 SYNCHRONIZER ASSEMBLY, 3-4 43 RING, SNAP...
Page 778 204. BOLT, 8.5 N-m (75 LBS. IN.) 205. RETAINER ASSEMBLY, INPUT J 2 3 9 0 7 SHAFT BEARING 210. RING, SNAP 3707r5194 Figure 9— Input Shaft Bearing Retainer 2 4 3 P L U N G E R , S H IF T S H A F T D E T E N T 2 4 4 S P R IN G , S H IF T S H A F T D E T E N T P L U N G E R 7.
Page 779 J 3289-20 J 36515 3707r5174 Figure 11—Removing and Installing Special Tools • Drive shift socket pin down using a 5-mm (3/16-inch) punch. • Pin will fall into the case. N O T IC E : E x c e s s iv e f o r c e w ill “p e e n ” t h e s h i f t s h a f t a n d d a m a g e t h e r e a r h o u s in g s h i f t s h a f t b e a r in g (3 0 9 ) c a u s in g i n c r e a s e d s h i f t e ffo r t.
Page 780 27. Output shaft bearing snap ring (43) (4WD only). 28. Tap housing with a rubber mallet and remove rear housing from assembly (figures 12 and 13). 29. Output shaft bearing retainer (302) (2WD models only) (figure 12). 30. Shift forks (100 and 101) (figure 14). 31.
Page 781 J 36515-15 J 36515 4. S H A F T A S S E M B L Y , MAIN (2WD) 5. S H A F T A S S E M B L Y , MAI N (4WD) 33. B E A R I N G A S S E M B L Y , O U T P U T S H A F T 43.
Page 782 J 8105 -J 21427-01 SHAFT ASSEMBLY, MAIN (2WD) 43 RING, SNAP 3707r5127 45 ROTOR, SPEED SENSOR Figure 15— Removing 2WD Speed Sensor Rotor SYNCHRO NIZER DISASSEMBLY Disassemble (Figure 22) ❖ 1. Place first-second, third-fourth, and fifth speed syn chronizers in separate shop towels. Wrap assem blies and press against inner hub.
Page 783 15 COLLAR 16 SPACERS 17 BEARING ASSEMBLY, SPEED GEAR NEEDLE 2 RING, SYNCHRONIZER 18 GEAR ASSEMBLY, 2ND SPEED 17 BEARING ASSEMBLY, SPEED GEAR NEEDLE 23 SHAFT. OUTPUT (2WD) 19 SYNCHRONIZER ASSEMBLY, 1 -2 24 SHAFT, OUTPUT (4WD) 22 GEAR, 1 ST SPEED 23 SHAFT, OUTPUT (2WD) 3707r5129 24 SHAFT, OUTPUT (4WD)
Page 784 23 SHAFT, OUTPUT (2WD) 2 RING, SYNCHRONIZER 24 SHAFT, OUTPUT (4WD) 17 BEARING ASSEMBLY, SPEED GEAR NEEDLE 30 BEARING ASSEMBLY, 5TH SPEED 23 SHAFT, OUTPUT (2WDI GEAR NEEDLE (MG5) 24 SHAFT, OUTPUT (4WDI 31 GEAR ASSEMBLY, 5TH SPEED (MG5) 25 GEAR ASSEMBLY, REVERSE SPEED 26 SYNCHRONIZER ASSEMBLY, 5TH-REVERSE (MG5) 29 RING, SNAP 3707r5131...
Page 786 200. H O U S IN G , FRO NT 228. B EA R IN G , S H IF T SH A FT FRO NT H O U S IN G J 23907 V IE W A V IE W B 8 SLEEVE, S Y N C H R O N I Z E R 9 BALL, S Y N C H R O N I Z E R D E T E N T 10 SPRING, S Y N C H R O N I Z E R D E T E N T...
Page 787 REAR HOUSING DISASSEMBLY Disassemble (Figures 28, 29, and 30) ❖ Tools Required: Hydraulic Press J 23907 Slide Hammer with Pilot Bearing Puller J 26941 2WD Output Shaft Oil Seal Remover (2WD models only) 1. Rear housing shift shaft bearing (309), using J 23907 with pilot bearing puller (figure 28).
Page 788 3 0 7 3 3 B E A R IN G A S S E M B L Y , O U T P U T S H A F T 2 0 2 R A C E , C O U N T E R S H A F T B E A R IN G 3 0 0 H O U S IN G , R E A R (2 W D ) H O U S IN G , R E A R (4 W D ) 3 0 3 R E T A IN E R , O U T P U T S H A F T B E A R IN G (4 W D )
Page 789 3. Synchronizer sleeves for: 3. Bearings (35) for roughness of rotation, burred, or • A sliding fit on the synchronizer hubs and for pitted condition. Replace if these conditions exist. the hubs to have a force fit on the mainshaft 4.
Page 790 100. FORK, FIFTH AND REVERSE SHIFT 108. SHAFT, SHIFT 101. FORK, FIRST AND SECOND SHIFT 109. SPRING, BIAS 110. BRACKET, ANTI - ROTATION 102. FORK, THIRD AND FOURTH SHIFT 103. BUSHING, SHIFT SHAFT BLOCK-OUT 111. RETAINER, ROLLER 104. LEVER, SHIFT SHAFT 112.
Page 791 only. Replace the assembly for any shift lever rat I ® Inspect (Figure 33) tle/buzz. • Boot (130) for cracks, tears, or distortion. Replace • Anti-rotation plate for wear or distortion with a the boot if any of these conditions exist. straight edge.
Page 792 Three bolts (306). Apply threadlocker GM P/N REAR HOUSING ASSEMBLY 12345382 or equivalent to the threads. Assemble (Figures 1, 2, 36, and 37) Tighten Tools Required: • Bolts (306) to 22 N-m (16 lbs. ft.). J 36190 Drive Handle 3. Two dowel pins (321). J 36503 Output Shaft Oil Seal Installer •...
Page 793 3. Clutch fork pivot assembly (219) using J 36510 and REVERSE IDLER GEAR J 36190 (figure 39). ASSEMBLY • Grease after installation through lube fitting Assemble (Figure 23) 4. Two detent plunger bushings (242), using J 36507 (figure 40). • Lubricate all components as assembly progresses. A.
Page 794 1. Bearing assembly (17) and reverse speed gear (25) (figure 41). 2. W hen pressing the fifth -re v e rs e synchronizer assembly (26): A. Manually align and engage splines. B. Press until seated. C. Be sure all shavings are removed. 3.
Page 795 J 6133-01 23 SHAFT, OUTPUT (2WD) 2 RING, SYNCHRONIZER 24 SHAFT, OUTPUT (4WD) 17 BEARING ASSEMBLY, SPEED GEAR NEEDLE 30 BEARING ASSEMBLY, 5TH SPEED 19 SYNCHRONIZER ASSEMBLY, 1-2 GEAR NEEDLE (MG5) 22 GEAR, 1ST SPEED 31 GEAR ASSEMBLY, 5TH SPEED (MGS) 23 SHAFT, OUTPUT (2WD) 24 SHAFT, OUTPUT (4WD) 3707r5134...
Page 796 23 OR 24 J 22912-01 2 RING, SYNCHRONIZER 15 COLLAR 6 RING, SNAP 16 SPACERS 7 SYNCHRONIZER ASSEMBLY, 3 -4 17 BEARING ASSEMBLY, SPEED GEAR NEEDLE 13 GEAR ASSEMBLY, 3RD SPEED 18 GEAR ASSEMBLY, 2ND SPEED 14 BEARING ASSEMBLY, 3RD SPEED GEAR NEEDLE 23 SHAFT, OUTPUT (2WD) 23 SHAFT, OUTPUT (2WD) 3707r5137...
Page 797 1. Pilot bearing (3) into input shaft (1) (figure 46). TRANSM ISSIO N ASSEMBLY A. Turn the smaller diameter of the bearing cabe toward the input shaft. Assemble (Figures 46 through 53) B. Retain with TRANSJEL ™ J 36850 or equiva lent.
Page 798 J 36515-10 assembly bore MUST be heated for 3 to 5 min utes with J 25070 before assembly (figure 48). 10. J 36515-10 through bolt (304) and (305) holes in NOTE: SMALL the rear housing (figure 49) (2WD models only). DIAMETER OF •...
Page 799 J 36502 301. HOUSING, REAR (4WD) 320. SEAL, OUTPUT SHAFT OIL (4WD) 3707r5150 Figure 51— Installing 4WD Rear Housing Oil Seal 18. Idler shaft support (310) and bolt (311) (figure 52). A. Line up the bolt threads in the idler shaft sup port with bolt hole.
Page 800 Tighten Important • Bolt to 22 N.m (16 lbs. ft.). A. Install smaller diameter of bearing cage into the bearing race. 19. Position J 8763-21, J 8763-02, and J 36824 onto B. Press each roller into cage and retain with the transmission case (figure 11).
Page 801 Tighten • Bolts (312) (figure 5) to 35 N-m (26 lbs. ft.). 42. Blockout bushing anchor bolt (236) (figures 1 and Tighten • Anchor bolt to 25 N-m (18 lbs. ft.). 43. Fill transmission with Synchromesh Transmission Fluid or the equivalent. 44.
Page 802 SPECIAL TOOLS J 3 2 8 9 - 2 0 J 8 7 6 3 - 0 2 J 2 2 9 1 2 -0 1 J 8 7 6 3 -2 1 J 36183 J 23907 J 36184 J 6 1 2 5 -1 8 J 2 4 4 2 0 -B J 6 1 3 3 -0 1 J 36190...
Page 803 SPECIAL TOOLS pH® J 36515 J 3 6 5 1 5 -1 5 J 36507 J 3 6 5 1 5 -1 6 J 36511 J 36800 J 36513 J 36824 20. SHIFT SHAFT DETENT BUSHING REMOVER/INSTALLER 21. SHIFT SHAFT DETENT PLUG REMOVER 22.
Page 804 NOTES...
Page 805 SECTION 7B2 NEW VENTURE GEAR 4500 MANUAL TRANSMISSION N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a lw a y s r e in s t a ll th e m a t th e s a m e lo c a t io n f r o m w h ic h t h e y w e r e r e m o v e d .
Page 807 30. DAMPER, VIBRATION . LEVER, GEAR SHIFT STUB . CAR MASTER CONTROL HOUSING 31. WASHER, MAINSHAFT NUT 3. SEAT, CONTROL LEVER SPRING 32. NUT, MAINSHAFT 4. SPRING, CONTROL LEVER 33. BOLT, RETAINER 34. PIN, RETAINER DOWEL BUSHING 5. PLUG, CUP EXPANSION INTERLOCK 35.
Page 809 57. ROTOR, SPEEDOMETER DRIVE MAGNETIC SHAFT, TRANSMISSION COUNTER 102. 58. GEAR, MAINSHAFT OVERDRIVE KEY, COUNTER GEAR 103. 59. BEARING, MAINSHAFT REAR 104. GEAR, THIRD COUNTER 60. WASHER, REVERSE GEAR THRUST 105. GEAR, COUNTER DRIVE 61. GEAR, MAINSHAFT REVERSE SPEED 106. WASHER.
Page 810 30. DAMPER, VIBRATION V2822 Figure 5— Mainshaft Nut Removal (4WD Models) Figure 6— Vibration Damper Removal (4WD Models) Figure 7— Countershaft Rear Bearing Removal DISASSEMBLY AND ASSEMBLY OF SUB-ASSEMBLIES M AIN DRIVE GEAR Inspect • Parts for damage and wear. Disassemble (Figures 3, 4, and 8) ❖...
Page 811 £ = 3 58. GEAR, MAINSHAFT OVERDRIVE 59. BEARING, MAINSHAFT REAR 60. WASHER, THRUST 61. GEAR, REVERSE SPEED 69. SHAFT, MAIN V2946 Figure 9— Reverse Speed Gear Removal 20. Bearing (63) and spacer (64). 2. Synchronizer ring (90). 21. Sleeve (62). 3.
Page 812 7. Reverse gear (61), thrust washer (6), bearing (59), REAR O IL RETAINER overdrive gear (58), and rotor (57), if equipped EXTENSIO N HOUSING (2WD models only) (figure 10). 8. Synchronizer ring (73). BEARING REPLACEMENT (2WD MODELS) 9. Retaining ring (72). 10.
Page 813 23. RETAINER, REAR OIL V2952 Figure 11— Rear Oil Retainer Seal Installation Figure 12— Rear Oil Retainer Seal Installation S H IFT COVER 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.
Page 814 8. COVER, SHIFT LEVER 10. PIN, SHIFT ROD INTERLOCK 11. FORK, THIRD AND FOURTH SHIFT 14. RAIL, FIRST AND SECOND SHIFT 15. RAIL, THIRD AND FOURTH SHIFT 16. FORK, FIRST AND SECOND SHIFT 38. LUG, FIRST AND SECOND SHIFT 40. LUG, THIRD AND FOURTH SHIFT 42.
Page 815 118. CUP, COUNTERSHAFT FRONT BEARING 121. CASE, TRANSMISSION V2956 Figure —Checking Countershaft End play Figure 15— Countershaft Front Bearing Cup Installation 12. Countershaft bearing cap (117) using J 38856 (fig ure 18). • Ensure outer lip is hit evenly until flush with case.
Page 816 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 washer (31) and nut (32) using J 38805 (figure 21) (4WD models only). Tighten &...
Page 817 29. Fill transmission with proper amount of lubricant, 31. Shift lever cover bolts (6). Important Tighten Use of any lubricant other than Castrol Syntorq GL-4 transmission fluid or equivalent will result in * Bolts (6) to 23 N-m (17 lbs. ft.), transmission failure.
Page 818 SPECIAL TOOLS J 38807 J 22828 J 38856 J 22834 J 38801 J 39314 J 38805 1. INPUT SHAFT BEARING INSTALLER/COUNTERSHAFT BEARING CONE INSTALLER 2. EXTENSION HOUSING SEAL INSTALLER (2WD MODELS) 3. INPUT SHAFT SEAL INS1ALLER 4. OUTPUT SHAFT NUT SOCKET (4WD MODELS) 5.
Page 819 SECTION 7B3 BORG-WARNER T5 MANUAL TRANSMISSION N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a lw a y s r e in s t a ll th e m a t th e s a m e lo c a t io n fr o m w h ic h t h e y w e r e r e m o v e d .
Page 820 • Roller bearings support the mainshaft indepen PRECAUTIONS dently in the drive gear. Certain precautions should be followed when repair • The drive gear and mainshaft are engaged by a ing the transmission. Unless proper care is taken, the synchronizer for direct drive in top gear. components may be damaged.
Page 821 UNIT DISASSEMBLY 18. Front bearing retainer (96). TRANSM ISSIO N DISASSEMBLY 19. Front bearing race (99) and the shim pack (98) (figure 10). 4"+ Remove or Disconnect (Figures 1 and 2) 20. Main drive gear (100). • Turn the gear so the cutout is toward the coun Required: iG G is tershaft (figure 11).
Page 822 3707r5079...
Page 823 1. COVER, TRANSMISSION 52. GEAR CLUSTER, COUNTERSHAFT 2. BOLT, ALIGNMENT DOWEL 53. RACE, REAR COUNTERSHAFT 3. BOLT 54. SHIM, COUNTERSHAFT BEARING ADJUSTMENT 55. RETAINER, COUNTERSHAFT 4. SEAL, O -R IN G 5. PLUG, SHIFT RAIL 56. BOLT, COUNTERSHAFT RETAINER 6. RAIL, SHIFT 57.
Page 824 76. CLIP, RETAINING 77. LEVER, FIFTH AND REVERSE SHIFT 3707r5156 78. BOLT, PIVOT Figure 6— Fifth Speed and Reverse Shift Lever Retaining Clip 63. RETAINER 64. RING, SNAP 3707r5086 Figure 7— Fifth Gear Synchronizer Retainer 75. RAIL, FIFTH SPEED AND 62.
Page 825 14. SHAFT, MAIN \ 25. GEAR, FIFTH 26. RING, SNAP 3707r5087 67. CASE, TRANSMISSION 3707r5081 Figure 9— Fifth Gear Snap Ring Figure 12— Mainshaft Removal 98. SHIM, MAIN DRIVE GEAR BEARING 99. RACE, MAIN DRIVE GEAR BEARING 3707r5109 Figure 10— Main Drive Gear Shim Pack Figure 13—...
Page 826 17. CONE, INNER 18. CONE, OUTER 19. RING, BLOCKER 3707r5090 Figure 18—Three Piece Blocker Ring 101 29 3? 8 P ! 29. BEARING, THRUST 30. RACE, THRUST BEARING 99. BEARING, DRIVE GEAR 100. GEAR, MAIN DRIVE 101. BEARING, PILOT 3707r5159 Figure 19—...
Page 827 Fifth gear blocker ring is brass and can be checked visually for wear and damage. Important Make certain the blocker rings are correctly identified before assembly. The first-second synchronizer blocker ring does not have friction material. The third-fourth synchronizer blocker ring has friction material.
Page 828 t j j Measure • Gap between vertical faces of blocker teeth and clutch teeth. Nominal gap is 0.81 - 1.40 mm (0.032 - 0.055 inch) for new blocker ring assem blies. SYNCHRO NIZER KEYS AND SPRINGS Important (Figures 22 through 25) The synchronizer hubs and sliding sleeves are a 15.
Page 829 58. RING, BLOCKER 61. KEYS 59. SPRING 62. SLEEVE 60. HUB 63. RETAINER 3707r5094 Figure 24— Fifth Gear Synchronizer Bushing J-21426 15. SPRING 33. KEY 3707r5102 Figure 25— Synchronizer Springs and Keys DRIVE GEAR BEARING RETAINER O IL SEAL B8614 Remove or Disconnect (Figure 28) Figure 27—...
Page 830 2. Shift rail. • For damage and bends. • For worn or damaged plates. • For smooth fit in the cover. 3. Transmission cover. • For cracks and warping. • For smooth shift rail fit. • Shaft plug for damage or leaks. ❖...
Page 831 49. O -R IN G 50. RACE, BEARING 67. CASE, TRANSMISSION 3707r5100 Figure 30— Removing Bearing Race from the Case Figure 32— Front Countershaft Bearing Assembly 1. Countershaft front bearing (51) onto the counter Important shaft (52) using J 37357 with J 22912-01, J 8092, •...
Page 832: Automatic Transmission
UNIT ASSEMBLY Use new seals, gaskets, and thread sealer on all bolt 4. Locating pin (46) into the main shaft (14). 5. Sleeve (20) and needle bearing (21) into mainshaft, threads when assembling the transmission. Tighten all aligning notch in sleeve with locating pin. bolts to specified torque.
Page 833 1. Countershaft (52) into case (67). 2. Rear countershaft bearing (51) to countershaft using J 37372 and a press (figure 34). • Support the countershaft with J 37357. Important • Failure to properly support the countershaft may result in permanent distortion of the case during installation.
Page 834 19. Transmission cover (1). A. Move the shift forks and the synchronizers to the neutral positions. B. Apply a 3 mm (1/8-inch) bead of RTV sealant GM P/N 12345739, or equivalent, sealer to the cover mating surface. C. Lower the cover onto the case, aligning the shift forks into the synchronizers.
Page 835 SPECIFICATIONS FASTENER TIG H TE N IN G SPECIFICATIO NS Lbs. In. Lbs. Ft. Countershaft Retainer Bolts................— Drain Plug......................— Drive Gear Bearing Retainer Bolts..............— Extension Housing Bolts..................— Fill Plug........................— Pivot B o lt......................—...
Page 836 SPECIAL TOOLS J 6 1 3 3 -0 1 J 8001 J 8092 J 37357 J 21426 J 37358 - 1 10 . ( Z 7 ) J 3 7 3 5 8 - 2 J 2 2 9 1 2 -0 1 J 37359 J 2 3 0 6 2 -1 4 J 37360...
Page 837 SECTION 7D TRANSFER CASE CONTENTS SUBJECT PAGE New Process 233 Transfer C ase..........................7D1-1 New Process 241 Transfer C ase..........................7D2-1 New Process 231 Transfer Case..........................7D3-1 Borg-Warner 4401 Transfer C ase..........................7D4-1 Borg-Warner 4472 Transfer C ase..........................7D5-1 Borg-Warner 4470 Transfer C ase..........................7D6-1 SECTION 7D1 NEW PROCESS 233 TRANSFER CASE N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a l w a y s r e in s t a ll th e m a t th e s a m e lo c a t io n f r o m w h ic h t h e y w e r e r e m o v e d .
Page 838 GENERAL DESCRIPTION connected and operated by the drive chain. The plane MODEL 233 tary gear assembly consists of a 4-pinion planetary car The Model 233 is an electronic shift transfer case rier and an annulus gear that provide the four-wheel with three modes of operation: two-wheel drive range, drive low range when engaged.
Page 839 gear to the range shift hub and mainshaft. Torque flow Torque is transmitted through the drive sprocket to the continues through the slip yoke which is splined to the driven sprocket by the connecting drive chain. The mainshaft, and finally to the rear propeller shaft and torque flows through the front output shaft to the front axle.
Page 841 1. SEAL, REAR OUTPUT SHAFT 35. SCREEN, PUMP PICK-UP 64. SEAL, O-RING 2. BUSHING, EXTENSION HOUSING 36. CARRIER, PLANETARY 68. PLUG, POPPET 3. BOLT, EXTENSION HOUSING/CASE HALF 37. WASHER(2), THRUST 69. SEAL, O-RING 4. EXTENSION, HOUSING 38. GEAR, INPUT 70. PLUNGER, POPPET 5.
Page 842 J 29369-1 J 2619-01 38. Input Drive Gear F5392 Figure 7— Removing the Input Gear Bearing Disassemble ❖ • Mark the location of the synchronizer hub and sleeve to aid in assembly. Synchronizer teeth must Removal align with struts (30). 1.
Page 843: Automatic Transmission
7. Synchronizer stop rings for cracks, chips, spalling, 10. Oil pump gears and case halves for wear, spalling, or excessive wear. cracks, and damage. Replace complete assembly 8. Synchronizer hub and sleeve for cracks, chips, if there is wear. spalling, or excessive wear. 11.
Page 844 4. Shift sector with shaft (55), O-ring seal (64), and retainer (snap ring) (63) into the front case half (45) (figures 3 and 4). 5. Range shift hub (34) and range shift fork into the front case half (45). • It is necessary to rotate the sector to align the range shift fork.
Page 845 15. Speedometer tone wheel (11) onto mainshaft (19). 16. Pump retainer housing (8) and pump housing bolts (7) to the rear case half (17) (figures 3 and 4). •A p p ly Loctite 242 or (GM P/N 12345382) to pump housing bolt threads. Tighten •...
Page 846: Automatic Transmission
17. Rear Case Half 18. Oil Pump Pick Up Tube Dowel Pin Location 26. Connector Pump Pick Up Screen F5434 Figure 14— Oil Pump Location SPECIFICATIONS FASTENER TIG H TEN IN G SPECIFICATIONS Lbs. Ft. Case Half B o lts............................31 Encoder Motor B o lts........................
Page 847 SPECIAL TOOLS 1. SLIDE HAMMER 8. BEARING INSTALLER 2. DRIVER HANDLE 9. BEARING INSTALLER 3. BEARING REMOVER 10. SEAL INSTALLER 4. BEARING REMOVER 11. EXTENSION HOUSING SEAL INSTALLER 5. OUTPUT SHAFT BEARING REMOVER 12. BEARING INSTALLER 6. ADAPTER 13. BEARING REMOVER 7.
Page 848 NOTES...
Page 849 SECTION 7D2 NEW PROCESS 241 TRANSFER CASE N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a lw a y s r e in s t a ll th e m a t th e s a m e lo c a t io n f r o m w h ic h t h e y w e r e r e m o v e d .
Page 850 teeth of the drive sprocket. This locks the drive sprocket In the 4LO range, the path of torque through the transfer case is exactly the same as in the 4HI range to the mainshaft through the synchronizer. Torque is but with one major difference. then transmitted through the drive sprocket to the driven In the 4LO range, the range shift hub is shifted into sprocket by the connecting drive chain.
Page 851 8. Shift lever nut (63), washer (64), shift lever (65), sector and shaft (55), plastic washer (66), and O-ring (67) from the front case half (45). 9. Input bearing retainer bolts (43) and input bearing retainer (44) from front case half (45). 10.
Page 853 1. Oil Seal 58. Chain 28. Main Drive Synchronizer 2. Bushing 59. Retainer Snap Ring Stop Ring 60. Retainer Snap Ring 3. Rear Extension Housing 29. Synchronizer Sleeve Bolts/Case Bolts 61. Front Output Bearing 30. Strut (3) 4. Rear Extension 62.
Page 854 51. Range Fork 52. Mode Fork Spring 25. Magnet 54. Mode Fork 45. Front Case Half 55. Sector W ith Shaft 54. Mode Fork 63. S hift Lever Nut 55. Sector W ith Shaft 65. Lever 81. Synchronizer Assem bly F5391 F5389 Figure 5—...
Page 855: Automatic Transmission
Figure 8— Removing the Input Gear Bearing Bearing CLEANING AND INSPECTION 3. Gear splines for excessive wear, spalling, cracks, IJJi Clean twist, or corrosion. 4. Shaft splines for excessive wear, spalling, cracks, 1. Bearings. distortion, or corrosion. • Remove all old lubricant and dirt. 5.
Page 856 3. Bearing (61) into front case half (45) using J 37371 (figures 11 and 12). 4. Bearing retainer (60) into front case half (45). 5. Bearing (6) into pump retainer housing (8) using J 36371 (figures 13 and 14). 6. Bearing (84) to the input gear (38) using J 36372 and J 8092.
Page 857: Automatic Transmission
J 36371 F5430 Figure 13— Installing the Pump Housing Bearing 8. Shift lever O-ring (67), plastic washer (66), shift 17. Oil pump pickup tube (18), oil tube connector (26), lever (65), washer (64), and nut (63) to the front and pump pickup screen (35) into rear case half case half (45) (figure 15).
Page 858 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). •A p p ly RTV (GM P/N 1052366) to the mating surfaces. • Apply Loctite 242 or (GM P/N 12345382) to the extension housing bolts.
Page 859 17. Rear Case Half 18. Oil Pump Pick Up Tube Dowel Pin Location 26. Connector Pump Pick Up Screen F5434...
Page 860 F5435...
Page 861: Automatic Transmission
1. Extension Housing Oil Seal 37. Thrust Washer 2. Bushing 38. Input Gear 3. Rear Extension Housing Bolts/Case Bolts 39. Retainer Snap Ring 4. Rear Extension Housing 40. Input Bearing 5. Retainer (Snap Ring) 41. Retainer (Snap Ring) 6. Front O utput Bearing 42.
Page 862 SPECIAL TOOLS J2619-01 J 33832 J 8092 J 36371 J 22912-1 J 36370 J 29369-1 J 36372 J 29369-2 J 36373 J 9276-21 C i - 1. SLIDE HAMMER 2. DRIVER HANDLE 7. BEARING INSTALLER/REMOVER 3. BEARING REMOVE . FRONT AND REAR OUTPUT SHAFT BEARING INSTALLER 4.
Page 863 SECTION 7D3 NEW PROCESS 231 TRANSFER CASE N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a lw a y s r e in s t a ll th e m a t th e s a m e lo c a t io n fr o m w h ic h t h e y w e r e r e m o v e d .
Page 864 4. M ainshaft Extension 7. Pump Retainer Housing 15. Drain and Fill Plugs 17. Rear Case Half 80. Identificatio n Tag F5847 Figure 1—231 Rear Case Half torque flows through the front output shaft to the front et to the mainshaft. As a result, torque is not transferred to the driven sprocket.
Page 865 DISASSEMBLY EXTERNAL COMPONENTS The annulus gear found in this transfer case is not | Clean serviceable or removable, and should only be replaced as a unit with the front case half. If the annulus gear is The transfer case exterior using solvent and a stiff removed, damage will result to the case.
Page 867 1. Oil Seal 31. Synchronizer Hub 61. Front Output Bearing 32. Spring Retainer (2) 2. Bushing 62. Annulus Gear 3. Rear Extension Housing 33. Dowel 63. Shift Lever Nut Bolts/Case Bolts 34. Range Shift Hub Prev. Torque 4. Rear Extension 35.
Page 868 12. Oil Pump 17. Rear Case Half 18. Oil Pump Pickup Tube 35. Oil Filter F5851 Figure 5— Oil Pump, Pickup Tube, and Screen 48. S hift Rail 51. Range Fork 52. Mode Fork Spring 54. Mode Fork 55. Sector W ith Shaft 63.
Page 869: Automatic Transmission
J 29369-1 J 2619-01 38. Input Drive Gear F5392 Figure 8— Removing the Input Gear Bearing Removal CLEANING AND INSPECTION 3. Gear splines for excessive wear, spalling, cracks, Clean twist, or corrosion. 4. Shaft splines for excessive wear, spalling, cracks, 1.
Page 870 •8092 J 36370 Installation 20. Mainshaft Drive Sprocket Needle Bearings F5394 Figure 10— Front Drive Sprocket Needle Bearing Installation. 7. Thrust washer (37) into planetary carrier (36). 8. Input gear (38) and thrust washer into planetary carrier (36). Figure 12— Front Output Shaft Seal Installation 9.
Page 871 Tighten • Nut (63) to 27 N-m (20 lbs. ft.)). 6. Range shift hub (34) and range shift fork into the front case half (45). • It is necessary to rotate the sector to align the range shift fork. 7. Chain over main shaft onto drive gear. •...
Page 872 17. Rear Case Half 18. Oil Pump Pick Up Tube 33. Dowel Pin Location 26. Connector 35. Pump Pick Up Screen F5434 Figure 15— Oil Pump Location 19. Rear extension housing (4) and extension housing Tighten bolts (3) to the pump retainer housing (8). •A p p ly RTV sealer (GM P/N 1052366) to the •...
Page 873: Automatic Transmission
SPECIFICATIONS FASTENER TIG H TEN IN G SPECIFICATIONS Ft. Lbs. Case Half B olts..........................Fill and Drain P lugs........................Front Output Yoke N ut........................ Input Shaft Bearing Retainer Bolts.................... Mainshaft Extension Housing Bolts................... Poppet S crew ..........................Pump Housing B o lts................
Page 874 SPECIAL TOOLS 1. SLIDE HAMMER 8. BEARING INSTALLER 2. DRIVER HANDLE 9. BEARING INSTALLER 3. BEARING REMOVER 10. SEAL INSTALLER 4. BEARING REMOVER 11. EXTENSION HOUSING SEAL INSTALLER 5. OUTPUT SHAFT BEARING REMOVER 12. BEARING INSTALLER 6. ADAPTER 13. BEARING REMOVER 7.
Page 875 SECTION 7D4 BORG-WARNER 4401 TRANSFER CASE N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a l w a y s r e in s t a ll th e m a t th e s a m e lo c a t io n fr o m w h ic h t h e y w e r e r e m o v e d .
Page 876 GENERAL DESCRIPTION sary for servicing information. If the tag is removed or 4401 TRANSFER CASE becomes dislodged during service operations, be sure The Borg-Warner 4401 transfer case is a chain driv to keep the identification tag with the unit. en, four-position unit providing four-wheel drive high POWER FLOW and low ranges, a two-wheel high range, and a neutral position.
Page 877 synchronizer sleeve is shifted into engagement with the In 4L0 range, the path of torque through the transfer clutch hub teeth on the mainshaft. This locks the drive case is exactly the same as in 4Hi range but with one sprocket to the mainshaft through the synchronizer major difference.
Page 878 F9167...
Page 879 1. Speedometer Tone Wheel 45. Rear Output Bearing 3. Tone Wheel Snap Ring 46. Rear Case 4. Rear Output Bearing Snap Ring 47. Rear Output Shaft Seal 5. Clutch Coil Wire Connector 48. Shift Lever 6. Clutch Coil Nuts 49. Detent Roller 7.
Page 880 / I T~t*r 4 - REAR OUTPUT O UTPUT 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 8. Shift Rail Spring 15. Front Output Shaft Snap Ring 10. Clutch Coil Housing Snap Ring 16. Front Output Shaft 11. Clutch Coil Housing 17. Flat Washer 23. Mainshaft F6604 F6606 Figure 8— Removing the Clutch Coil Housing Figure 10— Removing the Front Output Shaft Snap Ring...
Page 882 16. Front Output Shaft 18. D rivtQ N r 19. Driven G 20. Drive Chain 22. Front Output Bearing V2836...
Page 883 23. Mainshaft 30. Annulus Gear Snap Ring 24. Oil Pump Assembly 31. Front Case 25. Input Carrier AMwmbly 32. Annulus Gear 26. Oil Pump Pickup F6610 V2837 Figure 14— Removing the Annulus Gear Snap Ring Figure 12— Removing the Mainshaft and Oil Pump 31.
Page 884 36. Retainer Clip 37. Sector Shaft 38. Cam 25. Carrier Assembly Input Shaft 39. Detent 34. Input Carrier Snap Ring 48. Shift Lever 49. Detent Roller F6617 F7657 Figure 16— Removing the Carrier Assembly Snap Figure 18— Sector and Shaft Assembly Ring 25.
Page 885 Snap Ring J 2619-01 46. Rear Case 85. Front Output Shaft Rear Bearing F7659 Figure 21— Removing the Front Output Shaft Rear Bearing SYNCHRONIZER HUB ASSEMBLY Disassemble 1. Synchronizer hub snap ring (51) from the synchro nizer hub assembly (12) (figure 24). 51.
Page 886 23. Mainshaft 26. Strainer 63. Oil Pump Retainer Bolts 64. Oil Pump Rear Cover 66. Oil Pump Housing 67. Oil Pump Pins 68. Oil Pump Spring 69. Oil Pump Retainer 70. Oil Pump Front Cover 71. Pickup Tube Retainer Clip 72.
Page 887 CLEANING AND INSPECTION 4. Shaft splines for excessive wear, spalling, cracks, X JS ji Clean distortion, or corrosion. 1. Bearings. 5. Retainer rings for excessive wear, distortion, or 2. Shafts. damage. 3. Sprockets. 6. Case halves for damaged or warped mating sur 4.
Page 888 ASSEMBLY During assembly of the transfer case, lubricate all SYNCHRONIZER HUB necessary parts with Dexron® ME automatic transmis ASSEMBLY sion fluid, or equivalent. O IL PUM P ASSEMBLY Assemble (Figure 24) 1. Compression spring (53) to the lockup collar (54). Assemble (Figure 25) 2.
Page 889 12. Input carrier snap ring (32) to the input carrier (25) (figure 16). 13. Input shaft front oil seal (33) to the front case (31) using J 37668. 14. Annulus gear (32) to the front case (31) (figure 15). 15. Annulus gear snap ring (30) to the front case (31) (figure 14).
Page 890 F9168...
Page 891: Automatic Transmission
1. Speedometer Tone Wheel 36. Retainer Clip 3. Tone Wheel Snap Ring 37. Sector Shaft 4. Rear Output Bearing Snap Ring 38. Sector 39. Detent Spring 5. Clutch Coil Wire Connector 40. Front Output Bearing Snap Ring 6. Clutch Coil Nuts 42.
Page 892 SPECIAL TOOLS J 8092 J 22912-01 J 8433-4 J 5590 J 29369-1 J8059 J 29169 J 2619-01 J 33832 1. Bearing and Gear Puller 2. Puller 3. Snap Ring Pliers 4. Bearing Remover/Installer 5. Bearing Remover/Installer J 37668 6. Seal Installer 7.
Page 893 SECTION 7D5 BORG-WARNER 4472 TRANSFER CASE N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a lw a y s r e in s t a ll th e m a t th e s a m e lo c a t io n f r o m w h ic h t h e y w e r e r e m o v e d .
Page 894 IDENTIFICATION The identification tag is an aluminum tag attached under one of the self-tapping case bolts (figure 1). The tag provides the Borg-Warner part number, General Motors part number, serial number, and the build date. The information on the tag is necessary for servicing information.
Page 895 DISASSEMBLY EXTERNAL COMPONENTS Clean The transfer case using solvent and a stiff brush. Remove or Disconnect (Figures 2, 3, 4 and 5) 1. Front output flange nut (1), steel flat washer (2), and rubber sealing washer (3) from the front output shaft (4).
Page 896 1. Front Output Flange Nut 2. Steel Flat Washer 22. Planet Carrier Assembly 3. Rubber Sealing Washer 23. Planet Carrier Assembly Thru 4. Output Shaft 24. Output Shaft Assembly 5. Front Output Flange 25. Extension Housing Bolts 6. Speed Sensor Bolt 27.
Page 897 Input Shaft Viscous Clutch Sun Gear Shaft Thrust Washer Planet Carrier Assembly Planet Carrier Assembly Thrust Washer 1. Front Output Flange Nut Output Shaft Assembly 2. Steel Flat Washer Extension Housing Bolts 3. Rubber Sealing Washer Breather Assembly 4. Output Shaft Output Shaft Bearing Snap Ring 5.
Page 898 24. Output Shaft Assembly 27. Output Shaft Bearing Snap Ring 28. Output Shaft Bearing 37. Speedometer Tone Wheel 42. Oil Scoop F7568 4. Front Output Shaft Figure 8— Removing the Output Shaft Rear Bearing 12. Front Output Shaft Spacer 13. Drive Chain 14.
Page 899 Bearing J 2619-01 BEARINGS AND SEALS Remove or Disconnect (Figures 9, 10, and 11) J 29369-1 Tools Required: J 22912-01 Bearing Remover J 23907 Puller J 2619-01 Slide Hammer J 29369-1 Front Output Shaft Front Bearing Remover J 38427 Front Output Shaft Rear Bearing Remover 1.
Page 900: Automatic Transmission
CLEANING AND INSPECTION ijjji 2. Gear teeth for excessive wear or damage, spalling, Clean cracks, or corrosion. 3. Gear splines for excessive wear, spalling, cracks, 1. Bearings. twist, or corrosion. 2. Shafts. 4. Shaft splines for excessive wear, spalling, cracks, 3.
Page 901 Figure 15— Installing the Front Output Shaft Front Bearing Figure 13— Installing the Input Shaft Pilot Bearing 11. Front Cover 34. Output Shaft Bearing Snap Ring 35. Output Shaft Bearing F7606 Figure 16— Installing the Front Output Shaft Front Bearing Snap Ring Tighten £...
Page 902 10. Rear Case Half 24. Output Shaft Assembly 27. Output Shaft Bearing Snap Ring 7 / 2 3 28. Output Shaft Bearing 42. Oil Scoop F7608 Figure 18— Installing the Output Shaft Bearing Snap Ring 21. Sun Gear Shaft Thust Washer 22.
Page 903 4. Output Shaft 12. Front Output Shaft Spacer F7636 Figure 22— Installing the Sun Gear Shaft Assembly Figure 24— Installing the Front Output Shaft Spacer Tighten • Front cover bolts (9) to 42 N-m (30 ft. lbs.). 19. Front output shaft oil seal (31) to the front cover (11) using J 37668.
Page 904: Automatic Transmission
SPECIFICATIONS FASTENER TIG H TEN IN G SPECIFICATIONS Lbs. Ft. Drain/Fill P lu g s..................... Extension Housing Bolts..................Front Cover B olts....................Front Output Flange Nut..................Speed Sensor B olt....................LUBRICATION SPECIFICATIONS Capacity................................. 1.2L (1.3 qts.) Type Recommended..................
Page 905 SECTION 7D6 BORG-WARNER 4470 TRANSFER CASE N O T IC E : W h e n f a s t e n e r s a r e r e m o v e d , a lw a y s r e in s t a ll th e m a t th e s a m e lo c a t io n f r o m w h ic h th e y w e r e r e m o v e d .
Page 906 Figure 1— BW4470 Front Case Half Figure 2— BW4470 Rear Case Half with one major difference. In the 4LO range the range assembly. Torque is transm itted through the drive sprocket by the connecting drive chain. Since the front hub is shifted into engagement with the planetary carri output shaft is splined to the driven sprocket, torque er.
Page 907 INTERNAL COMPONENTS 18. Annulus gear snap ring (30) from the front case (31) (figure 14). 19. Annulus gear (32) from the front case (31) (figure [*--► 1 Remove or Disconnect (Figures 3 through 23) 15). 20. Input shaft front oil seal (33) from the front case (31).
Page 909 1. Speedometer Tone Wheel 45. Rear Output Bearing 3. Tone Wheel Snap Ring 46. Rear Case 4. Rear Output Bearing Snap Ring 47. Rear Output Shaft Seal 5. Clutch Coil Wire Connector 48. Shift Lever 6. Clutch Coil Nuts 49. Detent Roller 7.
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 8. Shift Rail Spring 15. Front Output Shaft Snap Ring 10. Clutch Coil Housing Snap Ring 16. Front Output Shaft 11. Clutch Coil Housing 17. Flat Washer 23. Mainshaft F6604 F6606 Figure 8— Removing the Clutch Coil Housing Figure 10— Removing the Front Output Shaft Snap Ring...
Page 912 18. Drive Gear 19. Driven Gear 20. Drive Chain 66. Oil Pump Body 70. Oil Pump Cover F6607 Figure 11— Removing the Drive Chain 9. Shift Rail 23. Mainshaft 28. Range Fork 24. Oil Pump Assembly 29. Shift Hub 25. Input Carrier Assembly F6609 F6608...
Page 913 30. Annulus Gear Snap Ring 31. Front Case 32. Annulus Gear F6610 Figure 14— Removing the Annulus Gear Snap Ring Ring 31. Front Case 25. input Carrier Assembly 32. Annulus Gear 35. Power Take Off Drive Gear F6616 F6618...
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 51. Synchronizer Hub Snap Ring 52. Lockup Hub Assembly 53. Compression Spring 54. Lockup Collar F6624 Figure 24—Synchronizer Hub Assembly CLEANING AND INSPECTION 3. Gear splines for excessive wear, spalling, cracks, Clean twist, or corrosion. 1. Bearings. 4. Shaft splines for excessive wear, spalling, cracks, 2.
Page 916 5. Rear output bearing (45) to the rear case (46) using J 8092 and J 33832. 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).
Page 917 22. Front output shaft snap ring (15) to the front output shaft (16) (figure 10). 23. Synchronizer assembly (12) and mode shift fork S ^ - ^ 7 9 (13) aligning the synchronizer assembly to the mainshaft drive gear (18) and the mode fork to the shift rail (9).
Page 918: Automatic Transmission
SPECIFICATIONS FASTENER TIG H TEN IN G SPECIFICATIONS Lbs. Ft. Lbs. In. Case and Rear Bearing Retainer Screws............— — Clutch Coil N u ts....................— Drain/Fill P lugs....................Flange Nut (Front O utput)................. — Four Wheel Drive Indicator Switch..............—...

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S series 1994